Material Selection for refinery and

petrochemicals

1
Learning objectives
By the end of this course, you should be able to:

1
Describe fundamentals of metal and alloys,
Engineering materials and their properties
2
Describe the need for material selection
Recognize the principles of selecting metals or alloys
for specific applications 3

List candidate materials based on damage

mechanism / service condition in refinery / 4
petrochemical plant

2
Introduction to material selection

3
Introduction
The selection of materials has a significant impact on the operability, economics, and reliability of refining
2
units and petrochemical plants

Factors that influence the service life of equipment 3

• Design 4

5
• Materials of construction
• Specification 6

• Fabrication and quality control 7

8
• Operation
• Maintenance 9

• Environmental conditions 10

4
General guidelines for materials selection
• Select materials based on their functional suitability to the service environment 2

• Select More resistant Material for critical component 3

• Thorough assessment of the service environment and a review of options for corrosion control must 4
be made

• The use of fully corrosion-resistant materials is not always the best choice 5

• Focus should be on improved corrosion resistance through heat treatment / fabrication method 6

• Alloys chosen should be free of susceptibility to corrosion and should meet strength and fabrication 7
requirements.

• If, after fabrication, heat treatment is not possible, materials and fabrication methods must have
8
optimum corrosion resistance in their as-fabricated form.

5
General guidelines for materials selection
Materials with short life expectancies should not be combined with those of long life in non-reparable
assemblies. 1

For equipment for which heat transfer is important, materials prone to scaling or fouling should not be
used. 2

For service environments in which erosion is anticipated, the wall thickness of the equipment /
component should be increased or more resistant material should be selected. 3

Non-metallic materials should exhibit low moisture absorption, resistance to microorganisms, stability
through temperature range, resistance to flame and arc, freedom from out- gassing, resistance to
weathering, and compatibility with other materials. 4

Fragile or brittle materials whose design does not provide any special protection should not be employed
under corrosion-prone conditions.
5
The most economic material during production stage may not be the most economic one during the in-
use stage . Thus, life cycle cost approaches integrating the companies’ strategies allow more conscious 6
6
and informed decisions during product design stages.
Corrosion and damage control philosophy
2
Materials
upgradation

7 Refractory Design
Linings Changes 3
1
Corrosion
Control

Protective Process
6 Coatings Changes 4

Corrosion
Inhibitors
5

7
Principal Materials for Refineries and Petrochemicals
1
Material for refinery application are expected to exhibit following properti

2
Chemical Properties 8 Fabricability 13
Mechanical Properties

• Oxidation resistance 9 • Weldable 14

• Strength 3
15
• Corrosion resistance 10 • Formable drawing
• Ductility 4
• High melting point 11 • Castable 16
• Toughness 5

6 • Thermal conductivity 12 • Machinable 17

• Hardness
• Heat treatable 18
• Elasticity 7

8
Classification of materials
1
Materials

1 1
3
Metals Non Metals

Plastics Ceramics

5
2 2
Ferrous Non Ferrous

Eg. Steel, cast iron Eg. Cu, Zn, Mg etc

3 4
9
Ferrous Material Classisifaction
3 4
Ferrous

1 Steel 1 Cast Iron

5 Low Alloy 5 High Alloy

Plain
Alloy
Carbon 6 6

6
Stainless 6 Tool
10
Effects of alloying element
Specific effects of the addition of such elements are outlined below. 2

Element Principal Effects

Element Principal Effects
hardness of steel (or more accurately, the hardenability) is increased by the
Carbon (c) hardness of steel (or more accurately, the hardenability) is increased by the
Carbon (c) addition of more carbon
addition of more carbon
Sulfur (S)
Sulfur (S) Adds machinability, reduces weldability, ductility and toughness
Phosphorous (P) Adds machinability, reduces weldability, ductility and toughness
Phosphorous (P)
Increases corrosion resistance, hardenability, high-T strength; form hard wear
Chromium (Cr) Increases corrosion resistance, hardenability, high-T strength; form hard wear
Chromium (Cr) resistant carbide
resistant carbide
Nickel (Ni) Austenite former, increase hardenability and toughness
Nickel (Ni) Austenite former, increase hardenability and toughness
Molybdenum (Mo) Grain refinement, increases hardenability, high-T strength
Molybdenum (Mo) Grain refinement, increases hardenability, high-T strength
Vanadium (v) Grain refinement, increases hardenability, form wear-resistant carbide
Vanadium (v) Grain refinement, increases hardenability, form wear-resistant carbide

11
Principal materials for refineries and petrochemicals
Steels and other alloys for refinery applications fall within the following categories. 1

Steels Other alloys

Carbon Steel Copper Alloys

Low-alloy steels Titanium Alloys

Stainless steels

Nickel Steels

12
Principal materials for refineries and petrochemicals
1 5
Carbon Steels
• Most common type of material used
• Standard carbon steel used to 80% of components and almost all structural applications. 2
• In refineries, Distillation towers, separators, heat exchangers, storage tanks, most piping, and all structures are generally
fabricated carbon steel
• Limited corrosion resistance, mainly storage applications
• Recommended temperatures below 425° C

3 Low-alloy (Carbon-Chrome-Moly Steels) 6

• C-Cr-Mo steel used for applications of higher temperatures, hydrogen, and sulfide exposure
• C-Mo steels, primarily the C-1/2 Mo grade, will exhibit improved high temperature strength and creep resistance over
4
carbon steels
• Used for some elevated temperature applications
• C-0.5Mo has been deleted from Nelson curve (API 941 - Material suitability for Hydrogen service)
• 2.25Cr-1Mo low alloy steel suffers temper embrittlement (loss in toughness between 340 to 590 Deg C
Quick Fact : Concentrated Sulphuric acid attack on carbon steel plate forms
protective Iron sulfate which inhibit further corrosion 7 13
Principal materials for refineries and petrochemicals
1 Stainless Steels
Stainless steels are alloyed with at least 12% Cr to become “stainless” 2
4

Stainless Steels

Martensitic stainless Duplex stainless steels Precipitation

Ferritic stainless steels Austenitic stainless steels
steels hardening Steels

• Usually contain 12 – 14 • Similar

similar to
to ferrtici
ferrtici SS
SS in
in Cr • Usually contain 18% Cr & 18% Ni • Duplex stainless steel • Cu, Ti, Al added and Ni
% Cr Cr content.
content. and other minor alloying grades have a ferritic- reduced for
• also contain small • Carbon level up as high elements. austenitic Obtaining Precipitation
amount of Mo, C, Ni, Nb. as 1% • Ni Stabilizes the austenite microstructure. hardening SS.
• Magnetic • Can be hardened by heat phase. • Achieved by lowering Ni • Very high Strength SS
treatment due to high • Ti, Nb to stabilize the to 8%
Carbon Stainless Steel
• Magnetic • Non Magnetic

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Stainless Steel corrosion behaviour
Stainless Steels Corrosion response of various stainless steels are as follows: 1

Resistant to chloride stress corrosion cracking, and have good oxidation

Ferritic stainless steels 2
and sulfidation resistance.

Austenitic stainless steels 3 Excellent corrosion resistance and low temperature performance. Good
high temperature performance

Martensitic stainless steels 4 Good for high temperature sulfidic corrosion than low alloy steels

Excellent corrosion resistance, Increased resistance to chloride attack

Duplex stainless steels 5
Good resistance to stress corrosion cracking

Precipitation hardening Steels 6 Very high strength Steels. Types are 1’7-4PH, 17-7 PH, and 15-5 PH

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Typical application of Stainless steels in Refinery/Petrochemica

type 405 (S40500), are not subject to hydrogen stress cracking and are
Ferritic stainless steels 2
therefore used for vessel linings
Used in heat exchangers / piping where carbon and low alloy steel grades are not suitable.
Austenitic stainless steels 3 Stabilised grades SS321/SS347 are used in hydro processing heater and reactor system.
SS316/317 as heater tubes due to resistance against Naphthenic acid corrosion.

Typical applications include pump components, fasteners, valve trim, turbine

Martensitic stainless steels 4 blades, and tray valves and other tray components in fractionation towers. Heat
exchanger tubes, shell cladding prone to sulfidic corrosion.

Heat exchanger tubes where Cu alloy and SS tubes not permitted due to
Duplex stainless steels 5 ammonia / chloride presence in process streams. REAC tubes and header boxes.

Precipitation hardening Steels 6 It is used for valve seats, pump shafts, pump wear rings, and impellers.

Quick Fact : Stainless steel suffers sigma phase embrittlement when exposed to
temperatures in the range of 538 00C to 95400C).
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Stainless Steel family
Shown below is the evolution of stainless steel grades starting from basic 304 grade
1 Super Ferritic Stainless Steel
Ni-Cr-Fe
Duplex Stainless Steel
alloys

Add Cr, Mo Add Ni for corrosion resistance in high

temperature environment
Increase Cr, lower
347 430 309, 310 Ni for higher
strength
Add Nb, Ta to No Ni Add Cr & Ni for strength
reduce ferritic and oxidation resistance
sensitization
304 (“18 – 8”) Add Cu, Ti, Al lower
Add Ti Fe 18 to 20 Cr- Ni for Precipitation hardening SS
321
to reduce 8 to 10 Ni Precipitation
sensitization hardening

Add Mo for pitting

304L resistance
No Ni addition,
Lower C lower Cr,
316L 316 Martensitic
to reduce
sensitization
317L Add more Mo for pitting
resistance
Super Austenitic Stainless Add Ni Mo N
for corrosion 403, 410
Steel 317
resistance
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Typical application of stainless steels in refinery/petrochemica
Corrosion response of other alloys are: 1

Alloy
Alloy Properties

• Nickel alloys used for many high-temperature corrosion resistance

• Nickel content is increased above 30%, austenitic alloys become, for all practical purposes, 2
Ni Steel/Alloys
2 immune to chloride SCC but nickel alloys can be attacked and embrittled by sulfur-bearing gases
at elevated temperatures

• Copper and its alloys combine excellent corrosion resistance with good thermal conductivity,
3 ease of machinability and good strength, especially when alloyed
Copper Alloys • Copper and aluminum alloys are usually restricted to applications below 260°C because of 3
strength limitations

• Used for low temperature, but very corrosive sulfidic and chloridic environments
• Coolers and condensers having high salt content or using seawater
Titanium Alloys 4 • If hydrogen is present, temperatures should not exceed 80 0 C to prevent embrittlement by 4
hydride formation
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Typical application of stainless steels in refinery/petrochemica

• Nickel is an important alloy constituent of many corrosion resistant materials, including, the
austenitic stainless steels
Ni Steel/Alloys • The stress corrosion cracking resistance of austenitic stainless steels rapidly increases as the nickel
content is increased above 20 percent

• For example, Inconel 600 (700% Ni Cr Fe alloy) shows excellent stress corrosion cracking resistance
and is used for this reason in many refinery applications

Copper Alloys • Monel 400 (a Ni-Cu alloy) is used extensively as a lining in the top of crude oil distillation towers to
resist hydrochloric acid

• High nickel alloys, including Inconel 625 and Incoloy 825, are used to prevent polythionic acid
corrosion of flare stack tips and in hydroprocessing effluent piping

Titanium Alloys • Alloys C-276 have excellent resistance to all concentrations of sulphuric acid up to at least 930 C.

• Limitations : nickel alloys can be attacked and embrittled by sulfur bearing gases at elevated
temperatures 19
Typical application of stainless steels in refinery/petrochemica

• Copper and its alloys combine excellent corrosion resistance with good thermal conductivity, ease of
machinability and good strength, especially when alloyed.

• Copper is a relatively noble metal and is usually not corroded unless oxygen or other oxidizing
agents are present.
Ni Steel/Alloys
• Copper alloys are especially resistant to aqueous corrosion, in both fresh and saltwater, and are
commonly used for heat exchanger tubes.

• One of the more common copper alloys used in refineries is admiralty brass, a copper alloy
containing 28% zinc and 1 % tin, with trace amounts of antimony, arsenic, or phosphorous added for
Copper Alloys
improved resistance to corrosion.

• Admiralty tubes have been used extensively in water cooled condensers and coolers.

• Aluminum bronze, 90-10 cupro-nickel, and 70-30 cupro-nickel are other copper alloys often used in
Titanium Alloys refinery applications.

• Limitations : It experiences significant loss of strength above 260 0C and also have poor resistance to
sulfidic corrosion above this temperature.
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Typical application of stainless steels in refinery/petrochemica

• Titanium and its alloys Titanium is a highly reactive metal which depends on a protective oxide film
for corrosion protection

Ni Steel/Alloys • Tubes made from pure titanium (Grade 2) are used extensively in overhead coolers and condensers
on a number of units to prevent corrosion by chlorides, sulfides, and aqueous sulfur dioxide.

• Titanium tubes are very useful at locations where seawater or brackish water is used for cooling.
They are also good in sour water stripper overhead service.

• Titanium alloyed with nickel and molybdenum (Grade 12) can be use in under deposit corrosion
Copper Alloys
environment.

• Limitation: Titanium is not suitable for high temperature service and because of its reactivity must
be welded and cut under inert gas conditions to prevent contamination and embrittlement.

Titanium Alloys • From a practical standpoint, use of titanium in refinery service is limited to temperatures below
2600C. If hydrogen is present, temperatures should not exceed 800 F to prevent embrittlement by
hydride formation.
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 1

Non-Metals

Uses - plastic pipe, fittings,

Polyvinyl chloride Economical , excellent chemical resistance, high tensile strength, good impact resistance and the
(PVC) ability to withstand long term exposure to pressures.

Chlorinated Properties of PVC plus the ability to handle temperatures upto 930C.
polyvinyl chloride Uses: cpvc pipe, fittings, and valves suitable for hot corrosive service & hot water distribution
(CPVC) systems.

Lightest thermoplastic , low cost and good chemical temperature resistance up to 60”C. There are
Polyethylene (PE) 2 commercial forms of PE, high density(hdpe) and low density (LDPE).

Fibre reinforced Excellent corrosion resistant properties, composite fibre reinforced plastic (FRP) has displaced
plastic (FRP) other more costly metals. FRP+CPVC finds application in storage of various chemicals like caustic,
HCL, H2SO4 etc.

Borosilicate glass Excellent resistance to acids & thermal shocks.

Used in APH where metallic cast module suffers dew point corrosion

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Knowledge check
Knowledge check 1
For concentrated hydrochloric acid storage we require tank made of _______.
Select the correct option and then click submit.

Carbon steel

Rubber lined carbon steel

Stress relieved carbon steel

Nickel alloy
Knowledge check 2
Which of the following curve is used to check suitability for high temperature hydrogen attack
Select the correct option and then click submit.

API 941 (Nelson Curve)

Couper Gorman curve

McConomy curve

None of above
Knowledge check 3

Nickel is stabilizer for _________ phase?

Select correct option and then click Submit

Austenitic

Ferritic

Martensitic

Cementite
Knowledge check 4

Which of the following is typical phenomenon in low-alloy chromium steels?

Select correct option and then click Submit

Creep failure

Temper embrittlement

Caustic embrittlement

Stress corrosion cracking

 Corrosive constituents &
Candidate Material selection

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Corrosion resistance
Corrosive constituents enter into system through the crude which participate in corrosion of 1
equipment at refining and petrochemical units.

Corrosiveness of
3
Corrosiveness of Hydrocarbons 3 4 Other media
2
Crude Oils Oils

5 Refinery 6
Crude Oil
Ammonia
Sulphur CN

Nitrogen Hydrogen Sulphide

Hydrogen Chloride
Organic & inorganic acids Leads to Hydrogen Fluoride

Chloride H2SO4

Water Polythionic Acid

Oxygen
Dissolved gases
Carbon Dioxide
29
Corrosive constituent distribution in refinery/petrochemical un

3
2

30
Classification of corrosion

Low temperature (below 260oC) 2 High temperature (above 205oC) 5

• Corrosion mostly by pitting and 3 • Corrosion mostly by uniform thinning,

6
stress corrosion cracking local attack, and erosion-corrosion

• Always in the form of aqueous or • Generally in the absence of water taking

4 7
other liquid solutions the form of liquid or gas hydrocarbons

4
7

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Corrosion Resistance – Low Temperature Corrosion
Hydrogen Sulfide Corrosion

Preferred Materials -
• carbon steel (hardness <200BHN, Postweld heat treated
• Alloy 400 (<150 OC),
• type 405 or type 304 SS lining (low Chlorides)
• titanium grade 2 for Heat exchanger tubes
H2S corrosion – Shallow pits

Hydrogen Chloride

Preferred Materials -
• Piping - carbon steel.
• Cooler condenser tubes - admiralty brass / Titanium Gr-2,
• column top lining -Monel

HCL Corrosion of Air Fin

32 Cooler
Corrosion Resistance – Low Temperature Corrosion
Sulfuric Acid Corrosion interface Corrosion in Carbon steel tank
shell in H2SO4 service
Preferred Materials -
• Carbon Steel (concentration above 85% by weight and temp.
below 40 °C) .
• Alloy 400 for reactor effluent lines at caustic injection
points.
• Type 405 or 410 stainless steel tray valves

Caustic Corrosion & Caustic SCC

Preferred Materials -
• Carbon steel ( 50 to 80 °C, depending on concentration.
• Austenitic SS upto 120 °C, Caustic
• Nickel alloys at higher temperatures Gauging : Failed
tube cross
section
Corrosion Resistance – Low Temperature Corrosion Slide - 16

Recommended operating limits for carbon

steel in caustic service.
Corrosion Resistance – Low Temperature Corrosion
Ammonium bi-sulfide (Alkaline Sour water) corrosion

Preferred Materials -
• Carbon Steel (Velocity: 3-6M/Sec, NH4HS < 8wt%)
• Alloy 825, duplex SS
• Titanium and Alloy C276
ABS Corrosion - HPS sour water
line of HDT

Corrosion Rate, mm/A

Acidic Sour water corrosion

Corrosion Rate, mpy

Preferred Materials –
• 300 Series SS (< 600C)
• Copper alloys (vulnerable to ammonia)
• nickel alloys
Ammonium Bi-sulfide Concentration, % by wt. at 930C
 Slide - 17
Corrosion Resistance - Low-Temperature Corrosion
Ammonium bi-sulfide (Alkaline Sour water) corrosion

Preferred Materials -
• Carbon Steel (Velocity: 3-6M/Sec, NH4HS < 8wt%)
• Alloy 825, duplex SS
• Titanium and Alloy C276

ABS Corrosion - HPS sour water

line of HDT

Acidic Sour water corrosion

Preferred Materials –
• 300 Series SS (< 600C)
• Copper alloys (vulnerable to ammonia)
• nickel alloys

Under deposit corrosion due to

presence of H2S
Corrosion
Chloride Cracking
Resistance - Stress corrosion cracking
Preferred Materials -
• Carbon steels, low alloy steels and 400 Series SS are not
susceptible to Cl-SCC
• Duplex SS
• Alloys with nickel contents above 35%
Chloride Stress corrosion cracking in
Austenitic Stainless Steel

Ammonia Cracking

Preferred Materials –
• 300 Series SS and
• nickel base alloys

Crack in Brass Tubes in O/H Condenser in

PSU Unit
 Slide - 19
Corrosion
Amine Cracking
Resistance - Stress corrosion cracking

Preferred Materials -
• Carbon steel ( PWHT as per API RP 945)
• solid or clad stainless steel,
• Alloy 400

Amine Cracking

Polythionic Acid Cracking

Preferred Materials –
• chemically stabilized grades types 321 and 347 and
• nickel base Alloys 825 and 625
Material Susceptibility to SCC in different environment
Alloy Environment

Carbon Steel Carbonates and Bicarbonates / Caustic

Cyanide, Anhydrous Ammonia,
CO/CO2/H2O Mixtures

Austenitic Stainless Steel Organic and Inorganic Chlorides

Acidic Hydrogen Sulfide, Caustic
Sulfurous and Polythionic Acids

Nickel-Base Alloys Caustic

Hydrofluoric Acid

Copper-Base Alloys Amines, Dilute Ammonia,

Ammonium Hydroxide, Sulfur Dioxide
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Corrosion Resistance – High Temperature Corrosion
Sulfidic Corrosion Without Hydrogen Present

Preferred Materials –
• higher chromium alloy (refer Modified McConomy
Curve)
• solid or clad 300 Series SS or 400 Series SS

Sulfidic Corrosion With Hydrogen Present (H2/H2S)

High Temp Sulfidic Corrosion /
Preferred Materials –
• by using alloys with high chromium content. Sulfidation
• The 300 Series SS such as Types 304L, 316L, 321 and
347.

40
Corrosion Resistance – High Temperature Corrosion
Sulfidic Corrosion Without Hydrogen Present

Preferred Materials –
• higher chromium alloy (refer Modified McConomy
Curve)
• solid or clad 300 Series SS or 400 Series SS

Sulfidic Corrosion With Hydrogen Present (H2/H2S) Effect of sulfur content on corrosion rates predicted by
modified McConomy curves in 290- to 400- °C temperature
Preferred Materials – range.

• by using alloys with high chromium content.

• The 300 Series SS such as Types 304L, 316L, 321 and
347.

41
Corrosion Resistance – High Temperature Corrosion
Naphthenic Acids
Preferred Materials -
• A minimum of 2% to 2.5% Molybdenum in SS316 /
alloy.
• For severe conditions, Type 317L stainless steel or
other alloys with higher molybdenum.

Oxidation

Preferred Materials –

Material with higher Chromium content (refer table)

42
Corrosion Resistance – High Temperature Corrosion
Naphthenic Acids
Preferred Materials -
• A minimum of 2% to 2.5% Molybdnum in SS316 /
alloy.
• For severe conditions, Type 317L stainless steel or
other alloys with higher molybdenum.

Oxidation

Preferred Materials –

Material with higher Chromium content (refer table)

43
Corrosion Resistance – High Temperature Corrosion
Naphthenic Acids
Preferred Materials -
• A minimum of 2% to 2.5% Molybdnum in SS316 /
alloy.
• For severe conditions, Type 317L stainless steel or
other alloys with higher molybdenum.

Oxidation

Preferred Materials –

Material with higher Chromium content (refer table)

44
Other damage mechanisms
Pitting corrosion : is a localized form of corrosion by which cavities or
"holes" are produced in the material. 
Increase in Molybdenum content in steel increases its pitting Dense pitting
resistance. inside pipe

Preferred Material : SS316 exhibits good pitting resistance.

Fig. shows resistance to pitting and crevice corrosion of various alloys-

Sensitization : loss in corrosion resistance of Austenitic Stainless steel

exposed to temperature range 425 to 815 °C due to precipitation of
corrosion resistant alloy chromium as chromium carbide.

Preferred Materials -
• Stabilised grades SS321/347 of Austenitic stainless steel by
Titanium (SS 321) or Niobium (SS 347).
• Low Carbon grade 304L or 316L ASS
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Quick facts
Austenitic Stainless Steels are non magnetic

More than 30% Ni makes Austenitic SS immune to SCC

Copper alloy suffers Stress corrosion cracking in aqueous ammonia

Adding nickel to stainless steel in sufficient amounts, changes the microstructure to

“austenite”.

Bare carbon Steel vessel is suitable for storage of concentrated H2SO4

Sulfide scale is about 5 times the volume of lost metal.

Stainless steel cracks in chloride but not carbon steel or Copper Alloys
46
Knowledge check
Knowledge check 5
What is present in SS 321 for Stabilisation?
Select the correct option and then click submit.

Niobium

Columbium

Titanium

Molybdenum
Knowledge check 6
Match the columns.
Select the correct option and then click submit.

Damage Mechanism Susceptible Material

Chloride Stress Corrosion Cracking Austenitic Stainless Steel

Aqueous ammonia Cracking Copper alloy

Temper Embrittlement 2.25Cr 0.5Mo

885°F(475oC)Embrittlement 400 Series SS

Knowledge check 7

300 series stainless steel heater tubes in an oil-burning furnace in the hydrocracker began to leak and the
furnace was brought down. What was the probable cause of the cracking?
Select correct option and then click Submit

Chloride stress corrosion

Polythionic acid stress corrosion

Amine stress corrosion

Stress oriented hydrogen induced cracking

Knowledge check 8

As regards steel, its oxidation in air increases with increasing metal temperature and decreases with
increasing;
Select correct option and then click Submit

Moisture

Chromium content

Molybdenum content

Carbon content
Knowledge check 9

Which of the following materials is least affected by brittle fracture?

Select correct option and then click Submit

Carbon steel

Chromes

300 series stainless steel

400 series stainless steel

Application of commonly used alloy grades
ALLOY APPLICATION CONSIDERATION
Low alloy steels Hydro-treating, Reforming and Hydrocracker Units Carbide forming elements such as Cr &
1.25Cr 0.5 Mo equipment and piping above 2600C and Hydrogen Mo increases resistance of steel to
2.25Cr 1 Mo, partial pressure of 100 Psia Hydrogen attack .
5Cr-0.5Mo, and 9Cr-1Mo
Like reactors, REAC, recycle hydrogen gas section Materials are more resistant than carbon
etc steel against High temperature hydrogen
attack. Material selection shall be based
on Nelson curve

alloy steel FCCU reactor shell at hot wall portion This alloy is selected over CS due to high
1.25Cr 0.5Mo temperature strength and freedom from
graphitization.

Alloy steels For CDU /VDU /DCU piping based on temperature With increase in chromium content
5Cr-0.5Mo, and 9Cr-1Mo and Sulfur content, fractionator column, resistance to sulfidation increases. SS410,
equipment etc. SS316 are next superior metallurgies
In hydro processing unit before H2 injection point

Columns and large dia. piping, 12% Cr clad carbon

steel is used. For heat exchanger shells, 5Cr-0.5 Mo
or CS clad with 410SS is used
53
Application of commonly used alloy materials
ALLOY APPLICATION CONSIDERATION
SS- 304H Cyclone dipleg, piping for regeneration for flue gas More suitable for application at higher
temperature than SS304
SS 321/347 Hydro processing feed heater - reactor system In H2/H2S environment, it offers better
Type 321 – for exchanger bundles resistance against sulfidation than low
Type – 321/347 for cladding alloy steels. (after H2 injection point)

Hydro processing reactors shell cladding, internals, More resistant to sensitization

Feed heaters etc.

Duplex SS For REAC tubes and header boxes Excellent resistance to ammonium
(type 2205 / 2507/ bisulfide (NH4HS) corrosion. Selection is
2207) done based in (NH4HS) concentration and
Reboilers, lean/rich exchangers, regenerators, and velocity.
piping. Sour water corrosion resistance.

Cooler condenser tubes in place of Cu alloy for process Due to better resistance to H2S/ ammonia
stream containing high H2S and /or ammonia corrosion than Cu alloys.

Duplex SS PTA – acetic acid service For better resistance in acetic acid attack
54
(type 2205 / 2507/ between 80 to120 Deg C.
Application of commonly used alloy materials

ALLOY APPLICATION CONSIDERATION

SS 310 tube hangers, refractory anchor bolts, burners and highly resistant to oxidation and corrosion.
combustion chambers etc

Alloy 600 Nickel alloy 600 weld overlay is done in DCU reactor For high temperature sulfur corrosion
protection

Alloy 400 (Monel) Cladding on top section of CDU column, net gas For resistance against HCL corrosion
scrubber column distributors & inlet piping.

Alloy 800 / 800H/HT Used in hydrogen hot header, outlet pigtail tubes. Good high temperature properties, creep
Thermowell in cold collector resistance.
Alloy 800 has got application in REAC also subjected Excellent ammonium bi sulfide corrosion
to severe corrosion due to NH4HS at temp. below resistance.
60 Deg C

55
Application of commonly used alloy materials
ALLOY APPLICATION CONSIDERATION
HH Alloys furnace-tube supports and Hangers More resistant to ash corrosion by
(25Cr 15Ni to 50Cr 50Ni) vanadium and sodium contaminants in the
fuel occurs. Attention must be given to
strength requirement.

HP modified alloy 25Cr Reformer catalyst tube in HGU Hydrogen attack, creep and oxidation
35Ni No Ti resistance are important factors
Or Incoloy 800H
20Cr 32Ni

35Cr45Ni Naphtha Cracker Unit Heater Radiant Section Hydrogen attack, creep and oxidation
resistance are important factors
Cu-alloy Overheard condensing system for CDU & VDU : For cooling water corrosion.
(Admiralty brass) cooler condensers – Admiralty brass.
Cu alloy Cooler/ condensers tube sheet Higher strength and excellent cooling water
(Naval brass) corrosion resistance

56
Application of commonly used alloy materials
ALLOY APPLICATION CONSIDERATION
Haste alloy PTA – oxidation section Better resistant to HBr attack
(C-276)
Purification section For Erosion resistance
Alloy C-276 Aggressive corrosion occurring in hydro processing Excellent resistance to ammonium
(haste alloy) reactor effluent streams and in units handling bisulfide (NH4HS) corrosion. Selection is
alkaline sour water. done based in (NH4HS) concentration and
velocity. Other material like Titanium /
It is also used for stream containing dilute sulphuric duplex SS are also used.
acid.

Ti alloy PTA – acetic acid service For better resistance in acetic acid attack
(Gr-2) above 120 Deg C.

57
Knowledge check
Knowledge check 10

Which of the following is a Duplex grade Stainless Steel?

Select correct option and then click Submit

304L

316H

410S

2205
Knowledge check 11

For Hydrogen sulphide plus hydrogen service what is the preferred metallurgy ?

Select correct option and then click submit

Low alloy steels

High chromium steel

Austenitic stainless steel

None of above

Submit
Knowledge check 12

Brass tubes are used for what purpose?

Select correct option and then click submit

APH

Cooling water service

Acid service

Caustic service

Submit
Knowledge check 12

Titanium alloys are used for

Select correct option and then click submit

Reformer tubes

Cooling Water service

Acid service

Caustic service

Submit
Application of commonly used alloy materials

63
 Course summary
Selection of a material for a particular service is often done by considering
the loading and aggressive environments encountered. 1

The final selection is the result of a number of compromises between

a variety of technical considerations and the economic factors. 2

Selecting materials for equipment subject to corrosive environments

have five steps: defining the conditions of exposure and the
consequent requirements for each equipment item, establishing a
strategy for evaluating candidate materials of construction,
identifying the candidate materials, conducting an in-depth 3
evaluation of the candidate materials based on operational
experiences, past history, resistance to operative damage mechanism
etc. and selecting the final materials, with the necessary
documentation and communications.
Final Assessment
To complete the course, you must take the final assessment. The passing score on the
assessment is 80%.

While taking the assessment, you will not be able to access any other part of the course.

The assessment has 10 questions. Note that some questions could have more than one
answer.

You have unlimited attempts to take this assessment.

Begin Assessment

65
QUESTION 1

Which material is used for making tank required for storing concentrated Sulphuric acid?

Select correct option and then click submit

Carbon Steel

Rubber lined carbon steel

Stress relieved carbon steel

Nickel alloy

Submit
QUESTION 2

Which metallurgy/ alloys are preferred for Hydrogen Reformer tubes ?

Select correct option and then click submit

Titanium alloys

35 Cr/25 Ni alloys

Stainless steel -446

50Cr 50 Ni alloys

Submit
QUESTION 3

Molybdenum is added in SS 316 to improve which of the following?

Select correct option and then click submit

Resistance to sulphidic corrosion

Pitting resistance

Creep strength

None of above

Submit
QUESTION 4

For Concentrated hydrochloric acid storage we require tank made of which material?

Select correct option and then click submit

Carbon steel

Rubber lined carbon steel

Stress relieved carbon steel

Nickel alloy

Submit
QUESTION 5

Stainless steel sensitization can be controlled by which of the following?

Select correct option and then click submit

titanium

Niobium

Low carbon

all of above

Submit
QUESTION 6

What is preferred for wet H2S damage for carbon steel ?

Select correct option and then click submit

High hardness

Low hardness

Low pH

None of above

Submit
QUESTION 7

Which curve is used to check suitability for high temperature H2S corrosion (200 to 500 OC) ?

Select correct option and then click submit

API 941

Couper Gorman curve

McConomy curve

None of above

Submit
QUESTION 8

Match the correct option

Damage Mechanism Resistant Material

Caustic Stress Corrosion Cracking PWHT Carbon Steel

Naphthenic Acid SS 316 / SS317

Hydrogen chloride corrosion Monel

Cooling water corrosion Admiralty brass

Submit
Question 9

Hardness is primarily an issue with SSC. Typical low strength carbon steels should be controlled to produce
weld hardness less than ________.
Select correct option and then click Submit

225 BHN

237 BHN

200 BHN

240 BHN
Question 10
Caustic embrittlement is a form of stress corrosion cracking characterized by surface-initiated cracks that
occur in piping and equipment exposed to caustic, primarily adjacent to non-PWHT welds. Which of the
following materials is the most resistant to embrittlement?
Select correct option and then click Submit

Carbon steel

Nickel based alloys

Low alloy steels

400 Series SS
QUESTION 11

Which is the most common method for increasing oxidation resistance of a material

Select correct option and then click submit

Alloying

Heat treatment

Nitriding

Quenching

Submit
Question 12

Which of the following is a major component of stainless steel contributing to its passivity?

Select correct option and then click Submit

Nickel

Chromium

Molybdenum

Vanadium
Question 13

Sigma Phase Embrittlement occurs in ?

Select correct option and then click Submit

Carbon Steels

Alloy Steels

Stainless Steels

Copper Nickel alloys

Question 14

Chloride Stress Corrosion Cracking is most common in ?

Select correct option and then click Submit

Carbon Steels

Austenitic Stainless Steels

Copper Nickel alloys

Alloy Steels
Question 15

Caustic Stress Corrosion Cracking is more likely to occur in ?

Select correct option and then click Submit

Martensitic Stainless Steels

Carbon steel

High nickel alloys

Precipitation hardened Stainless Steels

Question 16

Material which is not susceptible to Polythionic Acid Stress Corrosion Cracking (PASCC)?

Select correct option and then click Submit

Carbon Steel

300 Series SS

Alloy 600/600H

Alloy 800/800H
Question 17

What is the structure of grade 304 stainless steel?

Select correct option and then click Submit

Martensitic

Austenitic

Duplex

Ferritic
Question 18

Passivation is done to prevent polythoinic acid cracking in .......

Select correct option and then click Submit

SS405

SS316

Austenitic Ni alloys

B&C
Question 19

Nickel is stabiliser for _________ phase?

Select correct option and then click Submit

Austenitic

Ferritic

Martensitic

Cementite
Question 20

For Concentrated caustic storage at 70 degree C we require tank made of

Select correct option and then click Submit

Carbon steel

Inconel

Stress relieved Carbon steel

Rubber lined carbon steel

Thank You!
You have successfully completed the course. Please
save the certificate of completion for your reference.

Once done, you may either retake the course again, or

exit.

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certificate

86