API Recommended Practice 571

Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

ITAC General Note: The entire API RP 571 document is not a part of the API 653 Inspector Certification Exam. Only the sections listed here are included on the exam. Color photographs of the corrosion damage are available only when the entire document is downloaded from the internet. The API RP 571 documents which were purchased as hard copies will include black and white photographs only. SECTION 1 - SCOPE 1.2. Scope General guidance as to the most likely damage mechanisms for common alloys used in the refining and petrochemical industry is provided in this recommended practice. SECTION - 2 REFERENCES Outlines the standards, codes and specifications which are cited in the recommended practice. This section is NOT included on the API 653 Certification Exam. SECTION - 3 DEFINITION OF TERMS AND ABBREVIATIONS These terms, symbols and abbreviations are NOT included on the API 653 Certification Exam; however, you are encouraged to become familiar with the terminology of the industry in order to effectively improve communication between you and the many people involved in the inspection process.

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SECTION 4 General Damage Mechanisms All Industries 4.1 General Damage mechanisms that are common to a variety of industries including refining and petrochemical, pulp and paper, and fossil utility are covered in this section. 4.2 Mechanical and Metallurgical Failure Mechanisms 4.2.7 Brittle Fracture 4.2.7.1 Description of Damage Brittle fracture is the sudden rapid fracture under stress (residual or applied) where the material exhibits little or no evidence of ductility or plastic deformation. The fracture travels through the part at the speed of sound! Temperature Considerations: 60oF (15 oC 16oC) Generally, there is no advance notice. 4.2.7.2 Affected Materials a. Carbon steels and low alloy steels are of prime concern, particularly older steels. b. 400 series stainless steels are also susceptible. 4.2.16 Mechanical Fatigue 4.2.16.1 Description of Damage a. Fatigue cracking is a mechanical form of degradation that occurs when a component is exposed to cyclical stresses for an extended period, often resulting in sudden, unexpected failure. b. These stresses can arise from either mechanical loading or thermal cycling and are typically well below the yield strength of the material. 4.2.16.2 Affected Materials All engineering alloys are subject to fatigue cracking, although the stress levels and number of cycles necessary to cause failure vary by material.
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4.3.2 Atmospheric Corrosion 4.3.2.1 Description of Damage A form of corrosion that occurs from moisture associated with atmospheric conditions. Marine environments and moist polluted industrial environments with airborne contaminants are most severe. Dry rural environments cause very little corrosion. 4.3.2.3 Affected Materials a. Carbon Steel b. Low alloy steels c. Copper alloyed aluminum 4.3.3 Corrosion Under Insulation (CUI) 4.3.3.1 Description of Damage Corrosion of piping, pressure vessels and structural components resulting from water trapped under insulation or fireproofing. 4.3.3.2 Affected Materials a. b. c. d. Carbon steel Low alloy steels 300 series stainless steel Duplex stainless steel

4.3.8 Microbiological Induced Corrosion (MIC) 4.3.8.1 Description of Damage A form of corrosion caused by living organisms such as bacteria, algae or fungi. It is often associated with the presence of tubercles or slimy organic substances. 4.3.8.2 Affected Materials Most common materials of construction, including: a. Carbon steel b. Low allow steel c. 300 series stainless steel d. 400 series stainless steel e. Aluminum f. Copper g. Some nickel based alloys
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4.3.9 Soil Corrosion 4.3.9.1 Description of Damage The deterioration of metals exposed to soils is referred to as a soil corrosion. 4.3.9.2 Affected Materials a. Carbon steel b. Cast iron c. Ductile iron 4.3.10 Caustic Corrosion 4.3.10.1 Description of Damage Localized corrosion due to the concentration of caustic or Alkaline salts that usually occurs under evaporative or high Heat transfer conditions. However, general corrosion can Also occur depending on alkali or caustic solution strength. 4.3.10.2 Affected Materials Primarily carbon steel, low alloy steels and 300 Series SS 4.5.1 Chloride Stress Corrosion Cracking (Cl SCC) 4.5.1.1 Description of Damage Surface initiated cracks caused by environmental cracking of 300 series stainless steel and some nickel base alloys under the combined action of tensile stress, temperature and an aqueous chloride environment. The presence of dissolved oxygen increases propensity for cracking. 4.5.1.2 Affected Materials a. All 300 series stainless steels are highly susceptible b. Duplex stainless steels are more resistant c. Nickel base alloys are highly resistant

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4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement) 4.5.3.1 Description of Damage 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 nonPWHTd welds. 4.5.3.2 Affected Materials a. Carbon steel b. Low alloy steels c. 300 series stainless steel Nickel base alloys are more resistant.

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SECTION 5 REFINING INDUSTRY DAMAGE MECHANISMS Damage mechanisms found in the refining environment are discussed in this section. Only Section 5.1.1.11 (Sulfuric Acid Corrosion) has been made a part of the API 653 Certification Exam, and the only item in this section which will be covered in this textbook. 5.1.1.11 Sulfuric Acid Corrosion 5.1.1.11.1 Description of Damage Sulfuric acid promotes general and localized corrosion of carbon steel and other alloys. Carbon steel heat affected zones may experience severe corrosion 5.1.1.11.2 Affected Materials In order of increasing resistance: a. b. c. d. e. f. g. Carbon steel 316L SS Alloy 20 High silicon cast iron High nickel cast iron Alloy B-2 Alloy C276

The rest of this document is tables and diagrams of process flow diagrams (PFDs), which are not covered in the API 653 Certification Exam.

ITAC API RP 571 Summary for API 653 Exam, Copyright 2006

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