API RP 571 - Damage Mechanisms Spreadsheet

urut No Damage Mechanisms

High Temperature Corrosion [>400°F

1 (204°C)]34 Sulfidation

Wet H2S Damage

REFINING Environment-Assisted2Cracking 62
(Blistering/HIC/SOHIC/SSC)

Mechanical and Metallurgical Failure3 Mechanisms

8 Creep and Stress Rupture

NDUSTRY Uniform or Localized Loss 4in Thickness

52Phenomena High Temp H2/H2S Corrosion

REFINING Environment-Assisted5Cracking 60 Polythionic Acid Stress Corrosion Cracking (PASCC)

NDUSTRY Uniform or Localized Loss 6in Thickness

54Phenomena Naphthenic Acid Corrosion (NAC)

Ammonium Bisulfide Corrosion

NDUSTRY Uniform or Localized Loss 7in Thickness
49Phenomena
(Alkaline Sour Water)
NDUSTRY Uniform or Localized Loss 8in Thickness
50Phenomena Ammonium Chloride Corrosion

NDUSTRY Uniform or Localized Loss 9in Thickness

51Phenomena Hydrochloric Acid (HCI) Corrosion

High Temperature Hydrogen Attack

REFINING Other Mech.10 65
(HTHA)

High Temperature Corrosion [>400°F

11 (204°C)]33 Oxidation

Mechanical and Metallurgical Failure

12Mechanisms
9 Thermal Fatigue

NDUSTRY Uniform or Localized Loss13

in Thickness
57Phenomena Sour Water Corrosion (Acidic)

Mechanical and Metallurgical Failure

14Mechanisms
18 Refractory Degradation

Mechanical and Metallurgical Failure

15Mechanisms
1 Graphitization
Mechanical and Metallurgical Failure
16Mechanisms
3 Temper Embrittlement

High Temperature Corrosion [>400°F

17 (204°C)]36 Decarburization

Caustic Stress Corrosion Cracking

Environment – Assisted Cracking
18 42
(Caustic Embrittlement)

Uniform or Localized Loss of Thickness

19 30 Caustic Corrosion

Mechanical and Metallurgical Failure

20Mechanisms
14 Erosion/Erosion - Corrosion

REFINING Environment-Assisted21Cracking 64 Carbonate Stress Corrosion Cracking

REFINING Environment-Assisted22Cracking 61 Amine Stress Corrosion Cracking

Chloride Stress Corrosion Cracking

Environment – Assisted Cracking
23 40
(CI-SCC)

High Temperature Corrosion [>400°F

24 (204°C)]35 Carburization
 Environment – Assisted Cracking
25 45 Hydrogen Embrittlement (HE)

Mechanical and Metallurgical Failure

26Mechanisms
11 Steam Blanketing

Mechanical and Metallurgical Failure

27Mechanisms
13 Thermal Shock

Mechanical and Metallurgical Failure

28Mechanisms
15 Cavitation

Uniform or Localized Loss of Thickness

29 32 Graphitic Corrosion

Mechanical and Metallurgical Failure

30Mechanisms
10 Short Term Overheating -Stress Rupture

Mechanical and Metallurgical Failure

31Mechanisms
7 Brittle Fracture

Mechanical and Metallurgical Failure

32Mechanisms
6 Sigma Phase Embrittlement

Mechanical and Metallurgical Failure

33Mechanisms
5 885°F Embrittlement
Mechanical and Metallurgical Failure
34Mechanisms
2 Softening (Spheroidization)

Mechanical and Metallurgical Failure

35Mechanisms
19 Reheat Cracking

NDUSTRY Uniform or Localized Loss36

in Thickness
58Phenomena Sulfuric Acid Corrosion

NDUSTRY Uniform or Localized Loss37

in Thickness
53Phenomena Hydrofluoric (HF) Acid Corrosion

Uniform or Localized Loss of Thickness

38 27 Flue-Gas Dew-Point Corrosion

Mechanical and Metallurgical Failure

39Mechanisms
12 Dissimilar Metal Weld (DMW) Cracking

REFINING Environment-Assisted40Cracking 63 Hydrogen Stress Cracking -HF

Uniform or Localized Loss of Thickness

41 31 Dealloying

Uniform or Localized Loss of Thickness

42 26 CO2 Corrosion

Environment – Assisted Cracking

43 41 Corrosion Fatigue
 High Temperature Corrosion [>400°F
44 (204°C)]38 Fuel Ash Corrosion

NDUSTRY Uniform or Localized Loss45

in Thickness
48Phenomena Amine Corrosion

Uniform or Localized Loss of Thickness

46 23 Corrosion Under Insulation (CUI)

Uniform or Localized Loss of Thickness

47 22 Atmospheric Corrosion

Environment – Assisted Cracking

48 43 Ammonia Stress Corrosion Cracking

Uniform or Localized Loss of Thickness

49 24 Cooling Water Corrosion

Uniform or Localized Loss of Thickness

50 25 Boiler Water Condensate Corrosion

Uniform or Localized Loss of Thickness

51 28 Microbiologically Induced Corrosion (MIC)

Environment – Assisted Cracking

52 44 Liquid Metal Embrittlement (LME)

Uniform or Localized Loss of Thickness

53 21 Galvanic Corrosion
Mechanical and Metallurgical Failure
54Mechanisms
16 Mechanical Fatigue

High Temperature Corrosion [>400°F

55 (204°C)]39 Nitriding

Mechanical and Metallurgical Failure

56Mechanisms
17 Vibration-Induced Fatigue

REFINING Other Mech.57 66 Titanium Hydriding

Uniform or Localized Loss of Thickness

58 29 Soil Corrosion

High Temperature Corrosion [>400°F

59 (204°C)]37 Metal Dusting

Mechanical and Metallurgical Failure

60Mechanisms
4 Strain Aging

Environment – Assisted Cracking

61 47 Sulfate Stress Corrosion Cracking

NDUSTRY Uniform or Localized Loss62

in Thickness
56Phenomena Phosphoric Acid Corrosion
NDUSTRY Uniform or Localized Loss63
in Thickness
55Phenomena Phenol (Carbolic Acid) Corrosion

Environment – Assisted Cracking

64 46 Ethanol Stress Corrosion Cracking (SCC)

Gaseous Oxygen-Enhanced Ignition and

Mechanical and Metallurgical Failure
65Mechanisms
20
Combustion

NDUSTRY Uniform or Localized Loss66

in Thickness
59Phenomena Aqueous Organic Acid Corrosion
Description of Damage Temperature Range

> 500°F

Blistering, HIC, and SOHIC ambient to

300°F or higher; SSC < 180°F

SEE Table 4-2 For Threshold Temp: C.S.

--> 700°F
C-1/2 Mo --> 750°F
1.25Cr thru 9Cr ->800°F
304H -> 900°F
347H --> 1000°F

> 500°F

Sensitization occurs 750°F -1500°F

425°F - 750°F; Has been

reported°From 350°F - 800°F

< 150°F
 < 300°F; May corrode well above
water dewpoint of 300°F

Increases with increasing temp up to

point where water vaporizes

Exposure to hydrogen at elevated

temperatures

Oxidation of CS significant > 1000°F;

300 Series SS susceptible to scaling >
1500°F. SEE Table 4-6 For CR at elev.
Temps

Temp swings exceeding 200°F

N/A

N/A

It is a change in the microstructure of

certain carbon steels and 0.5 Mo steels after
800°F - 1100°F; Graphitization before
long term operation in the 800 to 1100°F
Spheroidization < 1025°F
range may cause a loss in strength, ductility
and/or creep resistance.
reduction in toughness. This change causes
650°F - 1100°F; Quicker at 900°F but
an upward shift in the ductile-to-brittle
more severe in longterm exposure at
transition temperature, (by Charpy impact
850°F
testing)

Elevated temperatures

Increasing temps increase likelihood

and severity

High solution strength caustic general

corrosion of CS above 175°F and very
high CRates above 200°F.

N/A

Generally no temperature ranges;

However, > 200°F if CO2 > 2% in gas
scrubbing units

N/A

> 140°F

>1100°F
 Ambient - 300°F; Decreases with
increasing temp; Not likely to occur
above 160°F to 180°F

Short-term, high-temp°Failures.

Significant Temperature Differentials

More likely at temps approaching the

boiling point of the liquid

< 200°F in the presence of moisture or

an aqueous phase

Local overheating above design

temperature

Temperatures below ductile-to-brittle

transition temp

1000°F-1750°F

is a loss in toughness due to a metallurgical

change that occurs in alloys containing
600°F- 1000°F
a°Ferrite phase, as a result of exposure in
the temperatur range 600 to 1100.
 850°F - 1400°F; Spheroidization before
May cause a loss in strength and/or creep Graphitization > 1025°F May Cause a
resistance. loss in strength and or creep
resistance.

During PWHT or at elevated temps.

N/A

Increase with increasing temp; High

CRates observed > 150°F

Sulfuric acid dewpoint < 280°F;

Hydrochloric acid dewpoint < 130°F;
pH <6

> 510°F

Aqueous HF environments

N/A

Increasing corrosion with increasing

temp up to dewpoint < 300°F

N/A
Metal temps above the melting point
of liquid species: Oil ash - melting
points below 1000°F possible;
Waterwall corrosion - melting points
700°F; Coal ash - melting points
1030°F to 1130°F

Increases with increasing temps;

Above 220°F can result in acid
gas°Flashing and severe localized
corrosion

More severe 212°F - 250°F For CS

Corrosion rates increase with temp up

to about 250°F

Any temperature

Process side > 140°F; Brackish and salt

water outlet > 115°F

N/A

0°F to 235°F; pH range 0-12 (Any)

N/A

N/A
 N/A

> 600°F; Severe > 900°F

N/A

> 165°F

Corrosion rates increase with

increasing metal temperature

900°F - 1500°F

found in most older vintage steels and 0-0.5

Mo low alloy steels under the combined
effects of deformation and aging at an
Intermediate Temperature
intermediate temperature. This results in an
increase in hardness and strength with a
reduction in ductility and toughness

N/A
 Minimal below 250°F; Rapid CRates
above 450°F

The spontaneous ignition or combustion of

metallic and nonmetallic components can
result in fires and explosions in certain
oxygen-enriched gaseous environments if
not properly designed, operated and
maintained.
 Affected Materials
CS, low alloys, 300 SS and 400 SS;
Ni base alloys to varying degrees
depending on Cr content; Copper
base alloys at lower temps than CS
CS and low alloys
All metals and alloys
Order of increasing resistance: CS,
low alloys, 400 SS, and 300 SS
Sensitized austenitic SS; 300 SS,
Alloy 600/600H, and Alloy
800/800H
2% - 2.5% molybdenum shows
CS, low alloys, 300 SS, 400 SS, and
improved resistance; Change or
Ni base alloys
CS; 300 SS, duplex SS, Al alloys and exchangers; Maintain velocities
Ni base alloys more resistant
materials > 20 fps; Water wash
Prevention Inspection
Upgrade to higher Cr; Al
Monitor process conditions and
diffusion treatment of low
temperatures; UT For thickness loss;
alloys may reduce but not
Proactive and retroactive PMI
completely protect
Coatings or alloy cladding;
Water wash to dilute HCN or
inject ammonium polysulfide's Monitor free water phase; Crack
to convert to thiocyanates; HIC- detection best with WFMT, EC, RT or
resistant steels; PWHT can ACFM; SWUT For crack sizing; AET
prevent SSC and help with
SOHIC; Inhibitors
Minimize temperatures; Higher
Combination of techniques; Tubes
PWHT may help; Minimize hot
bulging, sagging, diametric growth
spots in heaters
Use alloys with high chromium UT, VT and RT For thickness; Verify
content; 300 SS are highly operating temps; Check process H2S
resistant at service temps levels periodically
Material selection; Flush with
alkaline or soda ash to
neutralize or purge with Flapper disc sanding to remove
nitrogen or nitrogen/ammonia; deposits and PT
Keep firebox above dewpoint;
Heat treatment at 1650°F
RT or UT Thickness; Monitor TAN,
sulfur, Fe, and Ni contents
blend crudes; Inhibitors
Symmetrical/balanced flow in
and out of air cooled
Frequent UT and RT profile thickness;
IRIS and ECT tubes; Monitor water
10 to 20 fps For CS, resistant
injection
injection and low oxygen
 All commonly used materials;
Pitting resistant alloys more RT or UT Thickness; Monitor feed
Order of increasing resistance: CS,
have improved resistance; Limit streams; Corrosion coupons may be
low alloys, 300 SS, Alloys 400,
chlorides; Water wash;°Filming helpful if salts deposit on the
duplex SS, 800, and 825, Alloys 625
inhibitors element
and C276 and titanium.

Upgrade CS to Ni base can

help; Remove chlorides
All common materials of AUT or RT For thickness; Corrosion
(neutralize, water wash,
construction coupons; Check pH
absorb, etc.); Minimize
carryover of water and salts

Alloys with Cr (> 5 Cr) and Mo UT using combination of velocity

Order of increasing resistance: CS,
or tungsten and vanadium; Use ratio and backscatter (AUBT); In-situ
C 0.5Mo, Mn-0.5Mo, 1Cr, 1.25Cr,
a 25°F to 50 °F safety factor; metallography; VT For blistering;
2.25Cr-1 Mo, 2.25Cr-1Mo-V, 3Cr,
300 SS overlay and/or roll bond WFMT and RT in advanced stages
5Cr
clad material with cracking

CS and low alloys; All 300 SS, 400
SS and Ni base alloys oxidize to
varying degrees
Upgrade alloy; Addition of Cr
Monitor process conditions and
primary element For oxidation
temperatures; UT For thickness loss
resistance

Design and operation; Liner to

All materials of construction prevent cold liquid from VT, MT/PT, SWUT For cracking
contacting hot surface

Material selection; 300 SS < RT or UT Thickness; Monitor pH of

Primarily CS; SS, Cu alloys, and Ni
140”F; Cu and Ni resistant, but ovhd accumulators; Corrosion
base alloys usually resistant
Cu vulnerable in ammonia coupons

Refractory materials Selection; Design; Installation VT during shutdown; IR online

Some grades of CS and 0.5Mo

Addition of 0.7% Cr Full thickness sample metallography
steels
 Pressurization sequence - MPT
of 350°F For older steels and
Primarily 2.25Cr; Older 2.25Cr
150°F newer; Heat treat to Impact test sample blocks from
manuf. prior to 1972 particularly
1150°F and cool rapidly For original heat
susceptible
temporary reverse; Limit J and
X Factors.

Control chemistry of gas phase;

Field metallography; Hardness tests
CS and low alloys Cr and Mo Form more stable
For softening
carbides

PWHT at 1150°F For CS; Alloy

WFMT, EC, RT, ACFM For crack
upgrade to Ni based alloys;
CS, low alloys and 300 SS; Ni base detection; PT not effective (tight,
Design/operation of injection
alloys more resistant. scale filled cracks); SWUT For crack
system; Water wash
depth
equipment prior to steamout

Design; Adequate water UT Scans, RT, Injection points,

Primarily CS, low alloys and 300 SS flooding; Burner management; Boroscope steam generating
Dilution of caustic equipment
Design; Erosion - harder alloys;
Corrosion - corrosion resistant VT, UT, RT; Corrosion coupons; IR
All metals, alloys and refractories
alloys; Impingement plates; scans For refractory
Tube ferrules
PWHT at 1150°F; Material
Monitoring of pH and CO3-2
selection; Coatings or alloy
concentration; WFMT or ACFM For
CS and low alloys cladding; Water wash non-
crack detection; SWUT For crack
PWHT prior to steamout or
depth: AET
heat treatment; Inhibitors
PWHT all CS welds; Material
selection (clad or solid); Water Crack detection best with WFMT or
CS and low alloys wash non-PWHT CS prior to ACFM; PT usually not effective;
welding, heat treatment or SWUT crack depths; AET
steam out

Material selection; Low

chloride water For hydrotest;
300 SS; Ni 8% -12% most
Coatings under insulation; VT in some oases, PT (surface prep
susceptible; Ni > 35% highly
Avoid designs with stagnant may be necessary), ECT, UT
resistant, Ni > 45% nearly immune
areas where chlorides can
concentrate

CS and low alloys, 300 SS and 400 Alloy selection (Si & Al
Hardness/Field metallography if
SS, cast SS, Ni base alloys with oxidizers); Lower temperatures
process side accessible; RT, UT, MT
significant Fe content and HK/HP and higher oxygen/sulfur
For cracking in advanced stages
alloys partial pressures.

CS, low alloys, 400 SS, Precipitation
welding; Bake out at 400°F or
Hardenable SS, some high strength
Ni base alloys.
Protective lining, SS cladding,
CS and low alloys
All metals and alloys
Most common materials of
construction
Primarily gray cast iron, but also
nodular and malleable cast irons
which tend to crumble when
attacked
All Fired heater tube materials and
common materials of construction
CS and low alloys esp. prior to
1987; 400 SS also susceptible
Ferritic, martensitic, austenitic,
and duplex SS
Use low ferrite or non-ferritic Impact/bend test samples; Cracking
Alloys containing a°Ferrite phase;
alloys; Heat treat to 1100°F and during t/a or when below 200°F;
400 SS and Duplex SS
Use lower strength steels;
PWHT; Low hydrogen, dry
electrodes, and preheat For
MT or PT For surface cracks; UT may
higher; Controlled be helpful; RT not sensitive enough
pressurization sequence;
or weld overlay
Tube rupture quickly Follows
Visual For bulging on tubes and
DNB; Burner management;
burners
BFW treatment
Minimize flow interruptions,
severe restraint, rain/fire water Highly localized; MT/PT to confirm
deluge; Review injection cracking only
points; Thermal sleeves
Mechanical, design, or
Accoustic monitoring; Pumps may
operational change; Sufficient
sound like pebbles being thrashed
NPSH; Streamline flow;
around; VT, UT, RT For loss of
Remove air; Decrease
thickness
velocities; Fluid additives
Difficult to predict; Internal
coatings/cement linings For
Loss of "metallic ring"; Reduction in
internal graphitic corrosion;
hardness
external coatings or CP in
corrosive soils
Minimize temperature
Visual; IR monitoring; Tubeskin
excursions; Burner
thermocouples
management
Material selection; Minimize
pressure at ambient None to minimize; Susceptible
temperatures; PWHT; "Warm" vessels inspect For pre-existing flaws
pre-stress hydrotest
SS with sigma may have lack of
toughness below 500°F;
Minimize weld metal ferrite Testing of samples; Cracking during
content; Solution anneal at t/a or when below 500°F
1950°F and water quench to
reverse
cool rapidly Increase in hardness

CS and low alloys
low alloys, 300 SS, and Ni base
alloys; High Strength Low Alloys
(HSLA)
Order of increasing resistance: CS,
316L, Alloy 20, high Si cast iron,
high Ni cast iron, Alloy B-2 and
Alloy C276
Low alloys, 300 SS and 400 SS are For thickness; Minimize water,
generally not suitable; CS, Cu-Ni
alloys, Alloy 400, an other Ni base contaminants in feed; Alloy 400
alloys have been used in some (solid or clad) used to eliminate
applications
Maintain temps > 280°F; Avoid
CS, low alloys and 300 SS
Widely differing thermal expansion
used in low temp location only; Visual and MT/PT For OD cracks; UT
coefficients; Most common CS to
Austenitio SS
CS and low alloys
Primarily copper alloys as well as
Alloy 400 and cast iron
CS and low alloys
All metals and alloys
Minimize exposure to elevated Field metallography or removal of
temps samples
Joint configurations in heavy UT and MT/PT For surface cracks; UT
walls; Minimize stress risers For embedded cracks
Materials selection; Proper
UT or RT of turbulent zones and
operation; Caustic wash to
hottest areas; Corrosion coupons
neutralize
Monitor CS operating > 150”F
oxygen, sulfur and other RT or UT Thickness; Monitor small
bore piping, flange face corrosion,
blistering/HIC/SOHIC
blistering/HIC/SOHIC. PWHT to
minimize possibility of SCC.
300 SS if chlorides present;
UT For wall loss; VT and PT For SCC
Soda Ash wash to neutralize
the acids
Ni based fillers; 300 SS rods
Pup piece with intermediate For ID cracks
coefficient
PWHT; Weld hardness < 200
HB and no localized zones >
237 HB; CS with Carbon WFMT For cracks; Hardness testing
Equivalent < 0.43; B7M Bolts;
Coatinas or allov cladding
Difficult to predict; Addition of VT (may change color but may
alloying elements may help; CP require scale removal),
or coatings may help Metallography, Loss of "metallic ring"
Cr > 12% (SS); Corrosion
inhibitors; Increase pH > 6;
Operation problems; 400 SS VT, UT, RT
and Duplex SS resistant; Water
analysis
Reduce corrosion (inhibitors,
material selection, coatings,
BFW chemical control, etc.); UT, MT
PWHT; Controlled start-up
(thermal expansion)

All conventional alloys for process
heaters and boilers; 50Cr-50Ni
family show improved resistance
Primarily CS; 300 SS highly
resistant
CS, low alloys, 300 SS and duplex
SS
CS, low alloys, and copper alloyed
Al
Copper alloys with aqueous
ammonia and/or ammonium
compounds; CS in anhydrous
ammonia
CS, all grades of SS, copper, Al,
titanium and Ni base alloys
Primarily CS; Some low alloy, 300
SS and copper based alloys
Most common materials of
construction
Many commonly used materials
All metals with the exception of
most noble metals; SEE Table 4-4
for Galvanic Series
Blend or change fuel source;
Burner design/management;
Low excess oxygen; Alloy VT; UT For loss of thickness
upgrade to 50Cr-50Ni For
hangers/supports
Proper operation; Avoid
buildup of HSAS; Design should
control local pressure drop to VT and UT thickness internal; UT
minimize flashing; Avoid scans or profile RT For external;
oxygen inleakage; Remove Corrosion coupons
solids and hydrocarbons;
Corrosion inhibibitors
Selection of insulation type;
Maintain coatings and Strip insulation; VT, UT, IR, etc.
insulation
Surface prep and proper
VT and UT
coating
Copper - zinc content below
15%, 90-10CuNi and 70-30CuNi
nearly immune, prevent ingress Copper - monitor pH, ECT or VT on
of air, upgrade to 300 SS or Ni tubes For cracking; CS - WFMT, AET,
alloys; CS - PWHT or addition or External SWUT
water (0.2%), weld < 225 BHN,
prevent inaress of oxvaen
Design process inlet < 135°F;
Operation; Chemical pH; Oxygen content; Outlet temps;
treatment; Maintain water EC/IRIS tubes
velocities; Avoid ERW tubes
Oxygen scavenging treatment; Water analysis; Dearator cracking
Amine inhibitor treatment WFMT
Treat water with biocides;
VT; Measure biocide residual;
Maintain flow velocities; Empty
Operating conditions indicate
hydrotest water; Maintain
Fouling; Foul smelling water
coatinqs
Keep metal with low melting
MT or PT For cracks, RT For mercury
point away from other metal;
deposits inside tubes
Grind out cracks not acceptable
Design; Differing alloys not in
Visual and UT Thickness
intimate contact; Coatings
All alloys; Stress levels and number Good design; Material MT, PT, SWUT For cracks; Vibration
of cycles to failure vary by material selection; Minimize stress risers monitoring

Change in color to dull gray; Hardness

Carbon steels, low alloys, 300 SS testing (400 - 500 BHN); Check 300 SS
and 400 SS; Ni based alloys more Alloy change to 30% - 80% Ni For magnetism; Metallography; ECT;
resistant PT, RT, or UT For cracking in
advanced stages

Design; Supports and vibration

All engineering materials dampeners; Stiffeners on small Visual/Audible signs of vibration
bore; Branch sizing

No titanium in known hydriding

services such as amine or sour
Titanium alloys water; Use all titanium if ECT; Metallography; Crush/Bend test
galvanic coupling may promote
hydriding

Most effective coatings and

Carbon steel, cast iron, and ductile
iron
All; No known alloy immune under
all conditions
Structure to soil potential; Soil
cathodic protection; Special
resistivity; VT, guided UT, Pressure
backfill may help to lesser
testing
degree
Protective layer of sulfur
(usually as H2S); Material Compression wave UT For heater
selection For specific tubes; RT For pitting/thinning; VT if
application; Al diffusion ID is accessible
treatment

No issue For newer steels with

Mostly pre-1980's carbon steels enough Al For deoxidizer; BOF
with large grain size and C-0.5 Mo better than older Bessemer; None
low alloy steel Pressurization sequence; PWHT
or "Butter"

304L satisfactory For

concentration 100% and temp
Order of increasing resistance: CS, < 120°F ; 316L required 120°F - RT or UT Thickness; Sample Iron in
304L SS, 316L SS, and Alloy 20 225°F; 316L and Alloy 20 water; Corrosion coupons
effective at concentrations up
to 85% at boiling temps
 Material selection; Velocity <
Order of increasing resistance: CS, RT or UT Thickness; Corrosion
30 fps; Recovery ovhd temps at
304L, 316L and Alloy C276 coupons
least 30°F > dew point

Carbon steels and low alloy steels

 Appearance

Most often uniform thinning but

may be localized; Sulfide scale will
usually cover the surface

Blistering, HIC "stepwise cracking",

SOHIC stacked arrays, SSC through
thickness potentially

Noticeable deformation may be

observed; May have significant
bulging before final fracture occurs

Uniform loss in thickness°From the

process side with an iron sulfide
scale

Intergranular; Quite localized;

Typically next to welds, but may be
in base metal

Localized corrosion, pitting, or flow

induced grooving in high velocity
areas

General loss in thickness with

potential For high localized rates;
Low velocities may have localized
under-deposit corrosion
 Possible Fouling or corrosion

General uniform thinning, localized

corrosion or underdeposit attack

Intergranular and adjacent to iron

carbide areas in CS; Some blistering
may be visible to the naked eye

General thinning; Usually covered

on the outside surface with an oxide
scale

Cracks propagate transverse to the

stress and usually dagger-shaped,
transgranular, and oxide filled; May
stop and restart; May be axial or
circumferential, or both, at the same
location;

General thinning; Localized

corrosion or underdeposit attack
can occur

Cracking, spalling or lift-off from the

substrate, softening or general
degradation from exposure to
moisture; Erosive services: washed
away or thinned

N/A
 N/A

N/A

"spider web"; Predominantly

intergranular, parallel to weld in
adjacent base metal but can occur in
the weld or HAZ

Localized metal loss as grooves in a

boiler tube or thinned areas under
insulating deposits;
Localized loss in thickness; Pits,
grooves, gullies, waves, rounded
holes and valleys; Often with a
directional pattern

"spider web"; Parallel to weld in

adjacent base, but also in weld or
HAZ; Predominantly intergranular

Surface cracking on ID primarily in

HAZ, but also in weld or adjacent to
HAZ; Typically parallel to weld, but
in weld, either transverse or
longitudinal

"spider web"; Branched,

transgranular, and may have
"crazecracked" appearance

In advanced stage may be a

volumetric increase
Can initiate sub-surface, but in most
cases is surface breaking; Higher
strength steels cracking is often
intergranular

Open burst with edges drawn to a

near knife-edge

Surface initiating cracks may appear

as “craze" cracks

Sharp-edged pitting but may have a

gouged appearance in rotational
components

Widespread or localized; Damaged

areas will be soft and easily gouged
with a hand tool

"fishmouth"

Cracks typically straight, non-

branching, with no plastic
deformation; Limited intergranular
cracking

Cracking particularly at welds or

areas of high restraint

N/A
 N/A

Intergranular and can be surface

breaking or embedded

General but attacks CS HAZ rapidly;

Hydrogen grooving in low flow

Localized general or severe thinning

of CS; May be accompanied by
cracking due to hydrogen stress
cracking, blistering and/or
HIC/SOHIC damage

General wastage often with broad,

shallow pits

Cracks at the toe of weld in the HAZ

of the ferritic material

Surface breaking intergranular

cracks

Often a color change or deep etched

appearance; May be uniform
through the cross-section or
localized

Localized thinning and/or pitting;

May be deep pitting and grooving in
areas of turbulence

"rabbit ears"; Transgranular but not

branched, often multiple parallel
cracks
 "alligatorhide"

General uniform thinning, localized

corrosion or localized underdeposit
attack

May be highly localized; Loose, flaky

scale covering the corroded
component
General or localized; Normally a
distinctive iron oxide (red rust) scale
Forms

Cu: bluish corrosion products at

surface cracks, single or highly
branched, either trans or
intergranular

General corrosion, localized

underdeposit, pitting, MIC, SCC,
Fouling, grooving along ERW tubes

Oxygen: pitting anywhere in the

system; CO2: smooth grooving

Localized pitting under deposits or

tubercles; Cup-shaped pits within
pits

Brittle cracks in an otherwise ductile

material

More active material can suffer

generalized loss in thickness or
crevice, groove or pitting corrosion
 "clam shell" type fingerprint with
concentric rings called "beach
marks"

"needle-like" particles of iron

nitrides

Crack initiating at a point of high

stress or discontinuity

N/A

External thinning with localized

losses due to pitting

Low alloys can be uniform but

usually small pits filled with crumbly
residue; SS and high alloys local,
deep, round pits

N/A

General or localized thinning of CS

General or localized corrosion of CS
 Material Temperatur Pr

catalytic reforming - ccr

fcc light ends recovery
crude unit / vacuum

delayed coker

fcc
No ANY 10 100 200 300 400 500 600 800
1 any >500 x x x
2 cs & low alloy >ambient <180 SSC
<300 x x x x
3 any x x x x
4 any >500
5 x x
6 x x x
7 x x
8 x x x x x
9 x x
10 x
11 x x x x
12 x x
13
14 x
15 x
16 x x
17 x
18 x
19 x
20 x x x x x
21 x x x
22
23 x x
24 x x x
25 x
26 x
27 x
28
29
30 x x x x
31
32 x
33 x x x
34
35 x x
36
37
38
39 x
40
41 x
42 x
43
44 x
45
46 x
47
48 x x x
49 x
50 x
51 x
52 x
53
54 x
55
56
57
58
59 x
60
61
62
63
64
65
66 x x
 Caustic Treating

x
Visbreaker
x
x
x

x
x
x
x
x

x
x
x

x
x
Hydrogen Reforming

x
x
x

x
x
x

x
x

x
Isomerization

x
x

x
x
Sour Water Stripper

x
Sulfur Recovery

x
x

x
Amine Treating

x
Process Unit

HF Alkylation

x
sulfuric acid alkylation

x
x
hydroprocessing units

x
x
x
x
x
x
x
x
x
x

x
x

x
x
x
catalytic reforming - fixed bed

x
x
x
x
x

x
 x x
x x
x
x
x x
x

x x x
x x x

x x

x
x

x x

x x

x
 Damage Mechanism
Sulfidation
Wet H2S Damage
Creep
High Temp H2/H2S corr
Polythionic Acid Cracking
Naphthenic Acid Corrosion
Ammonium Bisulfide Corrosion
Ammonium Chloride Corrosion
HCl Corrosion
High Temperature Hydrogen Attack
Oxidation
Thermal Fatigue
Sour Water Corrosion (acidic)
Refractory Degradation
Graphitization
Temper Embrittlement
Decarburization
Caustic Cracking
Caustic Corrosion
Erosion / Erosion-Corrosion
Carbonate SCC
Amine Cracking
Chloride Stress Corrosion Cracking
Carburization
Hydrogen Embrittlement
Steam Blanketing
Thermal Shock
Cavitation
Graphitic Corrosion (see Dealloying)
Short term Overheating – Stress Rupture
Brittle Fracture
Sigma Phase/ Chi Embrittlement
885oF (475oC) Embrittlement
Softening (Spheroidization)
Reheat Cracking
Sulfuric Acid Corrosion
Hydrofluoric Acid Corrosion
Flue Gas Dew Point Corrosion
Dissimilar Metal Weld (DMW) Cracking
Hydrogen Stress Cracking in HF
Dealloying (Dezincification/ Denickelification)
CO2 Corrosion
Corrosion Fatigue
Fuel Ash Corrosion
Amine Corrosion
Corrosion Under Insulation (CUI)
Atmospheric Corrosion
Ammonia Stress Corrosion Cracking
Cooling Water Corrosion
Boiler Water / Condensate Corrosion
Microbiologically Induced Corrosion (MIC)
Liquid Metal Embrittlement
Galvanic Corrosion
Mechanical Fatigue
Nitriding
Vibration-Induced Fatigue
Titanium Hydriding
Soil Corrosion
Metal Dusting
Strain Aging
Sulfate Stress Corrosion Cracking
Phosphoric Acid Corrosion
Phenol (carbolic acid) Corrosion
Ethanol Stress Corrosion Cracking
Oxygen-Enhanced Ignition and Combustion
Organic Acid Corrosion Of Distillation Tower Overhead Systems