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API RP 571 DAMAGE MECHANISMS AFFECTING FIXED EQUIPMENT IN THE REFINING INDUSTRY
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API RP 571
Note it specifically relates to fixed equipment such as pipes,vessels and exchangers(i.e. not rotating equipment such as pumps)
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API RP 571
damage mechanisms
Note how this general terminology of damage mechanism covers more than just corrosion mechanisms
Damage mechanisms
Corrosion mechanisms
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Other mechanisms
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4.2.3 Temper Embrittlement 4.2.7 Brittle Fracture 4.2.9 Thermal Fatigue 4.2.14 Erosion/Erosion-Corrosion 4.2.16 Mechanical Fatigue 4.3.2 Atmospheric Corrosion 4.3.3 Corrosion Under Insulation (CUI) 4.3.4 Cooling Water Corrosion 4.3.5 Boiler Water Condensate Corrosion 4.4.2 Sulfidation 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC) 4.5.2 Corrosion Fatigue 4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.1 High Temperature Hydrogen Attack (HTHA
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API RP 571:CONTENTS
The API 510 syllabus does not include all of API 571,only some of it15 damage mechanisms
4.2.3 Temper Embrittlement 4.2.7 Brittle Fracture 4.2.9 Thermal Fatigue 4.2.14 Erosion/Erosion-Corrosion 4.2.16 Mechanical Fatigue 4.3.2 Atmospheric Corrosion 4.3.3 Corrosion Under Insulation (CUI) 4.3.4 Cooling Water Corrosion 4.3.5 Boiler Water Condensate Corrosion 4.4.2 Sulfidation 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC) 4.5.2 Corrosion Fatigue 4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.1 High Temperature Hydrogen Attack (HTHA
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API RP 571:CONTENTS
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API RP 571:CONTENTS
We will deviate from the order of API 571 and look at these in slightly more logical groupings:
4.2.3 Temper Embrittlement This PowerPoint presentation will 4.2.7 Brittle Fracture 4.2.9 Thermal Fatigue as the first group of look at these 4.2.14 Erosion/Erosion-Corrosion 4.2.16 Mechanical Fatigue damaged mechanisms covered by 4.3.2 Atmospheric Corrosion API 571 4.3.3 Corrosion Under Insulation (CUI) 4.3.4 Cooling Water Corrosion 4.3.5 Boiler Water Condensate Corrosion 4.4.2 Sulfidation 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC) 4.5.2 Corrosion Fatigue 4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.1 High Temperature Hydrogen Attack (HTHA
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Description/appearance of the damage mechanism Have a look at the sections of API 571 and you will see this pattern
Critical factors
Related mechanisms
Inspection/ monitoring
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BRITTLE FRACTURE
Its a failure mechanismnot a corrosion mechanism,as such Flat fracture face Cracks tend to be straight Sudden fracture of the material without any plastic deformation
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BRITTLE FRACTURE
Caused by hydro-testing and/or operating below the Charpy impact transition temperature
Low temperature during pressure test =Low ductility =Low impact strength = Failure
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BRITTLE FRACTURE Vulnerable materials Plain carbon steels 400-series stainless steels
400
Low alloy steels(1-2%Cr etc)
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TEMPER EMBRITTLEMENT
This is a specific type of brittle fracture failurea different cause and different effect to the low temperature type Prolonged exposure to THE CAUSE IS: temperatures 342-593 degC (650-1100 degF).
THE EFFECT IS
Reduction in toughness(impact strength) during start-up and shutdown (rather than at operating temperature) leading to brittle fracture
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TEMPER EMBRITTLEMENT
Its an alloy-specific damage mechanism 2 Cr Mo low alloy steels and similar.Used in boilers,refinery reactors,cat crackers,cokers etc
AFFECTED MATERIALS:
The susceptibility to temper embrittlement is a function of trace element composition:Manganese,Silicon, and trace elements P,Sn etc
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TEMPER EMBRITTLEMENT
But the damage is more severe after prolonged exposure at 440 degC
BUT
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TEMPER EMBRITTLEMENT
The effect is an increase in the temperature at which the material becomes brittle
API 571 describes this as: an upward shift in the ductile-tobrittle transition temperature
NOW
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THERMAL FATIGUE
Rule of thumb
Variations of more than about 93 degC (200 degF) can cause thermal fatigue
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THERMAL FATIGUE
On a macro scale,cracks tend to be dagger-shaped ,wide and oxidefilled(caused by the oxidising effect of the temperature variations)
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MECHANICAL FATIGUE
The result of cyclic stresses caused by mechanical loadings Changes of section Keyways Rough welds Thread notches
Propagation to failure
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ENDURANCE LIMIT
(sometimes called Fatigue limit)
Stress amplitude S Below this stress, the material will not suffer fatigue cracking ,no matter how many stress cycles it sees
Number of cycles N
BUT
Many other materials e.g 300/400 stainless steels,and aluminium DO NOT have an endurance limit
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ENDURANCE LIMIT
Rule of thumb
Cycles N
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MECHANICAL FATIGUE
Mechanical fatigue failure is characterised by Beach Marks resulting from progressive propagation and arrest of the crack
API 571 prefers to call multiple initiation points and beach marks a clam shell fingerprint
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VIBRATION-INDUCED FATIGUE
This is simply mechanical fatigue caused by induced vibrations Failures commonly occur at socket welded or threaded joints: Like these:
Typical causes:
Water hammer Flash-off of fluid Small-bore pipes that are unsupported Vortex-vibration in heat exchangers Failure of pipe hangers
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571
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