API-571 Damage Mechanism comparison Chart

S.N Damage
O. Mechanism Description Affected Material Critical Factors Affected Units Appearance of Damage Prevention/ Mitigation Inspection/ Monitoring Remarks
Erosion/ Erosion- Corrosion removes All Metals/ Alloys & Velocity & Conc of Having Moving Localised loss in thk- pits, Best- More corrosion Visual, UT, RT, Corrosion
Corrosion protective Refractories Particles, Softer Material Fluids grooves, gullies, waves, resistant alloys or altering coupons
films/scales (Cu, Al), Temp, PH rounded holes & valleys, process, Improved design, IR Scan for refractory loss
1 Directional, Failure in Short Hardfacing, Impingement
time plate

Mechanical Fatigue Cyclic Mechanical or All Engineering alloys Design, C-LAS below Daily Operation Clam Shell type fingerprint Best- Good Design Low PT, MT, SWUT
Thermal loading even Endurance 0.4 to 0.5 UTS, having concentric ring called stress stamps & marking
2 below Y.S. 300 & 400 series & Al 106 beach marks
to 107 cycles

Galvanic corrosion corrosion at the all metals except anode,cathode,electrolyte, buried pipelines, crevice,groove or pitting good design, more noble VT & UT
junction of dissimilar noble metals electron flow.farther the heat exchangers corrosion. matrl. Should be coated.
3 metals table more corrosion

Atmospheric Marine & moist CS, LAS Physical location, Marine Poor paint/ Localized, If no coating then Surface Preparation & Proper VT & UT
Corrosion polluted indutrial & Copper alloyed Al 20mpy, Industrial 5-10 , coating General Coating
4 Rural <1, Temp upto 250 oF

CUI Trapped water under CS, LAS, 300 series & Intermittent all temp, Most All insulated C & LAS- Localised pitting, Proper Painting/ Coating , Stripping, UT, X-Ray, Neutron
Insulation Duplex severe 212oF to 350oF piping & 300 series SCC, Flaky scale good insultn, Al foil wrapped backscatter, Eddy-current, IR
Equipment SS piping, Closed-cell foam thermography & guided
5 glass, Low Cl insl for 300 wave UT

Boiler water General corrosion and CS,300 SS,copper result of dissolved gases, feed water pitting due to Oxygen scavanging water analysis.
condensate corrosion pitting in boiler based alloys. oxygen and co2. lines,pumps oxygen,aggressive where treatments include catalyzed
6 system and condnsate there is rapid water temp. sodium sulfide and
piping. rise hydrazine.

Microbiologically corrosion caused by CS,LAS,300SS,400SS,A Water presence,PH 0 to heat exchangers, localized pitting under water should be treated with monitered by measuring
Induced Corrosion living organisms such L,CU. 12, temp.0 to 235 deg.F, all bottom water of deposits or tubercles, biocides such as chlorine, biocide residual, microbe
(MIC) as bacteria, algae or require carbon nitrogen storage tanks. characterized by cup-shaped bromine, ozone, ultraviolet counts and visual
fungi and phosphorous. pits within pits in carbon light or proprietary appearance.
7 steel
 Soil Corrosion deterioration of Carbon steel, cast iron operating temperature, underground external thinning with combination of corrosion measuring soil potential
metals exposed to and ductile iron. moisture,oxygen piping, buried localized metal loss due to resistant coating with using dedicated reference
soils availability and soil tanks, storage pitting. cathotic protection. electrodes.
resistivity. tanks bottom
8

Caustic Corrosion Localised corrosion CS, LAS & 300 series NaOH or KOH Boilers, Steam Localized metal loss, grooves compounds. UT, RT
due to Alkaline salts Generators in boiler tubes, Local thinning
under insulation, CS
corrosion >175oF very high>
9 200oF, 300 series > 150oF

Sulfidation or Sulfidic Sulfur at high temp, All Iron base including Temp > 500oF . Increased Crude, FCC, Uniform thinning or localized Upgrading to higher Cr Alloy Monitoring process Fig 4-144
Corrosion H2 Presence SS, Ni base & Cu base resistance by Cr in 300 Coker, Vacuum corrosion conditions, PMI programs for
series & Ni alloys Corrosion
10 Vs temp

Cl SCC Surface initiated All 300 series SS, Temp > 140oF, PH >2, Ni All 300 series Surface break cracks, Use resistant Material, Low PT or phase analysis EC, UT
cracks under stress, Duplex SS. Ni 8% to 12%. Ni above 35% piping & Branches Cl in hydro, High temp SR for
temp & aqueous Cl alloys are highly highly resistant, CS, LAS 7 equipment 300 series
11 envnmt resistant 400 series not susceptible

Caustic SCC or Caustic Surface initiated CS, LAS & 300 series Caustic 50 to 100ppm Caustic & H2s on BM parallel to weld. Can PWHT >1150oF,Use Ni alloys, WFMT, EC, RT or ACFM PT Fig 4-146
embrittlement cracks exposed to Ni alloys are resistant Service also occur on WM or HAZ, Avoid steamout of Non not effective for Caustic
Caustic adjacent to Spider web PWHT pipes Soda
12 non PWHT'd welds Service
graph

HCL corrosion most often associated All common materials 300 series SS and 400 several units, CS and LAS suffer general upgrading to nickel based check PH of
with dew point of construction series SS are not usefully especially crude uniform thinning, localized Alloy, caustic injection. water,stragetically placed
corrosion resistant,Alloy 400, and vacuum units corrosion or underdeposit corrosion coupons
titanium and some other attack.300 SS and 400 SS will
nickel base alloys have often suffer pitting attack
13 good resistance, and 300 SS may experience
SCC
chloride stress corrosion
cracking

Sour Water Corrosion Corrosion of steel due Primarily affects H2S content, pH, overhead systems typically general Copper alloys and nickel scanning ultrasonic thickness
to acidic sour water carbon steel. SS, temperature, velocity and of FCC and coker thinning,localized alloys are generally not methods or
containing H2S at a copper and nickel oxygen concentration gas fractionation underdeposit attack can susceptible to acid sour profile radiography
14 pH between 4.5 and alloys are more plants occur, especially if oxygen is water corrosion
7.0 resistant. present,
 Amine Stress TS & corrosion in CS & LAS Residual stresses from All non PWHT'd Cracks parallel to welds, In PWHT, Use SS, Water wash WFMT or ACFM PT
Corrosion Cracking aqueous welding, cold working, lean piping & WM transverse or not effective
alkanolamine systems amine services & Wet H2s equipments in Longitudinal
to remoe H2S or CO2, lean Amine
Alkaline SCC, adjacent Services
15 to Non PWHT'd CS
welds