API 571 Reference Card

Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

GENERAL CORROSION MECHANISMS-MECHANICAL AND METALLURGICAL FAILURE MECHANISMS

Graphitization Loss in strength, ductility, creep resistance  Primary hot wall piping & Equipment in FCC, Catalytic reformer 800-1100 CS & .5Mo steel Metallographic test *
and Coker Units
 Coarse Pearlitic grades when compare to Bainitc grades Adding Cr +.7
Spheroidization/ Loss in strength, creep resistance- large agglomerated arbides in  Hot wall piping & Equipment in FCC, Catalytic reformer and Coker 850-1400 CS, Cr-Mo Temperature control MG, Tensile and
Softening 5-9% Cr Units hardness tests.
 Fired heaters or boilers also may affect
Temper Reduction in toughness- limited P to 25% of max design P for  Equipment in Hydro processing units particularly reactors, hot 650-1100 2.25Cr-1Mo New -Limit impurities* Charpy Impact
Embrittlement. temp’s below MPT(350 oF for older steel and 150oF for newer feed/ effluent exchanger components and hot HP separators Si, Mn, P, Sn, Sb, As)
steels)  Other units include CRUs, FCC Reactors, Coker and Vis-breaking
units
 Welds are more susceptible than the base metal
Strain Aging Increase in hardness and strength with a reduction in ductility and  Any heavy wall thickness equipment manufactured from - CS & C-.5 Mo Adding aluminum and PWHT No*
toughness. susceptible materials and has not been stress relieved.

885°F Embrittlement Loss in toughness due to a metallurgical change caused by high  Fractionator trays & Internals in High temperature vessels in FCC, 600-1000 400SS series, duplex SS, Use of low ferrite or non-ferritic Impact or bend test
temp. Crude, Vacuum and Coker Units wrought and cast 300 alloys* Hardness *
 Upset tower trays of materials type 409 & 410 while bending/ series SS Use of PWHT followed by rapid
welding. cooling
 DSS heat exchanger tubes.
Sigma Phase Loss of fracture toughness  SS cyclones, Piping duct work, Valves in High temperature FCC 1000-1750 Duplex, Ferritic & use alloys that are resistant to sigma Physical Testing*
Embrittlement Regenerator service. martensitic, with formations *Desigmatized by solution
 300 Series SS weld overlays, Tube-Tube sheet attachment welds Cr> 17%,300 SS wrought annealing@1950/4 hrs
during PWHT ,cast ,weld
 SS Heater tubes
Brittle Fracture Cracks are straight, non-branching with no plastic deformation  Equipment manufactured prior to ASME Sec VIII Div.1 Dec 1987 -- CS, LAS, 400 SS Design for low temp operation * N/A
addenda.
 Thick wall equipment during start-up, shut down or hydro test/
tightness testing.
Creep & Stress Increase of 25 F or 15% stress can cut the remaining life in half,  Heater tubes in fired heaters, tube supports, hangers, and other -- All PWHT UT,RT,ET,VT,WFMT,SW
Rupture Deformation/cracking furnace internals. UT, PT
 Piping & Equipment in or near creep range-
1. Hot-wall catalytic reforming reactors and furnace tubes,
2. Hydrogen reforming furnace tubes,
3. Hot wall FCC reactors,
4. FCC main fractionator,
5. Regenerator internals.
 Weld HAZ at nozzles, High stress areas on catalytic reformer
reactors
 Welds joining dissimilar metals due to differential thermal
expansion

Thermal Fatigue Thermal fatigue is the result of cyclic stresses caused by  Mix points of hot and cold streams such as hydrogen mix points in Temp. swing of 200F All Design & operation to minimize VT,PT,MT *
variations in temperature. Transgranular cracks filled with oxides. Hydro processing units, Where condensate comes in contact with thermal stress & cycling *
steam systems (Attemporators)
 Coke drum shells
 Coke drum skirts
 In Steam generating equipment- The rigid attachment between
super heaters and re-heaters
 Tubes in High temp. SH and RH penetrating through the cooler
water wall tubes
 Steam actuated soot blowers
Short Term Permanent deformation occurring at relatively low stress levels as  All boiler and fired heater tubes All Burner management, Minimize VT,IR, Heat indicating
Overheating – Stress a result of localized overheating. “fish mouth” failures.  Furnaces with coking tendencies-Crude, Vacuum, Heavy oil hydro localized temperature excursions. paint
Rupture processing and coker units,
 Hydro processing reactors
 Refractory lined equipment in FCC, Sulfur plant, and other units
 API 571 Reference Card
Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

that may suffer localized overheating.

Steam blanketing Departure from nucleate boiling (DNB) - near knife edge with  All SG equipment-Fired heaters, Waste heat ex. In sulfur plants, -- CS, LAS Design VT, IR scans
elongation of grains. Hydrogen reformers and FCC units.
 Can occur in SH, RH during start up when condensate blocks
steam flow.
DMW Cracking Occurs on ferrtic side of weld@ high temp. between austenitic and  Welds used to join clad pipe in locations such as transitions in >510 Ferrtic & austenitic Use nickel base filler VT,PT,MT
ferrtic Hydro processing reactor O/L piping
 Hydro processor exchanger I/L and O/L piping
 Alloy transitions inside Fired heaters
 All areas where the welds are done between Ferritic materials and
Austenitic materials

Thermal Shock Thermal fatigue cracking, when high and non-uniform thermal  FCC, Cokers, Catalytic reforming and high severity hydro - All Prevent interruption in flow of high PT/MT, difficult to locate
stress develop over a short time due to differential expansion or processing units temp line.
contraction. Usually occurs when a colder liquid contacts a  High temperature equipment and piping in any unit Minimize severe restraint.
warmer metal surface. Craze cracks  Materials that have lost ductility, such as Cr-Mo Install thermal sleeves
equipment(Temp.Embrittlement) Review hot/cold injection points
 Equipment subjected to accelerated cooling procedures to
minimize shutdown

Erosion/Corrosion Pits, groves, waves, rounded holes and valleys(directional  All equipment and piping exposed to moving fluids and/ or - All More corrosion resistant alloy * VT,UT,RT
pattern) catalysts.
 Piping systems particularly Bends, elbows, tees, reducers,
downstream of letdown valves and block valves, pumps, impellers,
agitators, agitated vessels, heat exchanger tubing, measuring
device orifices, turbine blades, nozzles, ducts and vapor lines,
scrapers, cutters, wear plates, equipment carrying slurries.
 HP reactor effluent piping- Due to Ammonium Bisulfide
 Crude and vacuum unit piping and vessels-Exposed to naphthenic
acid in some crude oils.
Cavitation Sharp-edge pitting damage  Pump casings - All Design VT,UT,RT
 Pump Impellers(Low pressure side)
 Piping D/S of orifice or control valves
 Can be found in restricted flow passages( Heat-ex, Venturis, Seals
and Impellers)
1. Thermal cycling: --
Mechanical Fatigue CS, titanium exhibit an endurance limit- 300 ss, 400 ss, aluminum  Equipment cycles in daily operation-Coke drums. All Design to minimize stress MT, PT
& non-ferrous alloys, don’t exhibit an endurance limit- “calm shell”  Continuous s/by equipment-Aux. boilers concentrations *
fingerprint with “ beach marks”- cracks initiate  Quench nozzle connections such as in water washing systems
2. Mechanical Loading:
 Pressure swing absorbers on Hydrogen purification units
 Rotating shafts on CF pumps and compressors
 Components such as small dia piping
 High pressure drop control valves or steam reducing stations can
cause serious vibration problems in connected piping
Vibration-Induced A form of mechanical fatigue  Socket welds are small bore piping at or near to compressors or --- All Design MT, PT*
Fatigue pumps
 Small bore by-pass lines and flow loops around rotating and
reciprocating equipment
 Small branch connections
Refractory Damage due to oxidation, sulfidation and other high temp  FCC reactor regenerator vessels, Piping, Cyclones, Slide valves -- All Refractories Design VT, IR scan
Degradation mechanisms and Internals; In fluid cokers; In Cold shell catalytic reforming
reactors
 In waste heat boilers and thermal reactors in sulfur plants
 Boiler fire boxes and stacks which also use refractories are
affected.
Reheat Cracking Due to stress relaxation during PWHT @ high temp’s- heavy wall  In heavy wall vessels in areas of high restraint including nozzle --- LAS, 300SS, NI-alloys Design UT, MT, PT
sections- intergranular. welds and heavy wall piping
 HSLA steels are highly susceptible for cracking.
 API 571 Reference Card
Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

Gaseous oxygen- Spontaneous ignition or combustion of metallic and non-metallic  Areas that uses oxygen or enriched air for combustion or other --- 1). CS, LAS-in low pressure 1. Proper cleaning of the component  Backlights can
Enhanced Ignition components can result in fires and explosions in certain oxygen process reasons oxygen greater than 15psig. after Maintenance and Inspection be used for
and combustion enriched gaseous environments if not properly designed, operated  SRU, FCCU, Gasification and Partial oxidation units (POX). With precautions these can 2. Maintain velocity with in check of
and maintained. This occurs at low pressures.  Oxygen piping systems especially valves, regulators and other be used in High pressure recommended limits( Normally 100ft/s hydrocarbon
impingement areas are potentially vulnerable. oxygen. 3. Ensure the suitability of replaced contamination
 Nonmetals such as used for seats and seals are easier to ignite 2). 300SS have more components  VT
than metals. resistance to low pressure 4. Use oxygen compatible lubricants
oxygen and generally 5. Don’t open oxygen systems
difficult to ignite below 200 unnecessarily as this could introduce
psig. contamination
3). Cu-Ni alloys are more 6. Thorough review of design
resistant. 7. Minimize sudden changes in the
4). Alloy 400 Highly pressure in the system
resistant. 8. Don’t use plastic pipes in the
5). Al and Ti should not be oxygen systems.
used.

GENERAL CORROSION MECHANISMS-UNIFORM OR LOCALIZED LOSS OF THICKNESS

Galvanic Corrosion 1) Electrolyte, 2) anode-cathode, 3) electrical connection- Heat ex Normally Tube to Tube sheet different particularly if sea water -- All VT & UT*
depends on cathode area- coat cathode rather than anode. cooling is utilized Design*
Buried pipe lines, Electrical Transmission support towers, ship hulls
Atmospheric Marine (20 mpy), humid (1-3) mpy, dry(<1 mpy) 1. Piping and equipment that operates at temperature sufficiently low <250 CS, LAS, Copper alloyed Design VT, UT
corrosion to allow moisture to present. Aluminum
2. Poor painting or coating condition
3. Equipment that temperature cycled from ambient to higher or vice
versa
4. Equipment idled/ Shutdown for longer periods unless properly
mothballed.
5. Tanks and Piping. Pipe that rests on supports entraps water
6. Piers and docks
7. Bimetallic connections
CUI Pitting damage, loss in thickness-loose flaky scale- carbuncle type 1. Damaged Insulation, Vapor barriers, Weather proofing or mastic or More severe 212- CS, LAS, 300 SS, 400 SS, Appropriate paint coatings, Maintain VT, UT, X-Ray profile,
CS:10°F to 350°F pitting protrusions through the insulations or at insulation termination such 250,>250 for marine env. DUPLEX SS insulation barriers * neutron backscatter.
SS:140°F to 400°F as flanges
2. Ping and equipment with damaged / leaking steam tracing etc….
3. Vibration piping systems, damaged paint locations, Pipe hangers
and supports, Valves and fittings, Bolted on pipe shoes,
4. First few feet of a horizontal pipe run adjacent to the bottom of a
vertical run.
Cooling Water Fresh water> 140°F, brackish water> 115°F, cause scaling- 1. Water cooled heat exchangers and cooling towers in all applications -- All Design Lab samples, velocity, U-
corrosion titanium hydrides >180°F across all industries. factor
Boiler Water Oxygen scavenging (catalyzed sodium sulfite or hydrazine)- 1. External treatment system, De-aerating equipment, Feed water --- CS, LAS, 300 SS, Copper Fe3O4 (magnetite) Water analysis *
Condensate amine inhibitor for CO2 corrosion lines, Pumps, stage heaters and economizers as well as the based alloys
Steam generation system on both water and fire sides and the
condensate return system.

CO2 Corrosion occurs when effluent stream temp drops below dew 1. Boiler feed water and condensate systems in all units <300F CS, LAS 300ss, 400ss, >12%Cr VT, UT, RT
points (300°F) 2. Effluent gas streams of the shift converters in H2 Plant
3. Overhead systems of regenerators in CO2 removal Plants
Flue-Gas Dew-Point Sulfuric & forms @ 280°F, hydrochloric acid forms @ 130°F 1. All fired process heaters and boliers that burns fuels containing -- CS, LAS, 300 ss Design VT, UT, PT, (300 SS to
sulfur locate SCC)
2. HRSG’s that have SS300 series feedwater heaters
Microbiologically Occurs where water is present, stagnant flow-cup shaped pit 1. Heat Ex., Bottom water of Storage tanks, Piping with stagnant or -- All Biocides, Tank internal-coating , Stream analysis
Induced Corrosion within pits in CS or subsurface pits in SS low flow conditions, Piping in contact with some soils. U/G-CP
2. Equipment with Hydro test water has not been removed
3. Product storage tank and water cooled heat exchangers
4. Fire water systems
Soil Soil resistivity is used to determine corrosivety 1. Underground piping and equipment as well buried tank and bottom --- CS, cast iron, ductile iron CP, Coating Measuring Potential *
-external thinning with localized pitting of storage tanks
 API 571 Reference Card
Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

2. Ground supported metal structures

Caustic Localized grooves 1. Steam generating equipment’s and boilers including Heat >175°F, >200°F (very CS, LAS, 300 SS Design* UT, RT
exchangers high)
2. Crude unit
3. Pre-heat exchangers, furnace tubes and transfer lines Units that
add caustic to remove sulfur from compounds
De-alloying Brass become reddish when dealloyed, while cast iron becomes 1. Underground Cast piping when exposed to certain soils <200°F Copper alloys, Cast CP, coating Acoustic techniques,
charcoal gray 2. Heat exch. Tubing-Brass, Al. Brass iron,Alloy400 Ultrasonic
3. Boiler feed water piping system and after boiler components attenuation,MG, UT is
including bronze pumps, monel strainers and brass pressure gage N/A
fittings.
Graphitic Graphite is cathodic-damage occurs in the presence of moisture 1. Under ground piping and boiler feed water equipment <200°F Cast iron Coating Acoustic techniques, MG,
or aqueous phase 2. Fire water systems are particularly vulnerable. UT is N/A

HIGH TEMPERATURE CORROSION [400 °F]

Oxidation General thinning with an oxide layer covering the surface 1. Fired heaters and boilers >1000°F - CS Iron-based alloys Upgrading more resistant alloy* UT
>1500 - 300SS
Sulfidation Hydrogen accelerates corrosion- Uniform thinning ( localized 1. Crude, FCC, Coker, Vacuum, Visbreaker and hydro processing >500, <500 for copper Iron, nickel and copper Add Cr UT
sometimes) units alloys based alloys
2. Boilers and fired heaters exposed to sulfur containing gases Oil
fired heaters where oil containing species of sulfur
Carburization Requires high carbon-activity gas, low oxygen potential 1. Fired heater tubes >1100F Iron-based alloys Lower temp, higher O2&S partial MG, hardness testing
2. Heater tubes in Catalytic reformers and coker units or other pressure
heaters where steam or air decoking is performed
3. Ethylene pyrolysis and steam reformer furnaces
Decarburization Requires low carbon-activity gas, CS will be pure iron. 1. Hydro processing units, Catalytic reforming units, Fired heater --- CS, LAS Add Cr, Mo FMR, MG, hardness test
tubes and pressure vessel components that are hot formed during
fabrication.
Metal Dusting Preceded by carburization-pits filled with crumbly residue of 1. Fired heater tubes, thermo wells and furnace components 900-1500 All No metal is immune-H2S forms VT* ,Heater tubes-
oxides and carbides in LAS operating in carburizing environments protective sulfide layer Compression wave UT*
Deep round pits in SS 2. CRU heater tubes, Coker heaters, Gas turbines, Methanol
reforming unit outlet piping and thermal hydro de-alkylation
furnaces and reactors.
Fuel Ash Contaminants are S, Na,K,V- Molten dissolves oxide layer & 50 1. Any fired heater or gas turbine utilizing fuels All Injecting special additives VT
Cr-50 Ni more resistant 2. Fired heaters burning vanadium, and sodium contaminated fuel
oils or residue.
Nitriding It’s rare- Nitrogen diffuses into surface forming needle-like 1. Steam-methane reformers Starts>600, severe >900 CS, LAS, 300SS, 400SS 30-80% Ni Mg, hardness test, VT,
particles of Fe3N and Fe4N hard brittle surface layer – dull gray 2. Steam gas cracking(Olefin plants) magnetism (300SS)
dry. 3. Ammonia synthesis plants
ENVIRONMENT- ASSISTED CRACKING
Chloride SSC, Surface initiated cracks under the combined action of tensile stress, 1. Water cooled condensers >140 F SS300 Use low chloride water PT, Phase analysis EC
temperature and an aqueous chloride environment. 2. Process side of crude tower overhead condensers techniques *
3. Drains in hydro processing units
4. Bellows and Instrument tubing, Hydrogen recycle streams
containing Cl-,Boiler drain lines, Insulated 300 series SS lines
Corrosion Fatigue Initiate @ pits, notches, surface defect. brittle fracture 1. Rotating Equipment- Galvanic couples between the impeller and ---- All Design UT, MTWFMT
,Transgranular, ,not branched. the pump shaft or any pitting due to any corrosion mechanisms
will act as stress raiser.
2. Deaerators- Residual fabrication or welding stresses, stress
raisers.
3. Cycling boilers: Due to several cold starts, because of differential
expansion will lead to crack the magnetite layer will lead to
corrosion.
Caustic SCC Surface cracks adjacent to non-PWHT- welds- 1. Piping and equipment that handles caustic, including H2S and ----- CS, LAS,300 SS PWHT, Ni alloys are resistant WFMT,EC,RT /ACFM,*
(Embrittlement) Integranular spider web and filled w/oxides- mercaptanremoval units PT Not Good
Transgranular in 300ss-50 to 100 ppm is sufficient for cracking 2. Sulfuric acid and HF alkylation units, improperly heat traced
piping/ equipment, BFW lines, Heat exchanger tubes, Boiler
tubes etc…

Ammonia SCC Copper alloys: aqueous, 8.5 pH, O2, zinc>15%, bluish corrosion 1. Cu-Zn alloy tubes in Heat exchangers. Any range Copper alloys CS PWHT CS-300SS, Ni alloys, 90- EC- Copper Alloys,
 API 571 Reference Card
Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

product, trans/intergranular cracks—CS- anhydrous ammonium, 2. Piping and equipment in ammonia refrigeration units, lube oil 10/70-30 CuNi are immune-process CS-WFMT,SWUT & AET
<.2% water, Air/O2, non PWHT weld or HAZ refining processes, Ammonia storage tanks. control
Liquid Metal Liquid Metal Embrittlement (LME) is a form of cracking those results 1. Location where LME couples are found(SS piping/ vessel in 300 SS –Zn, Cu Alloys All Prevented by protecting metal MT,PT
Embrittlement (LME) when certain molten metals come in contact with specific alloys. contact with Galv. Steel) –Mercury, Alloy 400 – substrates from coming into contact
Cracking can be very sudden and brittle in nature. 2. LME of Al. Can be found in LNG facilities and Cryogenic gas Mercury, Al. Alloys – with the low melting
Intergranular cracking plants due to condensation of liquid mercury. Mercury, HSS-Cd, metal.
Lead.
Hydrogen Loss in ductility-thick walls are more vulnerable as it takes hydrogen 1. CS piping and Vessels in H2S services in FCC, Hydro Ambient to 300F; not CS. LAS, 400SS, PH SS, Use lower strength alloys, PWHT PT, MT,WFMT,
Embrittlement more time to diffuse out- cracks are subsurface or surface initiating- processing, Amine, Sour water and HF Alkylation units. likely above 160-180F HS Ni alloys RT- Not Good
intergranular, brittle cracking. 2. Storage spheres made of HSS
3. Bolts and springs made of HSS
4. Cr-Mo reactors, Drums and exchanger shells on Hydro
processing units and CRU if Weld HAZ hardness exceeds 235
BHN.
Ethanol Stress 1) Surface Initiated cracks, Under the combined action of tensile 1. CS-Storage tanks, Rack piping, and associated equipment. -------- All grades of CS 1. Applying PWHT VT- Not effective since
corrosion cracking stress and a fuel grade ethanol (FGE) or gasoline blend 2. Pipeline used to transport FGE to and from a terminal 2. Apply Proper Coating crack is typically tight and
environment 3. Equipment handling FGE after blended with gasoline at end use filled with corrosion
2) Dissolved oxygen and presence of variable stresses increase the conc. in unleaded gasoline (10%). products
propensity of cracking. WFMT-Most effective
3) Stresses applied/ residual, Water content 0.1 to 4.5 % vol., Shear wave UT-If WFMT
Galvanic coupling of new to corroded steel, Cl- content increase the not feasible
susceptibility, ACFM can be used with
less surface preparation
than WFMT in areas
such as HAZ’s.
EC-Unproven method.
Sulfate stress Surface initiated cracks caused by environmental cracking of Cu 1. Commonly found in Heat exchanger tubes primarily in cooling -------- Some Cu alloys especially Periodic cleaning once in every 5 VT, EC on Heat exch.
corrosion cracking alloys in sulfate solutions. water services Admiralty brass-Highly years Tubes
2. Heat exchanger tube bundles in Overhead distillation systems susceptible Use 90/10 or 70/30 Physical bending of
where sulfate can form at low conc. 70/30, 90/10 Cu alloys are Non Cu based alloys are highly tubes to detect shallow
3. Crude tower overhead exchangers are best example. more resistant immune. cracks in beginning
stages.

GENERAL – UNIFORM OR LOCALIZED LOSS IN THICKNESS PHENOMENA

Amine corrosion Amine itself is not corrosive, contaminates are (CO2, H2S, 1. Amine units, Crude, Coker, FCC, Hydrogen reforming, Hydro >220F CS Proper Op’s, 300ss, avoid O2 VT&UT- Internal
degradation products, HSAS)-CS is suitable for most units- MED, processing and tail gas units. leakage, Avoid HSAS. Profile RT- External
DGA, ADIP, DEA, MDEA-3 TO 6 FPS (rich amine)20 FPS (lean 2. Regenerator re-boiler and regenerator
amine)- general thinning (low velocity), localized (high) 3. Rich amine side of Lean/Rich amine exchangers, hot lean amine
piping, Hot rich amine piping, amine solution pumps and
reclaimers
Ammonium Bisulfide 2% corrosive, 8% highly corrosive- low velocities cause under 1. Hydro processing units(NH4HS Salts) 120-150 CS, Cu alloys brasses Velocity 10-20fps, resistant UT, RT
( Alkaline Sour Water) deposit corrosion,NH4HS salts formed . 2. Air cooler header boxes( Fouling/ Velocity accelerated corrosion) alloys(duplex , 825) @ higher
3. FCC, Sour water stripper, Amine units, delayed coker, (Conc. of velocities
NH4HS)
Ammonium Chloride Occurs in absence of free water @ temp’s above Jew pint- 1. Crude tower overheads-Tower top, top trays, overhead piping, >300 All Ni alloy, Titanium alloys, water wash
Localized pitting-salt have whitish, greenish, brownish appearance exchangers.
UT,RT ,Corrosion Probes
2. Hydro processing units, Catalytic reforming, FCCU and coker
fractionator overheads and top pump arounds.
Hydrochloric Acid Associated with dew point corrosion- PH<4.5- oxygen increase 1. Crude unit, Hydro processing units, CRU --- All Proper Op’s, Ni alloy, Titanium alloy UT,RT, Monitoring Ph
(HCL) corrosion ,Corrosion probes
High Temp H2/H2S Hydrogen increase corrosion rate compared to high temp 1. Hydro processing units-De-sulfurizers, hydrotreaters and hydro >500F All Add Cr VT,UT ,RT
Sulfidation-uniform corrosion cracking units
2. D/S of hydrogen injection points
Hydrofluoric (HF) Acid LAS, 300,400ss aren’t suitable-CS forms protective fluoride scale- 1. Piping and equipment in HF alkylation units >150F CS, Cu & Ni alloys Proper Op’s, design, alloy C-276 UT ,RT
water concentration >3% is corrosive- In CS limit RE=%Cu+%Ni+ 2. HF acid rerun or regenerator tower, Flange faces, dead legs
%Cr=.2 max- Uniform loss for alloy 400 and cracking for non- including inlets to relief valves,
stress relieved alloy 400 3. Condensing overhead vapors in Piping and exchangers on top off
isostripper, de-propanizer and HF stripper/ propane stripper.
4. Heat exchanger bundles that heat acid containing streams.
 API 571 Reference Card
Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

Naphthenic Acid TAN as low as 0.1 could cause problems- corrosion is severe in 1. Crude and Vacuum heater tubes, Crude and Vacuum transfer lines, >425, severe >750 CS, LAS, 300SS, 400SS,Ni Add Mo UT,RT, Hydrogen probes
Corrosion mixed flow stream- Localized, pitting 2. Vacuum bottom piping, HVGO and LVGO circuits, HCGO and alloy
LCGO circuits.
3. Crude and Vacuum tower internals.
4. D/S of crude and vacuum units and U/S of hydrogen mix points.
Phenol (Carbolic It’s solvent to remove aromatics from lube oil -5 to 15% Phenol extraction facilities in lube plant <250F minimal, >450 CS CS, 304ss 316SS, C-276 (High velocities)- Ovhe UT,RT ,ER Probes
Acid) phenol(dilute) is very corrosive- general or localized corrosion. & 304SS temp >30F above dew point
Best prevented through proper material selection & control of ph
solvent chemistry.
Phosphoric Acid Catalyst in polymerization units- solid phosphoric acid is not 1. Piping and equipment in Polymerization unit where water mixes <120°F (300ss@100%), CS,304SS,316SS, Alloy 20 Upgrade metallurgy UT,RT,ER Probes
corrosive- may penetrate 0.25” steel in 8 hrs- general or localized with catalyst <225°F (316ss, alloy
2. Low velocity areas where there is little or no circulation such as 20@85%)
piping manifolds, bottom of kettle type re-boilers, Partial
penetration welds,
Exchangers where there is sufficient residence time to permit the
settling of acid droplets.
Sour Water (Acidic) H2S decreases pH to 4.5- general, localized pitting-SCC may 1. Overhead systems of FCC and coker gas fractionation plants with ------ CS SS,Cu alloys, Ni alloys UT,RT ,Corrosion Probes
occur in 300SS. High H2S levels and low NH3 levels.
Sulfuric Acid Affect CS-HAZ- Severe corrosion in CS@>3FPS and/or >65% 1. Sulfuric acid alkylation units including reactor effluent lines, re- --------- All Ni alloys RT,UT, ER probes
concentration, General corrosion boilers, deisobutanizer overhead systems and the caustic treating
section
2. Bottom of fractionation towers and re-boilers.

GENERAL- ENVIRONMENT-ASSISTED CRACKING

Polythionic acid Occurs during shutdowns, startups, when exposed to air& 1. Heat exchanger tubes, furnace tubes and piping Sensitize austenitic steels Use chemically stable steel (321ss, PT
Stress CC (PASCC) moisture-HAZ “L grade SS is less susceptible to sensitization- 2. FCC units, Hydro processing units, Crude and coker units, Boilers 750°F-1500°F for 347, alloy 825 and alloy625)
Intergranular cracks.” and high temperature equipment exposed to sulfur containing sensitization
combustion products

Amine Stress CC Occurs in lean amines- MEA, DEA mainly- concentration is not a 1. All Non-PWHT piping and equipments in lean amine service including >ambient PWHT, Resistant alloys ACFM/WFMT, PT(not
factor- initiate ID on welds ( transverse or longitudinal) or adjacent contactors, absorbers, strippers, regenerators, and heat exchangers as well good)*
to HAZ- Intergranular and filled with oxides as equipment subject to amine carry over.
Wet H2S Damage Caused by atomic hydrogen. H2 is formed due to corrosion. 1. In hydro processing units- Increasing conc. of above 2% of <180°F Process (pH, H2S below 50, wash Focus on weld seam and
(Blistering/HIC/SOHIC Amm.Bisulfide increase potential of Blistering, HIC and SOHIC CS, LAS water, ammonia &cyanides nozzles-VT, WFMT, EC,
/SSC) 2. Presence of CN- concentrations- PWHT RT/ACFM*
Vapor recovery section of FCC and Delayed coking units, SWUT- Volumetric
Fractionator OH drum, Fractionation towers, Compressor inspection & crack sizing
Interstage separators, KO drums *
HExs, Condensers and Coolers.
Sour water stripper and amine regenerator OH systems
3. SSC is mostly found in hard weld and HAZs in high strength
components including bolts, RV springs, 400 series SS valve trim,
Compressor shafts, sleeves and springs.

Hydrogen Stress Results by exposure to aqueous HF acid environment- HAZ- --- PWHT, Resistant alloys WFMT, Hardness testing
Cracking- HF Interganular- use CS with Carbon equivalent (CE) <0.43
Carbonate Stress Susceptibility increases with pH and carbonate concentration- 1. FCC Unit-Main fractionator OH condensing and reflux system, D/S >200°F PWHT, Resistant alloy WFMT, SWUT
Corrosion Cracking Propagate parallel to welds, weld deposits, HAZ- Intergranular wet gas compression system, Sour water emanating system.Both
and filled with oxides piping and equipment
2. Sour water stripping units of side pump around type in the
pumparound return line to the SWS tower; on the OD process side
of highly cold worked SA-179 Condenser tube U-bends.
3. Piping and equipment in KCO3 in catacarb and CO2 removal
facilities of Hydrogen manufacturing units.
 API 571 Reference Card
Corrosion Description Affected Unit or Equipment Temp. Range Affected metallurgy Prevention Inspection Methods
Mechanism in °F

GENERAL- OTHER MECHANISMS

HTHA Exposure to hydrogen at elevated temperatures and pressures- H 1. Hydro processing units such as hydro treaters(De-sulfirizers) and --- CS, C-Mo, Cr-Mo Add Cr&Mo UT techniques
reacts with carbides to form methane-300ss and >5Cr are not hydro crackers, Catalytic reformers, Hydrogen producing units and
susceptible to HTHA- may cause decarburization- Intergranular hydrogen cleanup units such as pressure swing absorption units
with blistering sometimes. 2. Boiler tubes in very high pressure steam service
Titanium hydriding Hydrogen diffuses into titanium to form hydride (brittle)- PH<3, 1. Primarily in SWS(Sour water strippers and amine units in OH >165°F, Titanium alloys Avoid titanium alloys in hydriding EC Techniques
PH>8 Condensers, Heat exch. Tubes, Piping and other titanium > 350°F in hydrogen services
equipment operating above 165°F atmosphere.
2. Hydrogen atmospheres at about greater than 350°F especially in
the absence of moisture or O2.
3. Cathodically protected equipment with protection potentials < -0.9v
SCE