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API Recommended Practice 571
Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry
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API Recommended Practice 571
General Note:
The entire API RP 571 document is not a part of the API
653 Inspector Certification Exam. Only the sections listed
here are included on the exam. Color photographs of the
corrosion damage are available only when the entire
document is downloaded from the internet. The API RP
571 documents which were purchased as hard copies will
include black and white photographs only.
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Section 1: Scope
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Scope
General guidance as to the most likely damage
mechanisms for common alloys used in the refining and
petrochemical industry is provided in this recommended
practice.
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Section 2: References
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References
Outlines the standards, codes and specifications which
are cited in the recommended practice. This section is
NOT included on the API 653 Certification Exam.
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Section 3: Definition of Terms and
Abbreviations
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Definition of Terms and Abbreviations
These terms, symbols and abbreviations are NOT included
on the API 653 Certification Exam; however, you are
encouraged to become familiar with the terminology of
the industry in order to effectively improve
communication between you and the many people
involved in the inspection process.
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Section 4: General Damage
Mechanisms-All Industries
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General
Damage mechanisms that are common to a variety of
industries including refining and petrochemical, pulp and
paper, and fossil utility are covered in this section.
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Mechanical and Metallurgical Failure
Mechanisms
4.2.7 - Brittle Fracture
4.2.7.1 - Description of Damage
Brittle fracture is the sudden rapid fracture under stress
(residual or applied) where the material exhibits little or
no evidence of ductility or plastic deformation.
The fracture travels through the part at the speed of
sound!
Temperature Considerations: 60°F (15°C - 16°C)
Generally, there is no advance notice.
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Mechanical and Metallurgical Failure
Mechanisms
4.2.7.2 - Affected Materials
a. Carbon steels and low alloy steels are of prime
concern, particularly older steels.
b. 400 series stainless steels are also susceptible.
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Mechanical and Metallurgical Failure
Mechanisms
4.2.16 - Mechanical Fatigue
4.2.16.1 - Description of Damage
a. Fatigue cracking is a mechanical form of degradation
that occurs when a component is exposed to cyclical
stresses for an extended period, often resulting in
sudden, unexpected failure.
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Mechanical and Metallurgical Failure
Mechanisms
b. These stresses can arise from either mechanical
loading or thermal cycling and are typically well
below the yield strength of the material.
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Mechanical and Metallurgical Failure
Mechanisms
4.2.16.2 - Affected Materials
All engineering alloys are subject to fatigue cracking,
although the stress levels and number of cycles necessary
to cause failure vary by material.
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Mechanical and Metallurgical Failure
Mechanisms
4.3.2 - Atmospheric Corrosion
4.3.2.1 - Description of Damage
A form of corrosion that occurs from moisture associated
with atmospheric conditions. Marine environments and
moist polluted industrial environments with airborne
contaminants are most severe. Dry rural environments
cause very little corrosion.
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Mechanical and Metallurgical Failure
Mechanisms
4.3.2.2 - Affected Materials
a. Carbon Steel
b. Low alloy steels
c. Copper alloyed aluminum
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Mechanical and Metallurgical Failure
Mechanisms
4.3.3 - Corrosion Under Insulation (CUI)
4.3.3.1 - Description of Damage
Corrosion of piping, pressure vessels and structural
components resulting from water trapped under
insulation or fireproofing.
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Mechanical and Metallurgical Failure
Mechanisms
4.3.3.2 - Affected Materials
a. Carbon steel
b. Low alloy steels
c. 300 series stainless steel
d. Duplex stainless steel
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Mechanical and Metallurgical Failure
Mechanisms
4.3.8 - Microbiological Induced Corrosion (MIC)
4.3.8.1 - Description of Damage
A form of corrosion caused by living organisms such as
bacteria, algae or fungi. It is often associated with the
presence of tubercles or slimy organic substances.
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Mechanical and Metallurgical Failure
Mechanisms
4.3.8.2 - Affected Materials
Most common materials of construction, including:
a. Carbon steel
b. Low allow steel
c. 300 series stainless steel
d. 400 series stainless steel
e. Aluminum
f. Copper
g. Some nickel based alloys
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Mechanical and Metallurgical Failure
Mechanisms
4.3.9 - Soil Corrosion
4.3.9.1 - Description of Damage
The deterioration of metals exposed to soils is referred to
as a soil corrosion.
4.3.9.2 - Affected Materials
a. Carbon steel
b. Cast iron
c. Ductile iron
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Mechanical and Metallurgical Failure
Mechanisms
4.3.10 - Caustic Corrosion
4.3.10.1 - Description of Damage
Localized corrosion due to the concentration of caustic or
Alkaline salts that usually occurs under evaporative or
high heat transfer conditions. However, general corrosion
can also occur depending on alkali or caustic solution
strength.
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Mechanical and Metallurgical Failure
Mechanisms
4.3.10.2 - Affected Materials
Primarily carbon steel, low alloy steels and 300 Series SS.
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Mechanical and Metallurgical Failure
Mechanisms
4.5.1 - Chloride Stress Corrosion Cracking (Cl SCC)
4.5.1.1 - Description of Damage
Surface initiated cracks caused by environmental
cracking of 300 series stainless steel and some nickel
base alloys under the combined action of tensile stress,
temperature and an aqueous chloride environment. The
presence of dissolved oxygen increases propensity for
cracking.
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Mechanical and Metallurgical Failure
Mechanisms
4.5.1.2 - Affected Materials
a. All 300 series stainless steels are highly susceptible
b. Duplex stainless steels are more resistant
c. Nickel base alloys are highly resistant
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Mechanical and Metallurgical Failure
Mechanisms
4.5.3 - Caustic Stress Corrosion Cracking (Caustic
Embrittlement)
4.5.3.1 - Description of Damage
Caustic embrittlement is a form of stress corrosion
cracking characterized by surface-initiated cracks that
occur in piping and equipment exposed to caustic,
primarily adjacent to non PWHT’d welds.
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Mechanical and Metallurgical Failure
Mechanisms
4.5.3.2 - Affected Materials
a. Carbon steel
b. Low alloy steels
c. 300 series stainless steel
Nickel base alloys are more resistant.
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Section 5: Refining Industry Damage
Mechanisms
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Refining Industry Damage Mechanisms
Damage mechanisms found in the refining environment
are discussed in this section. Only Section 5.1.1.11
(Sulfuric Acid Corrosion) has been made a part of the API
653 Certification Exam, and the only item in this section
which will be covered in this textbook.
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Refining Industry Damage Mechanisms
5.1.1.11 - Sulfuric Acid Corrosion
5.1.1.11.1 - Description of Damage
Sulfuric acid promotes general and localized corrosion of
carbon steel and other alloys. Carbon steel heat affected
zones may experience severe corrosion
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Refining Industry Damage Mechanisms
5.1.1.11.2 - Affected Materials
In order of increasing resistance:
a. Carbon steel
b. 316L55
c. Alloy 20
d. High silicon cast iron
e. High nickel cast iron
f. Alloy B-2
g. Alloy C276
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