4.

3 Uniform or Localized
Loss of Thickness

4.3 Uniform or Localized Loss of Thickness

4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
4.3.12

Galvanic Corrosion
Atmospheric Corrosion
Corrosion Under Insulation (CUI)
Cooling Water Corrosion
Boiler Water Condensate Corrosion
CO2 Corrosion
Flue-Gas Dew-Point Corrosion
Microbiologically Induced Corrosion (MIC)
Soil Corrosion
Caustic Corrosion
Dealloying
Graphitic Corrosion

2013- API570 Examination

2013-API510 Examination

Par. 3 Definitions

Par. 3. - Definitions

4.2.7 Brittle Fracture

4.2.3 Temper Embrittlement

4.2.9 Thermal Fatigue

4.2.7 Brittle Fracture

4.2.14 Erosion/Erosion Corrosion

4.2.9 Thermal Fatigue

4.2.16 Mechanical Fatigue

4.2.14 Erosion/Erosion-Corrosion

4.2.17 Vibration-Induced Fatigue

4.2.16 Mechanical Failure

4.3.1 Galvanic Corrosion

4.3.2 Atmospheric Corrosion

4.3.2 Atmospheric Corrosion

4.3.3 Corrosion Under Insulation (CUI)

4.3.3 Corrosion Under Insulation (CUI)

4.3.4 Cooling Water Corrosion

4.3.5 Boiler Water Condensate Corrosion

4.3.5 Boiler Water Condensate Corrosion

4.3.7 Flue Gas Dew Point Corrosion

4.3.10 Caustic Corrosion

4.3.8 Microbiological Induced Corrosion (MIC)

4.4.2 Sulfidation

4.3.9 Soil Corrosion

4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC)

4.4.2 Sulfidation

4.5.2 Corrosion Fatigue

4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC)

4.5.3 Caustic Stress Corrosion Cracking

4.5.3 Caustic Stress corrosion Cracking

5.1.2.3 Wet H2S Damage (Blister/HIC/SOHIC/SCC)

5.1.3.1 High Temperature Hydrogen Attack (HTTA)

5.1.3.1 High Temperature Hydrogen Attack (HTHA)

4.3.1 Galvanic Corrosion

4.3.1.1 Description of Damage
A form of corrosion that can occur at the junction of dissimilar metals when
they are joined together in a suitable electrolyte, such as a moist or aqueous
environment, or soils containing moisture.
4.3.1.2 Affected Material
All metals with the exception of most noble metals.

4.3.1.3 Critical Factors

a) For galvanic corrosion, three conditions must be met:
1. Presence of an electrolyte, a fluid that can conduct a current. Moisture
or a separate water phase is usually required for the solution to have
enough conductivity.
2. Two different materials or alloys known as the anode and the cathode,
in contact with an electrolyte.
3. An electrical connection must exist between the anode and the
cathode.

b) The more noble material (cathode) is protected by sacrificial corrosion of

the more active material (anode). The anode corrodes at a higher rate than
it would if it were not connected to the cathode.
c) A typical listing of the relative position of alloys in seawater is shown in
Table 4-6.
d) The farther the alloys are apart in the table, the higher the driving force for
corrosion.

e) The relative exposed surface areas between anodic material and the
cathodic material has a significant affect.
1. Corrosion rates of the anode can be high, if there is a small anode to
cathode ratio.
2. Corrosion rates of the anode will be less affected if there is a large
anode to cathode ratio.
3. If there is a galvanic couple, the more noble material may need to be
coated. If the active material were coated, a large cathode to anode
area can accelerate corrosion of the anode at any breaks in the coating.
4. The same alloy may act as both an anode and a cathode due to
surface films, scale, and/or local environment (for example, old steel
pipe connected to new steel pipe).

4.3.1.4 Affected Units or Equipment /

a) Galvanic corrosion can occur in any unit where there is a conductive fluid
and alloys are coupled. Heat exchangers are susceptible if the tube material
is different from the tubesheet and/or baffles, particularly if salt water
cooling is utilized.
b) Buried pipelines, electrical transmission support towers and ship hulls are
typical locations for galvanic corrosion.

Galvanic corrosion can occur in any unit where there is a conductive fluid
and alloys are coupled. Heat exchangers are susceptible if the tube material
is different from the tubesheet and/or baffles, particularly if salt water
cooling is utilized.

4.3.1.5 Appearance or Morphology of Damage

a) Damage occurs where two materials are joined at welded or bolted
connections.
b) The more active material can suffer generalized loss in thickness or may
have the appearance of a crevice, groove or pitting corrosion, depending on
the driving force, conductivity and relative anodic/cathodic areas ratio.
c) Corrosion of the anode may be significantly higher immediately adjacent to
the connection to the cathode, depending on solution conductivity
(Figure 4-70 and Figure 4-71).

Figure 4-71 Galvanic corrosion of a carbon steel nipple in a SS vessel in warm water service.

4.3.1.6 Prevention / Mitigation /

a) The best method for prevention/mitigation is through good design.
b) Differing alloys should not be in intimate contact in conductive
environments unless the anode/cathode surface area ratio is favorable.
c) Coatings can be helpful, but the more noble material should be coated.
d) For piping, specially designed electric insulating bolt sleeves and gaskets
can eliminate the electrical connection.
e) Galvanic corrosion is the principle used in galvanized steel, where the Zn
corrodes preferentially to protect the underlying carbon steel. (If there is a
break in the galvanized coating, a large anode to small cathode area
prevents accelerated corrosion of the steel). This anode-to-cathode
relationship reverses at water temperatures over about 150F (66C).

4.3.1.7 Inspection and Monitoring

Visual inspection and UT thickness gauging are very effective methods for
detecting galvanic corrosion. The damage may sometimes be hidden
underneath a bolt or rivet head.
4.3.1.8 Related Mechanisms
Soil corrosion (see 4.3.9).

This anode-to-cathode relationship reverses at water temperatures over about

150oF (66oC).