Corrosion and Materials is a field of study that focuses on understanding the causes and mechanisms of corrosion. According to API 510 and API 570, corrosion and materials specialists are professionals who are “knowledgeable and experienced in the specific process chemistries, degradations mechanisms, materials selection, corrosion mitigation methods, corrosion monitoring techniques, and their impact on equipment and piping systems.”
In reality, the roles and responsibilities of corrosion and materials engineers are extensive. Not only are they relied upon for corrosion and material expertise, they also have to be knowledgeable about nondestructive examination methods, inspection planning, risk-based inspection, process safety management, and much more. A list of 50 important roles and responsibilities of a corrosion and materials specialist can be found here.
Corrosion is one of the most problematic issues in the oil and gas and process industries and often leads to significant operation and maintenance costs. Corrosion takes place in a variety of environments from atmospheric conditions to aqueous solutions. The primary corrosive agent is dissolved oxygen, followed by sulfur compounds and salts, such as sodium chloride (which is inevitably found in marine environments).
Corrosion can develop in a number of different forms. The specific form is dependent on the environment in which a piece of metallic equipment is operating. The most common types of corrosion include:
Each of these processes occur by a specific mechanism and are dependent on the type of material, design of the component, and environmental conditions.
Corrosion also occurs at various rates and is determined by evaluating the amount of material loss over time. The rate of corrosion is also associated with the chemical reaction between the metal component and the surrounding environment. The basis of this chemical reaction is the transfer of electrons. Unfortunately, this reaction occurs spontaneously and is also electrochemically favourable, making corrosion issues difficult to manage.
Corrosion can have negative effects on ceramics at high temperatures, however, the most severe effects occur with ferrous metals. Metals should be carefully selected in order to optimize facility production and eliminate premature failure. Furthermore, metal materials should inherently possess corrosion and high-temperature resistance properties as well as desirable mechanical properties. The material selection process should also take into account material availability, costs, and safety. Once a material is selected, the design and fabrication of an asset should meet specifications and align with the facility’s goals to perform a specific function.
For example, stainless steel, galvanized steel, plain carbon steel, and aluminum and copper alloys are metals used in atmospheric environments. In marine environments, titanium, brass, and copper-nickel alloys are some of the materials of choice used in offshore oil facilities.1 If small amounts of corrosion are identified, the component may be repairable. However, significant corrosion damage can alter the ductility or strength of a component which can lead to adverse consequences.
Each type of corrosion can be treated individually using a number of methods. However, there are several general corrosion prevention techniques that can help control corrosion. These techniques include proper material selection and equipment design, protective coatings and films, the addition of corrosion inhibitors, and cathodic protection. Nondestructive testing techniques are also effective methods for monitoring corrosion and providing information of the condition of a component.
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Inadequate consideration of corrosion and material degradation of many older facilities has complicated the implementation of modern-day RBI programs. This article presents a case study of a heat exchanger with such a design.
Worldwide, microbial-induced corrosion and biofouling are a challenge to the oil and gas industry. Part 1 of this series reviews simple methods for identifying post-construction MIC damage, biofouling, and mitigation and the microbes that cause it.
A focus on typical damage morphology and inspection methods used to identify and characterize high-temperature creep including examples of creep damage and in-service failures to offer insight into this complex damage mechanism.
This final installment of a 3-part series on SCC mitigation will provide practical, actionable steps to improve long-term equipment reliability through design, fabrication/welding, heat treatment, maintenance/repair, and process operating practices.
Shedding some light on the realities of hydrogen diffusion in the context of repair planning and equipment management and helping answer the age-old question, “Do I have to bake this out?”
Our proprietary furnace tube inspection system, FTIS is an ultrasonic inspection technology capable of rapid, automated fired heater coil inspection in refinery fired heaters. The data captured by our furnace tube inspection system is...
As one of the simpler API 579 FFS assessments, there are relevant criteria to check that are necessary to assess and evaluate laminations.
Part 2 of the three-part series on stress corrosion cracking (SCC) that examines common engineering and FFS methods that can be leveraged to understand and evaluate the propensity for an existing form of SCC to lead to loss of containment.
Of the nearly 70 damage mechanisms listed in the latest edition of API RP 571, the highest FEMI risk may be the ones that are highly localized in nature and, therefore, the hardest to find.
An informative discussion with David Osage, President and Principal Engineer at The Equity Engineering Group, regarding the recent update to API 579/FFS-1, Fitness-for-Service, and why it's important to our industry.
A study of the level of deterioration on a catalytic reformer support structure, the challenges involved, the solutions presented, and the aggressive schedule that was required to complete the project.
AET is a powerful, non-intrusive inspection technique to verify the structural integrity of pressure vessels, spheres, high-temperature reactors and piping, coke drums, above-ground storage tanks, cryogenic storage tanks, and more.
The influence of sensitization on creep response of hydrocracker feed fractionator fired heater tubes made of AISI Type 347 stabilized steel after service exposure of around 20 years is investigated.
This article provides an overview of some of the more common forms of stress corrosion cracking (SCC) with a focus on effective inspection methods for detecting these forms of cracking.
This article describes HTHA predictive modeling advances that are designed to demonstrate a direct integration with inspection such that modeling and inspection can be leveraged together in a way never done before.
The application of a detailed design-by-analysis method using ASME Sec-VIII Div-2 confirms field-observed ratcheting and fatigue type failures in the tubesheet due to the complex cyclical thermal-mechanical loading encountered during operation.
A finite element analysis (FEA) was performed on five different models of varying configurations as an approach to establish best practices in the choice of the most appropriate factor of safety, depending on the type of metal loss.
Auto-refrigeration can impose low temperatures onto process vessels and piping causing them to be at risk of brittle fracture, the sudden break-before leak phenomena that can result in catastrophic rupture of the equipment.
Component type is important when assessing the applicability and limitations of a particular assessment (Part and Level) to a particular component. This article explains the evolution of component type definition over the years.
This edition of Damage Control will offer practical steps to mitigate different forms of wet H2S damage and help to minimize long-term inspection and maintenance costs related to wet H2S damage.
Establishing a proactive touch point corrosion integrity management program using engineered on-stream line lifting is a safe and effective means of mitigating unplanned downtime and related safety and potential environmental hazards.
This issue of Damage Control offers a perspective on how to assess the different forms of wet H2S damage using modern FFS and computational analysis techniques with the safe operation of damaged pressure vessels, piping, and associated components.
This article discusses an approach to implementing a corrosion management system using commonly developed documents in most facilities as part of their corrosion control practice.
FFS assessment techniques are applicable to a wide range of damage types: LTA's, cracks, creep damage, dents, and more. These are very powerful analytical tools that often allow operators to not only keep the plant running, but to keep it running...
This article summarizes the fundamentals of wet H2S-related damage mechanisms, offers some practical inspection guidance, and reviews a notable industry failure caused by different forms of wet H2S damage.
Quantifying corrosion for different crude fractions allows planners the ability to mix and match crude blends alternatively to achieve pre-set metal loss and reliability goals. This flexibility has significant implications for extensive cost savings.
Recent advances in UT technology now allow for inspection and continuous monitoring of sulfidic corrosion to be undertaken while the components are on-stream, at temperature, with high-resolution thickness data.
Practical steps to mitigate corrosion under insulation (CUI) damage on fixed pressure equipment and commentary on common mitigation techniques and good engineering practices for external insulation or fireproofing system design and application.
Hydrogen-induced damage mechanisms have been studied endlessly, leading to changes in equipment design and development of new inspection practices. However, the highly localized nature and difficulty of detection of HTHA add additional complexities.
It’s a scary thought to think that with all the new advancements in technology, some facilities still rely on traditional inspection contractors that perform out of date procedures. You rely on technology to keep your home and identity safe, so...
It can be challenging for failure analysts to present complex information to audiences that don't the same knowledge on specialized subjects. Sometimes, failure mechanisms can be summarized with images that can tell the whole story...
In this article, FFS assessment methods are summarized and practical guidance is offered for qualifying CUI damage on carbon and low-alloy steels.
Corrosion under insulation is a form of external corrosion that is caused by trapped water on insulated surfaces. It is an industry problem affecting equipment in the oil and gas, petrochemical, specialty chemical, fertilizer, and related industries.
This article discusses the benefits of an established heat treating process with regards to mechanical integrity, as well as certain quality control measures and the importance of a heat treatment plan.
“Condition monitoring location (CML) optimization” is a frequently used term, particularly for piping circuits. Everyone wants their circuits to be “CML optimized,” but what does this truly mean?
How long does it take for you to receive reports after an inspection has been completed? A week? A month? Does the data come from multiple sources with no way of knowing if it has been manipulated? Traditional inspection contractors do not have...
Temporarily or permanently installed thickness monitors can help to overcome shortcomings and uncertainties associated with manual ultrasonic inspections and can lead to significantly improved maintenance and asset replacement forecasting.
Heat treatment has been used by mankind for centuries. This article details reasons to heat treat, the types of heat treating available, methods of heat treating to achieve specific material properties, and the role of MI in heat treating.
Understanding asset integrity and its management framework is important to sustaining the integrity of assets in the oil and gas industry. This article will discuss eleven primary elements that make up an asset integrity management program.
This article reflects the first in a series on damage mechanisms that will appear in this recurring Inspectioneering column entitled “Damage Control.” The inaugural topic discussed in this column is thermal fatigue.
This article presents a model to better predict the corrosivity of hot crude oil streams, which is based on open literature going back for almost 60 years and incorporates published information from joint industry projects (JIPs).
Integrating a new digital technology that combines data-driven insights and data storage with innovative mobility can provide a new level of connected intelligence. Digitalization can improve workflow, increase worker productivity and allow better...
There are many places where brittle fracture risk can sneak into your plant and many reasons why a new or revised brittle fracture assessment may be required when reviewing your pressure systems. Don’t overlook this dangerous failure mechanism.
For an aging facility, where documents are missing and the operation depends heavily on experience rather than proper engineering designs, auditing a chemical treatment system is a rather challenging task for corrosion professionals.
Nelson curves, which are the foundation of the industry’s HTHA programs, can be tied to mechanistic models from several sources, allowing the recreation of Nelson curves for different operational histories and time durations.
FMR is a useful tool in many situations. It allows nondestructive evaluation of the surface microstructure that is entirely adequate in many cases. However, it is not a panacea, and there are many conditions where it is inadequate.
There are many sources and occurrences of metal fatigue in the chemical and refining industries. They range from low-cycle thermal stresses in an FCCU, to the relentless pressure cycling of a PSA, to the ultra-high cycles of a rotating pump.
Equity Engineering Practices® (EEPs) are a collection of design and maintenance focused corporate standards that include >850 engineering standards, and >300 piping classes. Enhance your mechanical integrity programs, improve equipment...
A refinery or process facility FEMI program consists of eight Pillars that are fundamental to achieve FEMI excellence. This article describes these Pillars in detail and suggests what distinguishes good Pillars from those that are less than adequate.
A cornerstone of Level 1 and 2 metal loss assessment methods in API 579 is the concept of measuring thickness on a grid and constructing a “critical thickness profile.” These concepts are fundamental to Level 1 & 2 assessments in both Parts 4...
MSDs are an important, but often misunderstood, element of FFS analyses. This column will help readers understand what an MSD is and why it is so important to Fitness-For-Service analysis under API 579.
A damage mechanism review, or DMR, is a structured process performed by a qualified team to gain a better understanding of unit operations, corrosion loops, materials of construction, and potential damage types and locations.
A significant number of pipeline failures due to external or internal corrosion have resulted from MIC, some with catastrophic consequences. This article demonstrates a three-step failure analysis process used to investigate the failure mechanism.
Training options to meet your needs. E²G contracts with API to deliver training programs for FFS, Risk–Based Inspection, Damage Mechanisms, and Pressure Relieving Systems. ETI and Customized Training offers specialized courses based on industry...
This is the second of a two-part column on “Creep.” This second part discusses the approach to creep assessment in plant equipment.
This blog article provides examples on addressing widely scattered pitting through the performance of a fitness-for-service assessment using the three conditions set out in the API 510 Pressure Vessel Inspection Code.
CCDs are critical components of a well-maintained MI program and encompass all necessary and relevant MI information for a given process unit. This article defines the value of having CCDs and addresses how to effectively develop and implement them.
Inspectioneering and PinnacleART recently hosted a roundtable discussion for a select group of mechanical integrity experts to discuss strategies for managing corrosion under insulation and corrosion under pipe supports, a.k.a. touch point corrosion.
This is the first of a two-part column on “Creep”. It presents an engineering overview of the phenomena, answers the question: “What is Creep?”, and provides readers with foundational knowledge for evaluating and managing remaining...
What do you need: CONSULTING - Subject matter experts, consultants, or team of highly skilled engineers to help solve my problem. SOFTWARE - My team requires software, products, or resources that will solve the problem. TRAINING - I require...
Brittle fracture and material toughness issues are important concerns in equipment design and FFS. These issues increase when temporary start-up and shutdown conditions require more detailed assessments than provided for in vessel and piping codes.
Understanding how steel can change and be manipulated is crucial to our ability to spot potentially harmful situations in the field. Whether it is a blade made too brittle or a weld that needs post-weld heat treat, knowledge is power.
Corrosion control knowledge and resources can be applied more effectively through the development and implementation of a corrosion management system (CMS). A CMS better-connects management system elements to the process of managing corrosion...
In this column, I touch on what I see as an underused FFS technique for corrosion assessment: point assessment of corrosion – a technique that does NOT require a thickness grid. The reason I find this technique useful is largely because it’s...
API 579-1 is a complex document covering several different types of equipment that may contain flaws or damage. Due to its complexity, this article condenses it into six things you need to know.
In today's chemical and refining industries, sustained long term reliability of facilities is critical to profitability and competitiveness. In fact, history shows that differences in operating expenses between best-in-class refineries, and poor...
This article presents a case study from a Middle Eastern refinery that explores a heat exchanger that failed unexpectedly after five years in service. There are multiple initiators that can cause under deposit corrosion (UDC) in heat exchangers in...
Sea water corrosion and erosion issues can affect almost all commonly used metallurgy in a refinery or petrochemical plant. This brief article explains the dangers behind sea water used in plant cooling systems and discusses several metallurgical...
Given the concern throughout industry regarding the potential for brittle fracture failures, PWHT guidance to address potential issues arising from the recent changes in PWHT code requirements for carbon steel is examined in this article, and...
Hydrogen is a common culprit of equipment damage in the process industries. As hydrogen-induced damage can occur in multiple forms, it’s critical to identify the specific damage mechanism you’re dealing with before undertaking measures to...
Thanks to the development of documents such as API RP 571 and API RP 586, as well as the emergence of qualification demonstration testing, we can align NDT techniques and inspection strategies better than ever. This article examines this progression...
Are you truly prepared for your next Turnaround? Effective work processes are required to successfully plan, manage, review and supervise plant turnarounds. Inspection planning and work scope selection are critical aspects of any turnaround...
Due to its high-cost, Level 3 FFS is typically carried out after Levels 1 or 2 and only in extreme cases. However, advancements in inspection technology and improved use of inspection data have made Level 3 analysis more practical and affordable,...
Amine systems that scrub H2S from hydrogen-rich gas experience rapid fouling of the heat transfer equipment, especially in a hot summer. Learn how temporary cooling solutions can improve process conditions during critical periods of the year with no...
Ensuring the integrity of oil and gas assets is a challenge for oil and gas operators. This article discusses several “pillars” of asset integrity management on which successful O&G operations rely, including Material Selection, Process...
Failure analysis of piping that has experienced corrosion damage provides operators with valuable information needed to prevent future failures. Effective processes and procedures are essential when investigating the cause of corrosion on pipelines...
Effective condition monitoring location selection is a key component of a best-in-class mechanical integrity program. Learn how moving beyond traditional qualitative approaches to optimized CML selection can reduce risk and maximize the value of...
Inspectioneering and API have teamed up to create the Mechanical Integrity Professional Initiative. The goal of this project is to raise the benchmark on industry knowledge and develop the next generation of SMEs. We believe that equipping MI...
Read a firsthand account of how organizing Process, People, Plant, and Performance can reveal breakdowns in your corrosion management practices and drive down corrosion related leaks.
This article summarizes a comprehensive survey conducted by the Research & Development Center (R&DC) of Saudi Aramco to understand top corrosion damage mechanisms experienced by its operating onshore surface facilities.
In this article, the roles and responsibilities of the corrosion and materials SME will be outlined as I see them, fully recognizing that there is probably no one person out there with all the knowledge and skills suggested herein.
Historically, if asked when or how likely an austenitic series stainless steel component is to crack, the usual answer was “very” or “maybe” or, later, “I didn’t see that coming.” With API’s new risk assessment methodology, the...
Beyond the financial hits, undetected degradation from corrosion can also lead to critical safety risks. To effectively manage mechanical integrity, organizations need reliable methods of identifying the current states of corrosion occurring within...
Becht’s industry-leading Corrosion and Metallurgical experts are here to help with significant owner-operator experience covering the refining, petrochemical and chemical industries. This expertise is leveraged to help our clients become more...
This article summarizes seven key questions that an organization needs to answer to create a robust mechanical integrity program that is properly designed to monitor corrosion and indicate when issues increase to a level requiring review or...
The concept of reducing Condition Monitoring Locations (CMLs) is misguided, and the number and location of CMLs should be OPTIMIZED, not systematically reduced. CML allocation in piping requires a good process, otherwise, you can run into a lot of...
Seasoned and knowledgeable inspectors are becoming harder and harder to keep. But using some of the industry documents in a smart way, inspectors with less experience can perform like an inspector with many more years of experience and even develop...
It is a commonly held belief with oil & gas (O&G), oil sands, and pipeline projects that material test reports (MTRs) are always required for turnover to the owner-user, but that is untrue. In this article I will describe what MTRs are, how these...
Experienced material specialists are in short supply and high demand these days. So if you are lucky enough to have one at your disposal, how can you squeeze the most out of that opportunity?
TEAM’s integrated touch point corrosion program manages all aspects of the integrity process from screening for damage to permanent repair assuring integrity – every time. TEAM’s unique turn-key approach to touch point corrosion integrity...
Aging equipment, along with more aggressive service, makes it more important than ever to carry out fitness-for-service (FFS) assessments in support of run/repair/replace decisions. Testing material in the service-degraded condition enables...
The main intention of this article is to introduce the Response Surface Methodology (RSM) using some of the elements of critical thinking as a guide. This methodology is not often used in the industry, but can be widely used by corrosion/process...
This is the second article of a two-part series published in Inspectioneering Journal, which is intended to provide a basis for understanding the differences between traditional tapped-transformer, fixed voltage type rectifiers, and High Frequency...
This article highlights the evolution of corrosion monitoring from conventional ultrasonic to ultrasonic phased array manual and automated solutions and their use for both general purposes and complex applications.
To ensure the mechanical integrity and fitness-for-service (FFS) of equipment, facility managers, reliability engineers, and inspection technicians must understand the HTHA damage mechanism.
Statistical techniques are meant to complement the work of SMEs and can provide deeper insights into the inspection data collected as part of a reliability program. Pinnacle has combined traditional methods, expertise, and Machine Learning to...
Understanding the common factors that promote corrosion threats in the oil and gas value chain helps operators create effective inspection strategies.
Once upon a time in the land of Ooze, there were two processing plants that boiled oil to make fuels and various other valuable petrochemical products. On one side of the river, rests a site called Perfecto Process Plant, while just across the river...
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Pinnacle's data-driven reliability framework ensures the right data is fueling the right intelligence, helping you make confident, strategic decisions.
The 2015 API Spring Refining and Equipment Standards Meeting will be held at the Seattle Sheraton during the week of April 13-16, with plenty of interesting meetings for Inspectioneers. You do not need...
The future of inspection will be based on predictive and proactive technologies that effectively monitor material properties of structures and systems over their entire service life.
Today, more than ever, refinery operators are focused on maintaining safe operations for their employees and extending the life cycle of valuable operating equipment to optimize efficiencies and avoid expensive unforeseen shutdowns. When process...
This article provides background on HTHA, discusses some current developments in HTHA inspection and mitigation, and describes how one refiner is instituting an HTHA risk management plan for its refineries along with challenges they have encountered.
Steam reformers are critical assets for the successful operation of hydrogen, ammonia, and methanol plants. The steam reformer is also one of the most expensive assets in these facilities. Catalyst tubes inside the reformer are one of the most...
Download Pinnacle's Economics of Reliability Report - Refining to see how reliability is affecting profitability.
Corrosion Under Insulation (CUI) is an insidious damage mechanism that, despite being incredibly well-known and understood, still makes up an inordinately large percentage of global maintenance expenditures. CUI has been extensively researched and...
One of the more insidious problems within the industry is the issue of atomic hydrogen dissolving into steel equipment. This can happen to some steel components under certain circumstances and can cause weld failure, or what is known as “hydrogen...
Jim Svetgoff, Corrosion Advisor at Devon Energy recently interviewed with American Business Conferences for the Crude Pipeline Asset Integrity Congress 2014.
Maintaining mechanical integrity for aging power boilers can be challenging. This article provides a case study on how mitigating one damage mechanism led to the discovery of another, and how refinery engineers collaborated with industry experts to...
A small leak from top tubesheet-to-tube welds prompted further inspection of the 1¼Cr- ½Mo Ammonia Converter Boiler Feed Water (BFW) Exchanger during a planned shutdown. Further cracks were identified in the top channel to tubesheet butt weld that...
Antea delivers highly flexible risk-based asset integrity software with 3D Digital Twin integration to optimize maintenance, reduce risk, and improve mechanical integrity for oil and gas, power generation, and chemical plants and facilities....
I've crunched some numbers and have come up with the three most popular damage mechanisms, based on the activity of our readers, that Inspectioneering publishes information on.
One of the more common inspection monitoring programs for pressure vessels is to perform thickness measurement at Corrosion Monitoring Locations (CMLs) to allow monitoring of minimum thicknesses and provide estimates for corrosion rates. These...
As any refining or petrochemical plant manager knows, corrosion can occur on insulated piping at any facility. CUI has been a major challenge for the petrochemical and refining industries since the first pipelines were insulated with wrappings.
High temperature sulfidation is probably the most well- known corrosion mechanism in the oil refining industry because it occurs in large sections of the refinery.
The intent of these two articles is to share lessons learned from recent experiences setting up a comprehensive HTHA review process across multiple refineries, and to help other operators define and mitigate the HTHA risk to an acceptable level.
Pro-Surve recently invested in the latest portable Higher Order Modes Clusters (HOMC) Guided Wave Testing tool, a new concept for the inspection of inaccessible regions using short-range guided waves. Inspection is carried out from the accessible...
This is the second of two articles published in Inspectioneering Journal discussing the value of hydrogen bake-outs. Our first article was published in the May/June 2013 issue and received a great response from the Inspectioneering community. In...
Fired furnaces in the petrochemical and refining industry are critical pieces of equipment that can have a major impact on process unit safety, reliability, and economics. They are complex pieces of equipment, where tubes and other pressure boundary...
Technicians inspecting oil & gas installations and petrochemical plants employ a wide variety of nondestructive testing (NDT) techniques. A new technology has recently been developed that utilizes a real-time portable imaging device which has...
Last week we mentioned three important tips to consider when addressing high temperature hydrogen attack (HTHA). This week, we'd like to provide the reader with a few helpful resources that deal with the topic of HTHA.
Over recent years large strides have been made in application, development, and utilization of Digital Detector Arrays (DDAs) in field radiography environments (an application previously limited to film and computed radiography [CR] techniques).
Tri-Lateral Phased Array is a novel robotic phased array ultrasonic testing technique for the on-stream inspection of fixed equipment in wet hydrogen sulfide (H2S) service. TriLat identifies and quantifies wet H2S damage in the base metal of...
While there are many types of damage mechanisms that can occur in a piece of equipment, localized metal loss is one of the most common. If an inspection reveals that metal loss has occurred, many questions are raised...
A recent High Temperature Hydrogen Attack (HTHA) failure atarefineryinthestateofWashingtonwasa“wakeupcall” to our industry. On April 2, 2010, the shell of a feed-effluent heat exchanger in the Naphtha Hydrotreating (NHT) unit at the Tesoro...
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Composite repair systems can be a great option for owner/ operators to extend the life of their assets without disrupting operations.
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The OmniScan™ X3 64 phased array and TFM flaw detector is equipped with enhanced phased capabilities and even faster TFM. The rugged and portable instrument features powerful 64-element probes with a 128-aperture TFM.
In the last issue of Inspectioneering Journal, Marc McConnell at PinnacleAIS submitted an article discussing hydrogen bake-outs. This article was extremely popular among our readers, both of the printed copy of the Journal and our online users.
Without doubt management needs to ensure that the appropriate resources (human and budgetary) need to be provided for corrosion control and prevention. The C/M engineer/specialist or other responsible party needs to assure that management is advised...
This week’s post takes up right where last week’s post left off in our discussion on Corrosion Management and Control (CM&C) Management Systems. Here are the last two Corrosion Management and Control Management Systems.
This week’s post takes up right where last week’s post left off in our discussion on Corrosion Management and Control (CM&C) Management Systems.
I will emphasize the systems, work processes and procedures for identifying and controlling the rate and types of deterioration in pressure equipment. These are not in any particular order, as they are meant to operate interdependently.
Ethos has assembled a team of experts who apply what they learned through years of process safety experience in the industry and dealing with OSHA and EPA. Click here to learn more about our services.
Remote metallography, in-place metallography, in-situ metallography, and field replication are all examples of typical trade names of this great tool used for assessing the condition of a metal component.
I have written several articles for Inspectioneering Journal to help create successful programs to achieve excellence in pressure equipment integrity and reliability (PEI&R).
With 30 years of refinery experience, I have been through many turnarounds and been involved with a lot of repairs. When I started in the business, we would have inspectors that “owned” their specific pieces of equipment.
Sulfidic corrosion of piping and equipment within the refining industry continues to be a significant cause of leaks and issues that can lead to early replacements, unplanned outages, and incidents potentially resulting in loss of property and...
Over the past few years increased feedstock flexibility has become a growing reality for sustainability of the refining business, requiring processing of more difficult crudes, increased volumes of spot cargoes, and rapid response to crude...
The bp refinery in Rotterdam was able to establish a continuous digital inspection process for the first time by using the DIMATE PACS – including the digital evaluation and transmission of quality-assured inspection data to the RBI.
If an operator finds cracking in a furnace waste heat boiler, excessive thinning in an absorption tower, or severe bulging in a converter, FFS assessments—not standard code analyses—are needed to evaluate the unit’s mechanical...
Perhaps the most important work process to achieve success in fixed equipment PEI&R is to create Corrosion Control Documents (CCD’s) for each process unit. In this article, I expand upon that work process in order to guide the interested...
On August 6, 2012, a piping failure occurred in the #4 Crude Unit at the Chevron U.S.A. Inc. refinery in Richmond, CA. Chevron U.S.A. would like to share some potentially significant preliminary information regarding the incident.
We have recently learned of one organized joint industry project (JIP) that was announced at the Spring 2012 API Refining meeting. As information has become available we have decided to present it to our readership.
Electroless nickel (ENC) is a family of coatings based on nickel-phosphorous metallic compounds. ENC was developed in 1943 by Abner Brenner, an electrochemist at the U.S. Bureau of Standards. While working on the electroplating of nickel onto...
Whether you decide for a Computed Radiography scanner with flexible imaging plates or a flat panel detector with the fastest imaging, or even combine the advantages of both technologies, DÜRR NDT's innovative systems offer high reliability and the...
What I am primarily concerned with, in this article, is erosion corrosion control. Now, what is erosion corrosion? Well, no matter how you might look at it, erosion corrosion involves the degradation of the material by some mechanical action, in...
The morning meeting at the plant was a tough one for you. As an area engineer you are not satisfied with the information you are receiving from your team's investigation into a major compressor wreck that has happened once again. The conclusion...
Deterioration of concrete structures has plagued petrochemical production facilities. As a result of sulfur compound exposure, concrete corrodes and weakens continuously over time. The proper operation of the structure deteriorates with it until...
Putting off the initial inspection (i.e. baseline) of piping and vessels in a new process unit is both common and problematic. The tendency of owners is to rely on the nominal thickness because the actual original thickness was either not measured...
Describes a non-destructive sampling procedure which records and preserves the topography of a metallographic specimen as a negative relief on a plastic film (replica).
On April 6, 2010, a tragic accident occurred at the Tesoro Refinery in Anacortes, WA, in the Naphtha Hydrotreater process unit (NHT). During routine operations involving an on-line switching of unit heat exchanger feed trains, seven employees were...
High Temperature Hydrogen Attack (HTHA) is a long known and still occurring degradation issue for fixed equipment construction materials in the hydrocarbon process industry where hydroprocess plants (hydrogen plus hydrocarbons) are in service....
The following references are from the American Petroleum Institute. They are widely used in the petroleum refining and petrochemical industries for managing equipment in HTHA service and are available in the public domain.
CUI (Corrosion Under Insulation) has always been a challenge for plant operators, quality assurance/reliability engineers and equipment owners. It is hard to identify the problem until it has become an emergency situation, often leading to unit shut...
Clearly, corrosion prevention and control has a major role in achieving excellence in Pressure Equipment Integrity and Reliability (PEI&R). But there is a lot more to PEI&R than just corrosion control. This article will show how corrosion control...
In the current economic environment, there is increasing pressure on petrochemical refineries and delivery systems to be more productive and to minimize unscheduled shutdowns due to leakage. Leakage can occur from either the piping itself or the...
The following is an interview with Scot Haines, (Corrosion Engineering Advisor). The IJ wishes to thank Scot and the Hess Corporation for taking the time to share with the "IJ" community.
Because of widespread interest in the proposed revision in progress to NACE International standard SP0169 (formerly RP0169), "Control of External Corrosion on Underground or Submerged Metallic Piping Systems," NACE is sponsoring an...
The American Petroleum Institute (API) is issuing this publication's announcement to inform companies involved in the distribution, transportation, storage, and blending of denatured fuel ethanol of a potential for metal cracking and product leakage...
NACE International has approved two highly anticipated standards dedicated to the control of internal pipeline corrosion.
Active corrosion in onshore and offshore pipelines is an increasing problem. Consequently, pipeline operators regularly use intelligent inspection pigs to detect and size corrosion. Inspection data can be combined with probability based...
As noted in the discussion on delayed cracking, when the steel contains hydrogen as a result of service exposure (or corrosion, or high temperature - high pressure hydrogen processing) then a hydrogen bake out may be needed to avoid cracking...
A few years ago, TWI investigated a corrosion failure in a 30 inch crude oil pipeline that regrettably led to an explosion and fire, and the death of several operating personnel. The pipeline was designed to ASME B31.4 and the investigation found...
Temper embrittlement is another form of metallurgical degradation resulting from exposure of susceptible low alloy steels to higher temperature ranges, usually in service, but can occur to some extent even during heat treatment. And, once again, if...
Strain-aging problems are another form of metallurgical degradation and thankfully are not very common and becoming less so; but since strain-aging does still occasionally occur, it still makes the list of one of the “99 diseases of pressure...
Another form of metallurgical degradation at higher temperatures is called sigma phase embrittlement. As the name implies, a metallurgical phase change occurs in some stainless steels when they are heated above about 1000F (540C).
Metals will slowly deform under stress and higher temperatures by the mechanism known as creep. The amount of creep deformation that will be experienced is highly dependent upon the level of stress, level of temperature and material properties....
Spheroidization is a rather technical term that describes a metallurgical aging phenomena that results in loss of mechanical and creep strength. It occurs when carbon and low alloy steels are exposed to temperatures in the range of 850F - 1400F...
Aging phenolic resin reactors built in the 1960's were constructed of SA304 stainless steel, many of which were originally fabricated to ASME Section VIII standards were never registered as such nor with the National Board. Some of these reactors...
Carbon dioxide (CO2) corrosion is most typically found in boiler condensate return systems that are not adequately treated with corrosion inhibitors (typically amines). Dissolved CO2 in condensate forms carbonic acid (H2CO3) which corrodes steels...
Boiler feed water (BFW) corrosion is mostly the result of dissolved oxygen in the feed water, but is also related to the quality of the BFW and the quality of the treatment system.
Cooling water (CW) corrosion may be the oldest form of corrosion in the petrochemical industry, yet the industry still struggles with it for two primary reasons.
MIC is caused by biological growth, i.e. organic slime (typically bacteria, algae, and fungi) in water under low flow or stagnant conditions. The industry experiences it in cooling water systems, piping, vessels and storage tank bottoms where the...
Most all flue gases produced by the combustion of fuels contain contaminants that can condense into acid droplets. The amount of contaminants will determine the concentration of the acid droplets.
HTHA falls into multiple categories of corrosion mechanisms, including environmentally assisted cracking, hydrogen assisted cracking, and high temperature degradation. Sometimes HTHA is confused with low temperature hydrogen cracking mechanisms...
Corrosion fatigue is closely related to mechanical and vibration fatigue cracking, except that it is initiated and accelerated by a corrosion mechanism, especially one that gives rise to pitting, from which cracks often initiate. But that...
Accounts with shop validation on carbon steel samples prior to field trials, on an in-service C 1/2 Mo vessel, were reported at a recent industry conference. The studies were successful in the laboratory and appear to make sense in field trials on a...
Several new API inspection recommended practices exist in which inspectors need to be knowledgeable and qualified. This article details some of those standards.
Corrosion from HCl is a significant problem in many refining and chemical process units, and often the materials solution to HCl corrosion is rather expensive, since the lower cost, more available alloys are usually not resistant to most...
Corrosion in the refining industry from HFA is not as widespread a problem as it is with HCl because it is only associated with HF Alkylation Units, which are usually fairly carefully controlled in order to avoid potential for a toxic HFA cloud...
Problems with naphthenic acid corrosion (NAC) are nearly as old as the refining industry. The first paper on the topic that I knew about was written by one of my early industry supervisors over 40 years ago.
Unlike NAC where we’re still on a learning curve, the knowledge of corrosion by sulfuric acid has not changed much in the last quarter century, and there are many good references for it included in API RP 571.
Corrosion from phosphoric acid is another “old knowledge” corrosion issue that effects only a few processes in the chemical and hydrocarbon process industry.
Catastrophic oxidation can occur when certain contaminants are present in a high temperature environment, i.e. inside furnace fireboxes, in our industry. Those contaminants are typically vanadium pentoxide with sulfur oxide or sodium sulfate.
High temperature oxidation is not a real common type of failure in our industry, but it can and does happen when temperatures exceed design maximums. All metals oxidize, even at room temperature, and in many cases that slow oxidation process...
The following is the final part of a 2-part series outlining the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to define an operating envelope.
High temperature sulfidation is probably the most common high temperature corrosion nemesis in the refining industry, since there are very few “sweet” refineries still in operation. Sulfidation corrosion typically is of concern in sour oil...
Though oxidation and sulfidation are quite prevalent high temperature corrosion mechanisms in many of our process units, we now come to a few that are not very common, but still deserve some attention to make sure they don’t lead to...
Decarburization is the antithesis of carburization and rarely results in equipment failure. However, surface decarburization is often a sign that something more serious is going on, ie high temperature hydrogen attack (HTHA), which is well covered...
Metal dusting is simply a severe form or extension of carburization in which the extensive carbides that form as a result of carburization lead to grains of metal falling out of the tube or piping and being swept away by the process...
Corrosion and fouling in HF Alkylation Units are closely linked to feed quality and operating conditions. This article outlines the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to...
Chloride cracking of austenitic stainless steels (300 series SS) is an off-shoot of CUI, and there’s nothing really magical about it. If you have insulated solid stainless steel equipment operating in the CUI temperature range you are likely to...
For purposes of this article, external (atmospheric) corrosion is what afflicts process equipment and structural members that are not insulated and exposed to moisture associated with atmospheric conditions, ie rain, condensation from humidity,...
Soil corrosion (underground corrosion) is another one of those extensively researched and documented types of corrosion, since so many pipes and pipelines are buried and nearly all storage tanks rest on the soil. An entire industry/ technology is...
CUI may be the most well known and widespread corrosion phenomena in our industry. It’s also one of the most difficult to prevent because by and large no matter what precautions we take, water eventually gets into the insulation and begins...
Repair welds can be another undetected and insidious "fabrication defect" that eventually results in equipment failure. Any experienced metallurgist that has completed numerous failure analyses over the years will tell you that periodically they see...
Speaking of stress raisers, they are another insidious type of flaw that can and do lead to equipment failures. Stress raisers (aka stress intensification sites) can be mechanical or metallurgical notches. Undercutting, physical weld flaws,...
When we specify that some equipment (vessels, flanges, fittings, etc.) be overlaid with a corrosion resistant alloy, we need to pay attention to making sure that the chemistry of the top layer of alloy welding, that will be exposed directly to...
When we specify that some equipment (vessels, flanges, fittings, etc.) be overlaid with a corrosion resistant alloy, we need to pay attention to making sure that the chemistry of the top layer of alloy welding, that will be exposed directly to...
DMW cracking is another fabrication issue that can and does result in equipment failure. It usually occurs at the weld juncture where carbon steel or low alloy steels are welded to austenitic (300 series) stainless steels in high temperature...
Liquid Metal Cracking (LMC) (aka "liquid metal embrittlement") is another insidious form of cracking that strikes when you least expect it. It most commonly afflicts austenitic stainless steels, but can afflict other copper, nickel and aluminum...
Carbonate cracking (CC) of carbon steel has seen an increase recently in frequency and severity in some refinery cat crackers, especially in fractionator and gas processing overheads. Some gas scrubbing units are also susceptible. CC is a form of...
Chloride stress corrosion cracking (SCC) is about as well known as any SCC mechanism can be, so I won't dwell much on it here, but want to mention it for the sake of completeness and hopefully mention something that is not as commonly known about...
Cavitation is the sudden formation and immediate collapse of vapor or air bubbles in a liquid stream when system pressure falls below the vapor pressure of the liquid. The sudden collapse of these tiny bubbles generates enormous, though tiny forces...
Few of us have not experienced or heard about vibration fatigue (cracking) failures, especially around pumps and compressors. Typically small branch connections, equalizer lines, vents and drains are susceptible, especially if they are screwed...
Graphitization is not something that operators can do much about, and thankfully it is not very common. We as engineers and inspectors have to know about this one and prevent it or detect it. It occurs when the microstructure of some carbon and...
This is the name given to a form of embrittlement that occurs in 400 series of stainless steels, duplex SS's and less commonly in some 300 series stainless steels containing a metallurgical phase called ferrite. The embrittlement occurs from 600...
During the past two years, a new High Resolution Gamma Ray Detector Array System to detect and measure small corrosion pits in real-time in the inservice piping in process industries, has been in development. This High Resolution Gamma Ray...
This failure mechanism is unfortunately all too common in our industry. It's also known as stress rupture, and it is usually entirely preventable by proper maintenance and operating procedures. It occurs when equipment, piping or furnace tubes...
Now you say, he's got to be putting me on. What is green rot? I didn't invent it. I first read about it in one of the early texts on corrosion engineering by Ughlig or Fontana, the venerable corrosion professors at MIT & Ohio State. But when I...
I already mentioned this common affliction in the introduction. Caustic cracking was long called caustic embrittlement, but since no embrittlement actually occurs that name is fading away.
John has primary responsibility for NDE consulting and troubleshooting for BP around the world in the refining, chemical and gas processing industries. We at the IJ thought it might be valuable to spend some time chatting about his background,...
One of the most important steps involved with regard to tank inspection, using API Standard 653, is establishing the internal inspection interval. API 653 says, "Section 6.4.1.1 Internal inspection is primarily required to: a. Ensure that the bottom...
This is the first of a series of articles that outlines the 101 essential elements that need to be in place, and functioning well, to preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers, furnaces, boilers,...
This paper describes the use of a UT fixture for detection of stress corrosion cracking in ferrous heat exchanger tube-to-tubesheet welds and external tube corrosion or pitting near the tubesheets including crevice OD corrosion.
One of the greatest challenges facing many of refining, fossil power, and pulp and paper industries is: How to effectively examine their insulated piping?
New inspection technology, when added to the proven practice of using tell tale holes (TTHs), proves effective in reducing significant releases and or catastrophic events that are related to internal corrosion / erosion of process piping. In fact,...
This is the fourth in a series of articles on piping inspection that I'm writing for the Journal. One of the previous ones dealt with improving thickness data taking accuracy with digital ultrasonic methods. This article is a "sister article" that...
Corrosion under insulation (CUI) is a real threat to the onstream reliability of many of today's plants. This type of corrosion can cause failures in areas that are not normally of a primary concern to an inspection program. The failures are often...
This article is a practical review of Nondestructive Examination (NDE) methods that can be used to find Erosion/Corrosion (E/C) and/or Corrosion wear in fossil fuel power piping systems. The article is based on experience with PG&E's E/C detection...
Engineers and scientists at Southwest Research Institute (SwRI) in San Antonio, Texas, may have found a cost-effective and practical method of detecting ID and OD corrosion of insulated piping systems.
Nelson Curve changes in the late 1980's provided cause for Shell Oil Company to look at more reliable NDE non-destructive evaluation methods for assessment of materials/equipment in high temperature hydrogen service. The primary change motivating...
In May 1995, Omega International Technology, Inc., began testing a new system to measure pipe wall thicknesses using digital radiography (RT) scanning. This new system has the potential for being faster, less labor intensive, and shown improved...
If it's glass-lined, chances are the environment is very corrosive to most metallics. In general, once the glass lining is breached, through-wall corrosion doesn't take very long. An effective maintenance, operation and inspection program will go...
Low-energy piping system failures in power-generating facilities are often the result of fouling and corrosion. These degradation mechanisms can affect the capacity of piping for fluid-carrying, the heat transfer rates of heat exchangers, and the...
Eight years ago PG&E began a program for its fossil plants for early detection, repair and prevention of Erosion/Corrosion (E/C) failure mechanisms. Since its inception, hundreds of worn piping components have been detected and repaired before...
Corrosion is one of those "equal opportunity" hazards that affects all industries indiscriminately, to the tune of billions of dollars annually in repair and replacement costs. Some types of corrosion are readily apparent, such as rusting of...
The CSB released a new safety video about the fatal explosion that occurred on April 3, 2017, at the Loy-Lange Box Company in St Louis, Missouri.
In this Whiteboard Discussion, Greg Alvarado describes the concept of damage accumulation, or looking at equipment holistically and considering all forms of damage to determine the integrity and remaining life of the equipment.
Clay discusses his professional journey, industry influences, major challenges faced in the process industries, exciting developments in mechanical integrity, and more.
CML Prioritization by the methodology presented in this case study by Pinnacle is a new CML Optimization methodology and predicts future thinning based on past performance from that same CML across repairs and replacements.
This white paper discusses some of the difficulties encountered when performing ultrasonic testing on nickel alloy welds and, in particular, stainless-steel welds, and presents an effective alternative utilizing Phased Array Ultrasonic Testing.
This white paper discusses a unique turn-key approach to touch point corrosion, which eliminates the need for operators to deal with multiple contractors, ensuring seamless integrity management of critical assets.
This Asset Intelligence Report on high temperature hydrogen attack (HTHA) serves as a primer to increase your familiarity with the causes, susceptible areas, prevention/mitigation strategies, detection methods, and remediation techniques for HTHA.
This eBook offers practical guidance for, and real examples of, in-service degradation attributed to stress corrosion cracking (SCC). It provides a detailed discussion on SCC detection, characterization and evaluation, and mitigation.
This Asset Intelligence Report on Corrosion Under Insulation (CUI) serves as a primer to increase your familiarity with the causes, detection methods, and prevention/mitigation strategies for CUI.
This eBook offers practical guidance for, and real examples of, in-service degradation attributed to wet H2s damage. It provides a detailed discussion on wet H2S damage detection, characterization and evaluation, and mitigation or remediation.
Using this interactive corrosion rate form, you can automatically calculate the short- and long-term corrosion rates, remaining life, next inspection, and retirement dates for your piping circuits.
This eBook offers practical guidance for, and real examples of, in-service degradation attributed to corrosion under insulation. It provides a detailed discussion on CUI detection, characterization and evaluation, and mitigation or remediation.
This eBook offers practical guidance for, and real examples of, in-service degradation attributed to thermal fatigue. It provides a detailed discussion on thermal fatigue detection, characterization and evaluation, and mitigation or remediation.
This Asset Intelligence Report on Sulfidation Corrosion serves as a primer to increase your familiarity with one of the most well-known corrosion mechanisms in the oil refining industry.
This Asset Intelligence Report on the hydrogen bake-out process serves as a primer to increase your familiarity with this technique used to drive hydrogen out of equipment prior to welding.
This publication outlines 101 Essential Elements that need to be in place and functioning well in order to effectively and efficiently preserve and protect the reliability and integrity of pressure equipment (i.e. vessels, exchangers, furnaces,...
Houston-based NACE International, The Corrosion Society, and Pittsburgh-based SSPC: The Society for Protective Coatings have merged to create the Association for Materials Protection and Performance (AMPP).
API is currently seeking presentations abstracts for the 2021 Inspection and Mechanical Integrity Summit, scheduled for June 7-10, 2021 in San Antonio, TX. The deadline to submit your abstract for consideration is September 15, 2020.
DNV GL published a recommended practice to manage CUI. This practice DNVGL-RP-G109 risk-based management of corrosion under insulation was developed as part of a collaborative project with partners from across the oil and gas industry.
Following the recent reports of six cases of Coronavirus Disease (COVID-19) in the Houston area, the NACE Board of Directors has voted to postpone their annual CORROSION 2020 conference and expo until June 14-18, 2020.
The American Petroleum Institute has published a new technical report offering guidance to O&G companies on selecting the right materials for bolting, a key to safe and reliable operations.
TEAM’s integrated touch point corrosion program manages all aspects of the integrity process from screening for damage to permanent repair assuring integrity – every time. TEAM’s unique turn-key approach to touch point corrosion integrity...
In a newly released 258-page report, California regulators say they now know the cause of the massive 2015 Aliso Canyon Gas Leak.
According to the report recently released by Research and Markets, the global Asset Integrity Management (AIM) services market is expected to grow at a CAGR of 8.9% over the next eight years and reach $37.92 billion by 2027.
At NACE International’s CORROSION 2019 Conference (Nashville, Tennessee; March 23-28) attendees will get an in-depth look at the latest technologies, research, and equipment that are driving industry innovation.
NACE International today released the "International Measures of Prevention, Application and Economics of Corrosion Technology (IMPACT)" study, in which it estimates the global cost of corrosion to be US$2.5 trillion.
In its final Regulatory Report entitled "Regulatory Report: Chevron Richmond Refinery Pipe Rupture and Fire,” the U.S. Chemical Safety Board (CSB) proposes recommendations for substantial changes to the way refineries are regulated in...
Auto-refrigeration can impose low temperatures onto process vessels and piping causing them to be at risk of brittle fracture, the sudden break-before leak phenomena that can result in catastrophic rupture of the equipment.
A massive explosion and fire at the Silver Eagle Refinery on November 4, 2009, in Woods Cross, Utah, which damaged homes in a nearby neighborhood, was caused by a rupture in a pipe that had become dangerously thin from corrosion, the U.S. Chemical...
The April 2010 fatal explosion and fire at the Tesoro refinery in Anacortes, Washington was caused by damage to the heat exchanger, a mechanism known as “high temperature hydrogen attack” or HTHA.
Pipelines are extremely safe and efficient for transporting energy across the United States, the industry’s continual efforts to improve the safety of the nation’s network of crude and petroleum product pipelines have reduced pipeline...
NACE International announces the commencement of its new global study on costs related to corrosion, an initiative to determine the financial and societal impact of corrosion on industry sectors including infrastructure, manufacturing, utilities,...
An explosion which occurred December 7, 2009, at the NDK Crystal manufacturing company in Belvidere, Illinois, fatally injuring a truck driver at a nearby gas station on the Illinois Tollway, resulted from corrosion in the walls of a pressure...
Chevron U.S.A. Inc. has reviewed Anamet, Inc.’s technical evaluation of the piping samples taken from the Chevron U.S.A. Richmond Refinery following the August 6, 2012 incident.
