API RP 571 - Damage Mechanisms Spreadsheet

urut No Damage Mechanisms

Temperature Corrosion [>400°F

1 (204°C)]
34 Sulfidation

Wet H2S Damage

FINING Environment-Assisted2 Cracking 62 (Blistering/HIC/SOHIC/SSC)

nical and Metallurgical Failure3 Mechanisms

8 Creep and Stress Rupture

Y Uniform or Localized Loss4in Thickness

52 Phenomena High Temp H2/H2S Corrosion

FINING Environment-Assisted5 Cracking 60 Polythionic Acid Stress Corrosion Cracking

(PASCC)

Y Uniform or Localized Loss6in Thickness

54 Phenomena Naphthenic Acid Corrosion (NAC)

49 Phenomena Ammonium Bisulfide Corrosion

Y Uniform or Localized Loss7in Thickness (Alkaline Sour Water)
 Y Uniform or Localized Loss8in Thickness
50 Phenomena Ammonium Chloride Corrosion

Y Uniform or Localized Loss9in Thickness

51 Phenomena Hydrochloric Acid (HCI) Corrosion

High Temperature Hydrogen Attack

REFINING Other Mech.
10 65 (HTHA)

Temperature Corrosion [>400°F

11 (204°C)]
33 Oxidation

nical and Metallurgical Failure

12Mechanisms
9 Thermal Fatigue

Y Uniform or Localized Loss13in Thickness

57 Phenomena Sour Water Corrosion (Acidic)

nical and Metallurgical Failure

14Mechanisms
18 Refractory Degradation

nical and Metallurgical Failure

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

Temperature Corrosion [>400°F

17 (204°C)]
36 Decarburization

Caustic Stress Corrosion Cracking

Environment – Assisted Cracking
18 42 (Caustic Embrittlement)

niform or Localized Loss of Thickness

19 30 Caustic Corrosion

nical and Metallurgical Failure

20Mechanisms
14 Erosion/Erosion - Corrosion

FINING Environment-Assisted
21Cracking 64 Carbonate Stress Corrosion Cracking

FINING Environment-Assisted
22Cracking 61 Amine Stress Corrosion Cracking

Chloride Stress Corrosion Cracking

Environment – Assisted Cracking
23 40 (CI-SCC)

Temperature Corrosion [>400°F

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

nical and Metallurgical Failure

26Mechanisms
11 Steam Blanketing

nical and Metallurgical Failure

27Mechanisms
13 Thermal Shock

nical and Metallurgical Failure

28Mechanisms
15 Cavitation

niform or Localized Loss of Thickness

29 32 Graphitic Corrosion

nical and Metallurgical Failure

30Mechanisms
10 Short Term Overheating -Stress Rupture

nical and Metallurgical Failure

31Mechanisms
7 Brittle Fracture

nical and Metallurgical Failure

32Mechanisms
6 Sigma Phase Embrittlement
nical and Metallurgical Failure
33Mechanisms
5 885°F Embrittlement

nical and Metallurgical Failure

34Mechanisms
2 Softening (Spheroidization)

nical and Metallurgical Failure

35Mechanisms
19 Reheat Cracking

Y Uniform or Localized Loss36in Thickness

58 Phenomena Sulfuric Acid Corrosion

Y Uniform or Localized Loss37in Thickness

53 Phenomena Hydrofluoric (HF) Acid Corrosion

niform or Localized Loss of Thickness

38 27 Flue-Gas Dew-Point Corrosion

nical and Metallurgical Failure

39Mechanisms
12 Dissimilar Metal Weld (DMW) Cracking

FINING Environment-Assisted
40Cracking 63 Hydrogen Stress Cracking -HF

niform or Localized Loss of Thickness

41 31 Dealloying
niform or Localized Loss of Thickness
42 26 CO2 Corrosion

Environment – Assisted Cracking

43 41 Corrosion Fatigue

Temperature Corrosion [>400°F

44 (204°C)]
38 Fuel Ash Corrosion

Y Uniform or Localized Loss45in Thickness

48 Phenomena Amine Corrosion

niform or Localized Loss of Thickness

46 23 Corrosion Under Insulation (CUI)

niform or Localized Loss of Thickness

47 22 Atmospheric Corrosion

Environment – Assisted Cracking

48 43 Ammonia Stress Corrosion Cracking

niform or Localized Loss of Thickness

49 24 Cooling Water Corrosion

niform or Localized Loss of Thickness

50 25 Boiler Water Condensate Corrosion
niform or Localized Loss of Thickness
51 28 Microbiologically Induced Corrosion (MIC)

Environment – Assisted Cracking

52 44 Liquid Metal Embrittlement (LME)

niform or Localized Loss of Thickness

53 21 Galvanic Corrosion

nical and Metallurgical Failure

54Mechanisms
16 Mechanical Fatigue

Temperature Corrosion [>400°F

55 (204°C)]
39 Nitriding

nical and Metallurgical Failure

56Mechanisms
17 Vibration-Induced Fatigue

REFINING Other Mech.

57 66 Titanium Hydriding

niform or Localized Loss of Thickness

58 29 Soil Corrosion

Temperature Corrosion [>400°F

59 (204°C)]
37 Metal Dusting
nical and Metallurgical Failure
60Mechanisms
4 Strain Aging

Environment – Assisted Cracking

61 47 Sulfate Stress Corrosion Cracking

Y Uniform or Localized Loss62in Thickness

56 Phenomena Phosphoric Acid Corrosion

Y Uniform or Localized Loss63in Thickness

55 Phenomena Phenol (Carbolic Acid) Corrosion

Environment – Assisted Cracking

64 46 Ethanol Stress Corrosion Cracking (SCC)

Gaseous Oxygen-Enhanced Ignition and

nical and Metallurgical Failure
65Mechanisms
20 Combustion

Y Uniform or Localized Loss66in Thickness

59 Phenomena 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 800°F - 1100°F; Graphitization before
after long term operation in the 800 to Spheroidization < 1025°F
1100°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
transition temperature, (by Charpy impact more severe in longterm exposure at
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

May cause a loss in strength and/or creep before Graphitization > 1025°F May
resistance. Cause a 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. This Intermediate Temperature
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 Prevention Inspection

CS, low alloys, 300 SS and 400 SS; Upgrade to higher Cr; Al
Ni base alloys to varying degrees Monitor process conditions and
diffusion treatment of low
depending on Cr content; Copper temperatures; UT For thickness loss;
alloys may reduce but not
base alloys at lower temps than Proactive and retroactive PMI
completely protect
CS

Coatings or alloy cladding;

Water wash to dilute HCN or
inject ammonium polysulfide's Monitor free water phase; Crack
CS and low alloys to convert to thiocyanates; detection best with WFMT, EC, RT or
HIC-resistant steels; PWHT can ACFM; SWUT For crack sizing; AET
prevent SSC and help with
SOHIC; Inhibitors

Minimize temperatures; Combination of techniques; Tubes

All metals and alloys Higher PWHT may help; bulging, sagging, diametric growth
Minimize hot spots in heaters

Order of increasing resistance: CS, Use alloys with high chromium UT, VT and RT For thickness; Verify
content; 300 SS are highly operating temps; Check process H2S
low alloys, 400 SS, and 300 SS resistant at service temps levels periodically

Material selection; Flush with

alkaline or soda ash to
Sensitized austenitic SS; 300 SS, neutralize or purge with
Alloy 600/600H, and Alloy nitrogen or Flapper disc sanding to remove
deposits and PT
800/800H nitrogen/ammonia; Keep
firebox above dewpoint; Heat
treatment at 1650°F

CS, low alloys, 300 SS, 400 SS, and 2% - 2.5% molybdenum shows
improved resistance; Change RT or UT Thickness; Monitor TAN,
Ni base alloys sulfur, Fe, and Ni contents
or blend crudes; Inhibitors

Symmetrical/balanced flow in
and out of air cooled
exchangers; Maintain Frequent UT and RT profile
CS; 300 SS, duplex SS, Al alloys velocities 10 to 20
and Ni base alloys more resistant resistant materialsfps For CS, thickness; IRIS and ECT tubes;
> 20 fps; Monitor water injection
Water wash injection and low
oxygen
 All commonly used materials;
Order of increasing resistance: CS,
low alloys, 300 SS, Alloys 400,
duplex SS, 800, and 825, Alloys
625 and C276 and titanium.
Pitting resistant alloys more RT or UT Thickness; Monitor feed
have improved resistance; streams; Corrosion coupons may be
Limit chlorides; Water helpful if salts deposit on the
wash;°Filming inhibitors element

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

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

CS and low alloys; All 300 SS, 400 Upgrade alloy; Addition of Cr Monitor process conditions and
SS and Ni base alloys oxidize to primary element For oxidation temperatures; UT For thickness loss
varying degrees 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; Cr and Mo Form more Field metallography; Hardness tests
CS and low alloys For softening
stable 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 Design/operation detection; PT not effective (tight,
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;

All metals, alloys and refractories Corrosion - corrosion resistant
alloys; Impingement plates;
Tube ferrules
PWHT at 1150°F; Material
selection; Coatings or alloy
CS and low alloys cladding; Water wash non-
PWHT prior to steamout or
heat treatment; Inhibitors
VT, UT, RT; Corrosion coupons; IR
scans For refractory
Monitoring of pH and CO3-2
concentration; WFMT or ACFM For
crack detection; SWUT For crack
depth: AET

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 Hardenable SS, some
high strength Ni base alloys.
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, Minimize weld metal ferrite Testing of samples; Cracking during
and duplex SS
Use lower strength steels;
PWHT; Low hydrogen, dry
electrodes, and preheat For
welding; Bake out at 400°F or MT or PT For surface cracks; UT may
higher; Controlled be helpful; RT not sensitive enough
pressurization sequence;
Protective lining, SS cladding,
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;
content; Solution anneal at t/a or when below 500°F
1950°F and water quench to
reverse
Alloys containing a°Ferrite phase; Use low ferrite or non-ferritic Impact/bend test samples; Cracking
alloys; Heat treat to 1100°F during t/a or when below 200°F;
400 SS and Duplex SS and cool rapidly Increase in hardness

Minimize exposure to elevated Field metallography or removal of

CS and low alloys temps samples

low alloys, 300 SS, and Ni base Joint configurations in heavy UT and MT/PT For surface cracks; UT
alloys; High Strength Low Alloys walls; Minimize stress risers For embedded cracks
(HSLA)

Order of increasing resistance: CS, Materials selection; Proper

316L, Alloy 20, high Si cast iron, UT or RT of turbulent zones and
operation; Caustic wash to
high Ni cast iron, Alloy B-2 and hottest areas; Corrosion coupons
neutralize
Alloy C276

Monitor CS operating > 150”F

Low alloys, 300 SS and 400 SS are
generally not suitable; CS, Cu-Ni
alloys, Alloy 400, an other Ni base 400 (solid or clad)
alloys have been used in some
applications
For thickness; Minimize water,
oxygen, sulfur and other
RT or UT Thickness; Monitor small
contaminants in feed; Alloy
bore piping, flange face corrosion,
used to
blistering/HIC/SOHIC
eliminate
blistering/HIC/SOHIC. PWHT to
minimize possibility of SCC.

Maintain temps > 280°F; Avoid

300 SS if chlorides present;
CS, low alloys and 300 SS Soda Ash wash to neutralize UT For wall loss; VT and PT For SCC
the acids

Ni based fillers; 300 SS rods

Widely differing thermal used in low temp location Visual and MT/PT For OD cracks; UT
expansion coefficients; Most only; Pup piece with For ID cracks
common CS to Austenitio SS intermediate coefficient

PWHT; Weld hardness < 200

HB and no localized zones >
CS and low alloys 237 HB; CS with Carbon WFMT For cracks; Hardness testing
Equivalent < 0.43; B7M Bolts;
Coatinas or allov cladding

VT (may change color but may

Difficult to predict; Addition of
Primarily copper alloys as well as alloying
elements may help; CP
Alloy 400 and cast iron
or coatings may help
require scale removal),
Metallography, Loss of "metallic
ring"

CS and low alloys
All metals and alloys
All conventional alloys for process Burner design/management;
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 Oxygen scavenging treatment;
SS and copper based alloys
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)
Blend or change fuel source;
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 VT and UT thickness internal; UT
drop to minimize flashing; scans or profile RT For external;
Avoid oxygen inleakage; Corrosion coupons
Remove 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, Copper - monitor pH, ECT or VT on
prevent ingress of air, upgrade tubes For cracking; CS - WFMT, AET,
to 300 SS or Ni alloys; CS - or External SWUT
PWHT or addition 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
Water analysis; Dearator cracking
Amine inhibitor treatment WFMT

Most common materials of
construction
Many commonly used materials
All metals with the exception of
most noble metals; SEE Table 4-4 Design; Differing alloys not in
intimate contact; Coatings
for Galvanic Series
All alloys; Stress levels and
number of cycles to failure vary by
material
Carbon steels, low alloys, 300 SS
and 400 SS; Ni based alloys more Alloy change to 30% - 80% Ni
resistant
All engineering materials
Titanium alloys
Carbon steel, cast iron, and
ductile iron
All; No known alloy immune
under all conditions
Treat water with biocides; VT; Measure biocide residual;
Maintain flow velocities; Operating conditions indicate
Empty hydrotest water; Fouling; Foul smelling water
Maintain coatinqs
Keep metal with low melting
point away from other metal; MT or PT For cracks, RT For mercury
Grind out cracks not deposits inside tubes
acceptable
Visual and UT Thickness
Good design; Material MT, PT, SWUT For cracks; Vibration
selection; Minimize stress monitoring
risers
Change in color to dull gray;
Hardness testing (400 - 500 BHN);
Check 300 SS For magnetism;
Metallography; ECT; PT, RT, or UT For
cracking in advanced stages
Design; Supports and vibration
dampeners; Stiffeners on small Visual/Audible signs of vibration
bore; Branch sizing
No titanium in known
hydriding services such as
amine or sour water; Use all ECT; Metallography; Crush/Bend test
titanium if galvanic coupling
may promote hydriding
Most effective coatings and 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

Order of increasing resistance: CS, Material selection; Velocity < RT or UT Thickness; Corrosion
30 fps; Recovery ovhd temps
304L, 316L and Alloy C276 coupons
at 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 Process

catalytic reforming - fixed bed

catalytic reforming - ccr
fcc light ends recovery
crude unit / vacuum

delayed coker
No ANY 10 100 200 300 400 500 600 800

fcc
1 any >500 x x x
2 cs & low alloy >ambient<180 <300 x x x x
3 any x x x x x
4 any >500
5 x x
6 x x x
7 x x
8 x x x x x x
9 x x x
10 x x
11 x x x x x
12 x x x
13
14 x 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 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 x
55
56
57
58
59 x 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 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