3 days’ training program on
API RP 571: Damage Mechanisms Affecting
Fixed Equipment in the Refining Industry
CONDUCTED FOR
RELIANCE INDUSTRIES LIMITED
NAVI MUMBAI.
VOLUME-1
CONDUCTED BY
ASIAN ACADEMY OF PROFESSIONAL TRAINING, PUNE
API RP 571: Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry
CONTENTS
1. INTRODUCTION AND REVIEW OF BASIC METALLURGY
2. MECHANICAL & METALLURGICAL FAILURE MECHANISMS
3. INTRODUCTION TO CORROSION
4. UNIFORM OR LOCALIZED LOSS OF THICKNESS
5. HIGH TEMPERATURE CORROSION [>400°F (204°C)]
6. ENVIRONMENT – ASSISTED CRACKING
7. REFINING INDUSTRY DAMAGE MECHANISMS
8. DAILY PUNCH POINTS
9. API 571 SUPPLEMENTAL CERTIFICATION INFORMATION
API RP 571: Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry
DAILY SCHEDULE
DAY-1
1. INTRODUCTION AND REVIEW OF BASIC METALLURGY
[Link] AND METALLURGICAL FAILURE
MECHANISMS
2.1 Graphitization
2.2 Softening (Spheroidization)
2.3 Temper Embrittlement
2.4 Strain Aging
2.5 885°F (475oC) Embrittlement
2.6 Sigma Phase Embrittlement
2.7 Brittle Fracture
2.8 Creep and Stress Rupture
2.9 Thermal Fatigue
2.10 Short Term Overheating – Stress Rupture
2.11 Steam Blanketing
2.12 Dissimilar Metal Weld (DMW) Cracking
2.13 Thermal Shock
2.14 Erosion/Erosion – Corrosion
2.15 Cavitation
2.16 Mechanical Fatigue
2.17 Vibration-Induced Fatigue
2.18 Refractory Degradation
2.19 Reheat Cracking
2.20 Gaseous Oxygen-Enhanced Ignition and Combustion
[Link] TO CORROSION
DAY-2
4. UNIFORM OR LOCALIZED LOSS OF THICKNESS
4.1 Galvanic Corrosion
4.2 Atmospheric Corrosion
4.3 Corrosion Under Insulation (CUI)
4.4 Cooling Water Corrosion
4.5 Boiler Water Condensate Corrosion
4.6 CO2 Corrosion
4.7 Flue-Gas Dew-Point Corrosion
4.8 Microbiologically Induced Corrosion (MIC)
4.9 Soil Corrosion
4.10 Caustic Corrosion
4.11 Dealloying
4.12 Graphitic Corrosion
5. HIGH TEMPERATURE CORROSION [>400°F (204°C)]
5.1 Oxidation
5.2 Sulfidation
5.3 Carburization
5.4 Decarburization
5.5 Metal Dusting
5.6 Fuel Ash Corrosion
5.7 Nitriding
6. ENVIRONMENT – ASSISTED CRACKING
6.1 Chloride Stress Corrosion Cracking (Cl-SCC)
6.2 Corrosion Fatigue
6.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement)
6.4 Ammonia Stress Corrosion Cracking
6.5 Liquid Metal Embrittlement (LME)
6.6 Hydrogen Embrittlement (HE)
6.7 Ethanol Stress Corrosion Cracking (SCC)
6.8 Sulfate Stress Corrosion Cracking
DAY-3
7. REFINING INDUSTRY DAMAGE MECHANISMS
7.1 Uniform or Localized Loss in Thickness Phenomena
7.1.1 Amine Corrosion
7.1.2 Ammonium Bisulfide Corrosion (Alkaline Sour Water)
7.1.3 Ammonium Chloride Corrosion
7.1.4 Hydrochloric Acid (HCl) Corrosion
7.1.5 High Temp H2/H2S Corrosion
7.1.6 Hydrofluoric (HF) Acid Corrosion
7.1.7 Naphthenic Acid Corrosion (NAC)
7.1.8 Phenol (Carbolic Acid) Corrosion
7.1.9 Phosphoric Acid Corrosion
7.1.10 Sour Water Corrosion (Acidic)
7.1.11 Sulfuric Acid Corrosion
7.1.12 Aqueous Organic Acid Corrosion
5.1.2 Environment-Assisted Cracking
7.2.1 Polythionic Acid Stress Corrosion Cracking (PASCC)
7.2.2 Amine Stress Corrosion Cracking
7.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SSC)
7.2.4 Hydrogen Stress Cracking - HF
7.2.5 Carbonate Stress Corrosion Cracking (ACSCC)
5.1.3 Other Mechanisms
7.3.1 High Temperature Hydrogen Attack (HTHA)
7.3.2 Titanium Hydriding
API RP 571: Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry
Bench Mark Quiz — Closed Book
I. A typical soil corrosion is aggravated under which of the following
conditions
a. High moisture content and high resistivity of soil.
b. High moisture content and low resistivity of soil.
c. Low moisture content and high resistivity of soil.
d. Low moisture content and low resistivity of soil.
II. Typical “high cycle fatigue is:
a. Thermal fatigue.
b. Mechanical fatigue.
c. Vibration fatigue.
d. Both a and b.
III. Reduction in likelihood of brittle fracture can be obtained by performing
a. Impact testing
b. Hydrostatic testing
c. PWHT
d. Pneumatic testing
IV. Thermal fatigue cracks usually are
a. Branching, Transgranular and initiate from within the material.
b. Dagger shaped, intergranular and initiate form within the material.
c. Dagger shaped, oxide filled and initiate form the surface.
d. Dagger shaped, clean and intergranular.
V. Erosion/Corrosion mitigation can be achieved by
a. Increasing the pipe diameter to decrease velocity
b. Increasing surface hardness by using harder alloys or hard facing
c. Using corrosion resistant alloys
d. All of the above.
VI. “Clam shell” type crack failure having concentric rings called “beach
marks” showing “waves” of crack propagation is typically the
description of
a. Mechanical Fatigue cracks.
b. Creep cracks.
c. Stress corrosion cracks.
d. Hydrogen induced cracks.
VII. Resistance to sulphidation is generally achieved by
a. Upgrading to higher nickel alloys
b. Upgrading to higher chromium alloys
c. Upgrading to higher copper based alloys
d. All of the above.
VIII. Characteristic Chloride SCC in Austenitic S.S. generally will be
a. Transgranular, branching and aggravated by higher temperature.
b. Intergranular and unidirectional (straight) and aggravated by
increasing temperature
c. Independent of chloride content
d. None of the above
IX. Caustic embrittlement may be reduced/prevented by::
a. Conducting PWHT.
b. Upgrading to Nickel alloys.
c. Using High hardness & High strength steels.
d. Both a and b.
X. High temperature hydrogen attack is typically due to
a. Methane gas formation.
b. Wet H2S formation
c. Temper embrittlement
d. Presence of Molybdenum in alloy steels.
Bench Mark Quiz — Closed Book
ANSWER KEY
Q. NO. ANSWER
1 B
2 C
3 C
4 C
5 A
6 A
7 B
8 A
9 D
10 A
