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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 1

    ASME B31.3 Process Piping

    Charles Becht IV, PhD, PE

    Don Frikken, PE

    Instructors

    BECHTENGINEERING COMPANY, INC. Materials - 2

    1. Establish applicable system standard(s)2. Establish design conditions3. Make overall piping material decisions

    Pressure Class

    Reliability

    Materials of construction

    4. Fine tune piping material decisions Materials

    Determine wall thicknesses

    Valves

    5. Establish preliminary piping system layout & support

    configuration6. Perform flexibility analysis7. Finalize layout and bill of materials8. Fabricate and install9. Examine and test

    Piping Development Process

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 3

    3. Materials

    Strength of Materials

    Bases for Design Stresses

    B31.3 Material Requirements

    Listed and Unlisted Materials

    Temperature Limits

    Toughness Requirements

    Fluid Service Requirements

    Deterioration in Service

    BECHTENGINEERING COMPANY, INC. Materials - 4

    The Material in This Section isAddressed by B31.3 in:

    Chapter II - Design

    Chapter III - Materials

    Appendix A - Allowable Stresses & QualityFactors Metals

    Appendix F - Precautionary Considerations

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 5

    Strength of Materials

    StressStrain

    Stress-Strain Diagram Elastic Modulus

    Yield Strength

    Ultimate Strength

    Creep

    Fatigue

    Brittle versus Ductile Behavior

    BECHTENGINEERING COMPANY, INC. Materials - 6

    Strength of MaterialsStress (S): force (F) divided by area (A)

    over which force acts, pounds force/inch2

    (psi), Pascals (Newtons/meter2)

    Strain (): change in length (L) divided

    by the original length (L)

    F

    L L

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 7

    Strength of Materials

    Strain

    Stress

    E = Elastic Modulus = Stress/Strain

    SY = Yield Strength

    ST = Tensile Strength

    Typical Carbon Steel

    BECHTENGINEERING COMPANY, INC. Materials - 8

    Strength of Materials

    ST = Tensile Strength

    Typical Stainless Steel Strain

    Stress

    SY = Yield Strength

    0.2% offset

    Proportional Limit

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 9

    Strength of Materials

    Creep: progressive permanentdeformation of material subjected toconstant stress, AKA time dependentbehavior. Creep is of concern for

    Carbon steels above ~700F (~370C)

    Stainless steels above ~950F (~510C)

    Aluminum alloys above ~300F (~150C)

    BECHTENGINEERING COMPANY, INC. Materials - 10

    Strength of Materials

    Time

    Strain

    Primary Secondary Tertiary

    Rupture

    Creep Rate (strain/unit time)

    Typical Creep Curve

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 11

    Strength of Materials

    Minimum Stress to Rupture, 316 SS

    Fig I-14.6B, ASME B&PV Code, Section III, Division 1 - NH

    BECHTENGINEERING COMPANY, INC. Materials - 12

    Strength of Materials

    Stress

    Number of Cycles

    Fatigue failure: a failure which results from arepetitive load lower than that required to causefailure on a single application

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 13

    Strength of Materials

    Brittle failure:

    Ductile deformation:

    BECHTENGINEERING COMPANY, INC. Materials - 14

    Strength of MaterialsBrittle failure:

    Ductile failure:

    Strain

    Stress

    Toughness

    Strain

    Stress

    Toughness

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 15

    Strength of Materials

    Measuring Toughnessusing a Charpy impacttest H1

    Charpy Impact Test

    Cv = W(H1 - H2)

    = Energy Absorbed

    H2

    H1 -H2W

    Pendulum

    Specimens tested at 40, 100 and 212F(4, 38 and 100C)

    BECHTENGINEERING COMPANY, INC. Materials - 16

    Strength of Materials

    Ductile to Brittle Transition for a Carbon Steel

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 17

    Bases for Design Stresses

    Most Materials

    Bolting

    Gray Iron

    Malleable Iron

    BECHTENGINEERING COMPANY, INC. Materials - 18

    Bases for Design StressesMost Materials (materials other than grayiron, malleable iron and bolting) below thecreep range, the lowest of (302.3.2)

    1/3 of specified minimum tensile strength (ST)

    1/3 of tensile strength at temperature

    2/3 of specified minimum yield strength (SY)

    2/3 of yield strength at temperature; exceptfor austenitic stainless steels and nickelalloys with similar behavior, 90% of yieldstrength at temperature

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 19

    Bases for Design Stresses

    Most Materials additional bases in thecreep range, the lowest of (302.3.2)

    100% of the average stress for a creep rateof 0.01% per 1000 hours

    67% of the average stress for rupture at theend of 100,000 hours

    80% of the minimum stress for rupture at theend of 100,000 hours

    BECHTENGINEERING COMPANY, INC. Materials - 20

    Bases for Design StressesASTM A106 Grade B Carbon Steel (US Customary Units)

    0.00

    5.00

    10.00

    15.00

    20.00

    25.00

    0 200 400 600 800 1000

    Temperature, F

    Stress,

    ksi

    2/3 of Yield

    1/3 of Tensile

    Allowable

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 21

    Bases for Design Stresses

    ASTM A106 Grade B Carbon Steel (Metric Units)

    0.0

    20.0

    40.0

    60.0

    80.0

    100.0

    120.0

    140.0

    160.0

    180.0

    0 100 200 300 400 500

    Temperature, C

    Stress,

    MPa

    2/3 Yield

    1/3 Tensile

    Allowable

    BECHTENGINEERING COMPANY, INC. Materials - 22

    Bases for Design StressesASTM A312 Gr TP316 Stainless Steel (US Customary Units)

    0.00

    5.00

    10.00

    15.00

    20.00

    25.00

    30.00

    0 200 400 600 800 1000

    Temperature, F

    Stress,

    ksi 2/3 Yield

    90% Yield

    1/3 Tensile

    Allowable

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 23

    Bases for Design Stresses

    ASTM A312 Gr TP316 Stainless Steel (Metric Units)

    0.0

    20.0

    40.0

    60.0

    80.0

    100.0

    120.0

    140.0

    160.0

    180.0

    200.0

    0 100 200 300 400 500

    Temperature, C

    Stress,

    MPa

    2/3 Yield

    90% Yield

    1/3 Ultimate

    Allowable

    BECHTENGINEERING COMPANY, INC. Materials - 24

    Bases for Design StressesAdditional Notes

    For structural grade materials, design

    stresses are 0.92 times the value determinedfor most materials (302.3.2)

    Stress values above 2/3 SY are notrecommended for flanged joints and othercomponents in which slight deformation can

    cause leakage or malfunction (302.3.2)

    Design stresses for temperatures below the

    minimum are the same as at the minimum

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 25

    Bases for Design Stresses

    Bolting below the creep range, the lowestof (302.3.2)

    1/4 of specified minimum tensile strength(ST); if properties are enhanced by heattreatment or strain hardening, 1/5 ST

    1/4 of tensile strength at temperature

    2/3 of specified minimum yield strength (SY);if properties are enhanced by heat treatment

    or strain hardening, 1/4 SY 2/3 of yield strength at temperature

    BECHTENGINEERING COMPANY, INC. Materials - 26

    Bases for Design StressesBolting additional bases in the creeprange, the lowest of (302.3.2)

    100% of the average stress for a creep rateof 0.01% per 1000 hours

    67% of the average stress for rupture at theend of 100,000 hours

    80% of the minimum stress for rupture at the

    end of 100,000 hours

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 27

    Bases for Design Stresses

    Gray Iron the lowest of (302.3.2)

    1/10 of specified minimum tensile strength(ST)

    1/10 of tensile strength at temperature

    BECHTENGINEERING COMPANY, INC. Materials - 28

    Bases for Design StressesMalleable Iron the lowest of (302.3.2)

    1/5 of specified minimum tensile strength (ST)

    1/5 of tensile strength at temperature

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 29

    B31.3 Material Requirements

    Listed and Unlisted Materials

    Temperature Limits

    Impact Test Methods & Acceptance

    Toughness Requirements

    Fluid Service Requirements

    BECHTENGINEERING COMPANY, INC. Materials - 30

    Listed and Unlisted Materials Listed Material: a material that conforms

    to a specification in Appendix A or to astandard in Table 326.1 may be used(323.1.1)

    Unlisted Material: a material that is notso listed may be used under certainconditions (323.1.2)

    Unknown Material: may not be used(323.1.3)

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 31

    Listed and Unlisted Materials

    An unlisted material may be used if(323.1.2)

    It conforms to a published specificationcovering chemistry, mechanical properties,method of manufacture, heat treatment, andquality control

    Otherwise meets the requirements of theCode

    Allowable stresses are determined in

    accordance with Code bases, and

    Qualified for serviceall temperatures (323.2.3)

    BECHTENGINEERING COMPANY, INC. Materials - 32

    Temperature LimitsListed materials may be used above themaximum described in the Code if (323.2.1)

    There is no prohibition in the Code

    The designer verifies serviceability of thematerial, considering the quality of mechanicalproperty data used to determine allowablestresses and resistance of the material to

    deleterious effects in the planned fluid service(323.2.4)

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    BECHTENGINEERING COMPANY, INC. Materials - 33

    Temperature Limits

    Listed materials may be used within thetemperature range described in the Code if(323.2.2)

    The base metal, weld deposits and heataffected zone (HAZ) are qualified inaccordance with Column A of Table 323.2.2.

    BECHTENGINEERING COMPANY, INC. Materials - 34

    Table 323.2.2Requirements for Low Temperature Toughness Tests

    Seepag

    e21ofthesu

    pplemen

    t.

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    BECHTENGINEERING COMPANY, INC. Materials - 35

    Temperature Limits

    Listed materials may be used below theminimum described in the Code if (323.2.2)

    There is no prohibition in the Code

    The base metal, weld deposits and heataffected zone (HAZ) are qualified inaccordance with Column B of Table 323.2.2.

    BECHTENGINEERING COMPANY, INC. Materials - 36

    Carbon Steel Lower Temperature Limits Most carbon steels have a letter

    designation in the column for minimumtemperature in Appendix A

    See page 26 of the supplement

    Note Min. Temp. column

    Read Appendix A note 7

    Read Appendix A note 4 & see page 27 For those that do, the minimum

    temperature is defined by Figure 323.2.2A

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    ASME B31.3 Process Piping Course 3. Materials

    BECHTENGINEERING COMPANY, INC. Materials - 37

    Figure 323.2.2AMinimum Temperatures without Impact Testing for Carbon Steel

    Seepag

    e23oft

    hesupp

    lement.

    BECHTENGINEERING COMPANY, INC. Materials - 38

    Carbon Steel Lower Temperature Limits Impact testing is not required down to

    -55F (-48C) if stress ratio does notexceed the value defined by Figure323.2.2B

    Impact testing is not required down to-155F (-104C) if stress ratio does not

    exceed 0.3

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    BECHTENGINEERING COMPANY, INC. Materials - 39

    Fig.323.2.2BReduction in Minimum Design Temperature w/o Impact Testing

    See page 24 of the supplement.

    BECHTENGINEERING COMPANY, INC. Materials - 40

    Carbon Steel Lower Temperature LimitsFig.323.2.2B provides a further basis for useof carbon steel without impact testing. Ifused: Hydrotesting is required

    Safeguarding is required for components withwall thicknesses greater than in. (13 mm)

    Stress Ratiois the largest of

    Nominal pressure stress / S Pressure / pressure rating

    Combined longitudinal stress / S

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    BECHTENGINEERING COMPANY, INC. Materials - 41

    Carbon Steel Lower Temperature Limits

    Design Pressure: 650 psig(45 bar)

    Design Temperature:735F (390C).

    Pipe material is ASTM A53Gr B seamless.

    What options are availableto deal with expected

    ambient temperaturesdown to -30F (-34C)? 0.971.000

    (25.40)

    30

    (750)

    0.860.500

    (12.70)

    12

    (300)

    0.740.237

    (6.02)

    4

    (100)

    0.710.178(4.52)

    1

    (25)

    StressRatio

    NominalWTin (mm)

    NPS

    (DN)

    BECHTENGINEERING COMPANY, INC. Materials - 42

    Impact Test Methods and Acceptance Impact testing is done in accordance with

    ASTM A370

    Each set of impact test specimensconsists of 3 bars

    Impact test temperature:

    For full size (10 mm square) Charpy V-notch

    specimens, the design minimum temperature For subsize specimens smaller than 8 mm,

    below the design minimum temperature[323.3]

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    BECHTENGINEERING COMPANY, INC. Materials - 43

    Impact Test Methods and Acceptance

    Acceptance criteria Most steels, based on energy absorbed per

    Table 323.3.5

    For high strength steels, including bolting,based on minimum lateral expansion of0.015 in. (0.38 mm) opposite the notch

    Retest of a second set of three specimensis permitted under certain conditions.

    [323.3]

    BECHTENGINEERING COMPANY, INC. Materials - 44

    Fluid Service Requirements (323.4.2)

    Ductile Iron

    generally limited to temperature range of

    -20F to 650F (-29C to 343C) and B16.42ratings

    welding is not permitted

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    BECHTENGINEERING COMPANY, INC. Materials - 45

    Fluid Service Requirements (323.4.2)

    Other Cast Irons may not be used under severe cyclic

    conditions

    may be used for other services ifsafeguarded for heat, thermal andmechanical shock, and abuse

    may not be used in above ground flammableservice above 300F (149C) or above 400

    psi (2760 kPa)

    BECHTENGINEERING COMPANY, INC. Materials - 46

    Fluid Service Requirements (323.4.2) Gray Iron

    may not be used in flammable service above150 psi (1035 kPa)

    may not be used in other services above 400psi (2760 kPa)

    Malleable Iron may not be used outside -20F to 650F

    (-29C to 343C) High Silicon Iron

    may not be used in flammable service

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    BECHTENGINEERING COMPANY, INC. Materials - 47

    Fluid Service Requirements (323.4.2)

    Aluminum Castings the designer is responsible for establishing

    design stresses and ratings if thermal cutting isused

    Lead, Tin & their Alloys

    may not be used with flammable fluids

    Clad Materials

    cladding may be considered to be part of thethickness of components under certainconditions

    BECHTENGINEERING COMPANY, INC. Materials - 48

    Deterioration in Service Selection of material to resist deterioration

    in service is not within the scope of theCode. (323.5)

    Recommendations for material selectionare presented in Appendix F.

    General considerations

    Specific material considerations

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    BECHTENGINEERING COMPANY, INC. Materials - 49

    Deterioration in Service

    Types of Damage Mechanisms Loss of metal

    Stress Corrosion Cracking

    Metallurgical and Environmental Degradation

    BECHTENGINEERING COMPANY, INC. Materials - 50

    Loss of MetalLoss of metal can be

    General

    Localized

    depending on thephysical conditions andthe specific mechanism.

    A Rainbow of Rust Colors

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    BECHTENGINEERING COMPANY, INC. Materials - 51

    Loss of Metal

    Mechanisms include Galvanic corrosion

    Atmospheric corrosion

    Corrosion under insulation

    Crevice

    BECHTENGINEERING COMPANY, INC. Materials - 52

    Galvanic CorrosionElectrochemical process

    The anode is the site atwhich the metal iscorroded

    The electrolyte is thecorrosive medium

    The cathode forms theother electrode in the celland is not consumed inthe corrosion process

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    Galvanic corrosion

    GALVANIC SERIES INSEA WATER

    CORRODED END (Anodic)MagnesiumZinc

    AluminumCadmiumMild SteelCast IronStainless Steels 18/8 (Active)LeadTinNickel (Active)BrassCopperAluminum BronzeCupro nickelSilver SoldersNickel (Passive)Stainless Steel 18/8 (Passive)

    Silver

    TitaniumGraphiteGoldPlatinumPROTECTED END (Cathodic)

    Carbon Steel Nipple Threaded into a

    Stainless Steel Water Tank

    BECHTENGINEERING COMPANY, INC. Materials - 54

    Galvanic corrosionMaterials Affected

    All metals, with the exception of most noble metals, are affected.

    Critical Factors

    For galvanic corrosion, three conditions must be met:

    Presence of an electrolyte

    Two different metals or alloys in contact with the electrolyte

    An electrical connection between the anode and the cathode

    The relative exposed surface areas between anodic material andthe cathodic material has a significant affect

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    Galvanic corrosion

    Prevention The best method for prevention/mitigation is through good design.

    The more noble material may need to be coated. If the activematerial were coated, a large cathode to anode area can accelerate

    corrosion of the anode at any breaks in the coating.

    Improvements in Materials of Construction

    Galvanic corrosion is the principle used in galvanized steel, wherethe zinc corrodes preferentially to protect the underlying carbonsteel.

    If there is a break in the galvanized coating, a large anode to smallcathode area prevents accelerated corrosion of the steel.

    This anode-to-cathode relationship reverses at water temperaturesover about 150F (65C).

    BECHTENGINEERING COMPANY, INC. Materials - 56

    Atmospheric CorrosionAtmospheric

    corrosion is a formof galvaniccorrosion.

    Different parts ofthe surface of themetal act asanodes and

    cathodes.Variations in the

    electrolyte alsocontribute.

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    Atmospheric Corrosion

    Materials Affected Carbon and low alloy steels are most affected.

    Critical Factors Marine environments can be very corrosive (20 mpy) as are

    industrial environments that contain acids or sulfur compounds thatcan form acids (5-10 mpy).

    Inland locations exposed to a moderate amount of precipitation orhumidity are considered moderately corrosive environments (1-3mpy).

    Dry rural environments usually have very low corrosion rates (

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    Corrosion Under Insulation

    CUI is a form ofgalvanic corrosion.

    Different parts of thesurface of the metalact as anodes andcathodes.

    CUI is caused bythe presence of an

    electrolyte, usuallyrain water.

    BECHTENGINEERING COMPANY, INC. Materials - 60

    Corrosion Under InsulationMaterials Affected Carbon and low alloy steels are affected by thinning

    Austenitic stainless steels are affected by SCC and biological attack

    Critical Factors Poor installations that allow water to become trapped.

    Corrosion rates increase with increasing metal temperature up tothe point where the water evaporates quickly.

    Corrosion becomes more severe at metal temperatures betweenthe boiling point 212F (100C) and 250F (120C), where water isless likely to vaporize and insulation stays wet longer.

    In areas where significant amounts of moisture are present, the

    upper temperature range where CUI may occur can be extendedsignificantly above 250F (120C).

    Insulating materials that hold moisture (wick) are more of aproblem.

    Cyclic thermal operation can increase corrosion.

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    Corrosion Under Insulation

    Prevention Maintaining the insulation

    sealing/vapor barriers toprevent moisture ingress

    Using appropriate coatings

    Selection of insulatingmaterials that will hold lesswater against the pipe wall

    Using low chloride insulationwith austenitic stainless steels

    Not insulating where heatconservation is not asimportant

    Improvements in Materials

    of Construction Generally not an economical

    approach.

    BECHTENGINEERING COMPANY, INC. Materials - 62

    Corrosion Under Insulation

    Near miss 230 psig (16 bar) propane line Remaining wall as little as 1 mm thick

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    Crevice Corrosion

    Localized form of corrosionStagnant solution in crevices such as

    Under gaskets Under fasteners Threaded joints Socket welded joints

    initiated by changes in local chemistry within thecrevice Depletion of inhibitor in the crevice Depletion of oxygen in the crevice

    A shift to acid conditions in the crevice Build-up of aggressive ion species (e.g. chloride) in

    the crevice

    BECHTENGINEERING COMPANY, INC. Materials - 64

    Crevice Corrosion

    Initially, the level of

    soluble oxygen and isthe same everywhere.

    Oxygen consumed by

    normal uniformcorrosion is very soon

    depleted in thecrevice.

    Corrosion products

    create acidicenvironment and further

    seal the creviceenvironment.

    Depletion of Oxygen in the Crevice

    http://www.corrosion-doctors.org/

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    Crevice Corrosion

    Materials Affected Carbon and low alloy steels are affected by loss of metal

    Austenitic stainless steels are affected by SCC and biological attack

    Critical Factors

    Aggressive ions like chlorides may be present in the electrolyte.

    Corrosion rates increase with increasing metal temperature.

    Prevention

    Avoiding crevices whenever possible; e.g. using butt weldinginstead of socket welding and threaded joints.

    Improvements in Materials of Construction

    Generally not an economical approach.

    BECHTENGINEERING COMPANY, INC. Materials - 66

    Stress Corrosion CrackingRequires Stress

    o Residual from Weldingo Design

    Right Material Right Environment

    o Chemical, pH

    o Concentrationo Temperature

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    BECHTENGINEERING COMPANY, INC. Materials - 67

    Stress Corrosion CrackingMechanisms include

    Chloride stress corrosion cracking (ClSCC)

    Hydrogen-induced cracking (HIC)

    BECHTENGINEERING COMPANY, INC. Materials - 68

    Chloride Stress Corrosion Cracking

    Requires thepresence of:

    Chlorides insufficientconcentration

    High enough stress

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    Chloride Stress Corrosion Cracking

    Materials Affected All 300 Series SS are highly susceptible.

    Duplex stainless steels are more resistant.

    Critical Factors Increasing temperatures increase the susceptibility to cracking.

    Cracking usually occurs at metal temperatures above about 140F(60C), although exceptions can be found at lower temperatures.

    Increasing levels of chloride increase the likelihood of cracking. Nopractical lower limit for chlorides exists because there is always apotential for chlorides to concentrate.

    SCC usually occurs at pH values above 2. At lower pH values,uniform corrosion generally predominates. SCC tendencydecreases toward the alkaline pH region.

    Stress may be applied or residual. Highly stressed or cold worked

    components, such as expansion bellows, are highly susceptible tocracking.

    BECHTENGINEERING COMPANY, INC. Materials - 70

    Chloride Stress Corrosion CrackingPrevention When hydrotesting, use low chloride content water and dry out

    thoroughly and quickly.

    Properly applied coatings under insulation.

    Avoid designs that allow stagnant regions where chlorides canconcentrate or deposit.

    Improvements in Materials of Construction Nickel content of the alloy has a major affect on resistance. The

    greatest susceptibility is at a nickel content of 8% to 12%. Alloyswith nickel contents above 35% are highly resistant and alloysabove 45% are nearly immune.

    Low-nickel stainless steels, such as the duplex (ferrite-austenite)stainless steels, have improved resistance over the 300 Series SSbut are not immune.

    Carbon steels, low alloy steels and 400 Series SS are notsusceptible to CISCC .

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    Hydrogen-Induced Cracking (HIC)

    Hydrogen Blisters Hydrogen blisters are surfacebulges on the surface of a pipe.

    The blister results from hydrogenatoms that diffuse into the steel,and collect at a discontinuity.

    The hydrogen atoms combine toform hydrogen molecules that aretoo large to diffuse.

    The gas pressure builds to thepoint where local deformationoccurs

    A primary source for the H atomsis from the sulfide corrosionprocess.

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    Hydrogen-Induced Cracking (HIC) Neighboring or adjacent blisters that are at slightly

    different depths (planes) can develop cracks that linkthem together.

    This is hydrogen-induced cracking. Interconnecting cracks often have a stair step

    appearance, and so HIC is sometimes referred to as"stepwise cracking.

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    Hydrogen-Induced Cracking (HIC) When HIC is assisted by high stresses in the piping, it

    is called Stress Oriented Hydrogen Induced Cracking(SOHIC).

    The SOHIC cracks usually appear in the base metaladjacent to the weld heat affected zones where theyinitiate from HIC damage.

    SOHlC is potentially more dangerous because it resultsin a through-thickness crack that is perpendicular to thesurface.

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    Hydrogen-Induced Cracking (HIC)Critical Factors All of these damage mechanisms are related to the absorption and

    permeation of hydrogen in steels.

    Hydrogen permeation or diffusion rates have been found to beminimal at pH 7 and increase at both higher and lower pH's. Thepresence of hydrogen cyanide (HCN) in the water phasesignificantly increases permeation in alkaline (high pH) sour water.

    Hydrogen permeation increases with increasing H2S partialpressure due to a concurrent increase in the H2S concentration inthe water phase.

    Blistering, HIC, and SOHlC damage have been found to occur

    between ambient and 300F (150C) or higher. HIC is often found in so-called "dirty" steels with high levels of

    inclusions or other internal discontinuities from the steel-makingprocess.

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    Hydrogen-Induced Cracking (HIC)

    Materials Affected Carbon and low alloy steels are affected.

    High alloy steels are not affected.

    Critical Factors (cont.) HIC damage can occur throughout the refinery wherever there is a

    wet H2S environment present.

    Increasing concentration of ammonium bisulfide above 2%increases the potential for HIC.

    Cyanides significantly increase the probability and severity of HICdamage.

    Prevention Coatings that protect the surface of the steel from the

    wet H2S environment can prevent damage.

    Process changes that affect the pH of the water phaseor cyanide concentration can help to reduce damage.

    BECHTENGINEERING COMPANY, INC. Materials - 76

    Metallurgical and Environmental DamageCauses degradation and loss of material

    properties

    Involve some form of mechanical and/orphysical property deterioration of thematerial due to exposure to a processenvironment

    Causes of metallurgical and environmentaldegradation failures are varied

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    Mechanisms include Graphitization

    Decarburization

    High Temperature Hydrogen Attack(HTHA)

    Metallurgical and Environmental Damage

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    GraphitizationGraphitization is the decomposition of

    carbide phases in steels after long-termoperation in the 800F to 1100F (430C to590C) range into graphite nodules.

    The decomposition causes a loss instrength, ductility, and creep resistance.

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    Graphitization

    Materials Affected Carbon and 0.5Mo steels are susceptible to graphitization.

    Critical Factors Graphitization is not commonly observed.

    What causes some steels to graphitize while others are resistant isnot well understood.

    Severe heat affected zone graphitization can develop in as little as5 years at service temperatures above 1000F (540C).

    Very slight graphitization would be expected to be found after 30 to40 years at 850F (450C).

    Prevention Graphitization can be prevented by using chromium containing low

    alloy steels for long-term operation above 800F (427C).

    BECHTENGINEERING COMPANY, INC. Materials - 80

    DecarburizationA condition where steel looses

    strength due the removal ofcarbon and carbides leaving onlyan iron matrix.

    Decarburization occurs duringexposure to high temperaturessuch as

    during heat treatment

    from exposure to fires

    from high temperature service in agas environment.

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    Decarburization

    Materials Affected Carbon and low alloy steels are affected.

    Critical Factors The material must be exposed to a gas phase that has a low carbon

    activity so that carbon in the steel will diffuse to the surface to reactwith gas phase constituents.

    The extent and depth of decarburization is a function of thetemperature and exposure time.

    Typically, decarburization is shallow, but loss in room temperaturetensile strength and creep strength may occur.

    Prevention Decarburization can be controlled by controlling the chemistry of the

    gas phase and alloy selection. Alloy steels with chromium and molybdenum form more stable

    carbides and are more resistant to decarburization.

    BECHTENGINEERING COMPANY, INC. Materials - 82

    High Temperature Hydrogen Attack High temperature hydrogen attack results from exposure

    to hydrogen at elevated temperatures and pressures.

    The hydrogen reacts with carbides in steel to formmethane (CH4), which cannot diffuse through the steel.

    Methane pressurebuilds up, formingbubbles or cavities,micro fissures andfissures that may

    combine to formcracks.

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    High Temperature Hydrogen Attack

    Materials Affected In order of increasing resistance: carbon steel, C-0.5Mo, Mn-0.5Mo,

    1Cr-0.5Mo, 1.25Cr-0.5Mo, 2.25Cr-1Mo, 2.25Cr-1Mo-V, 3Cr-1Mo,5Cr-0.5Mo.

    Critical Factors The loss of carbide causes an overall loss in strength.

    Failure can occur when the cracks reduce the load carrying abilityof the pressure containing part.

    For a specific material, HTHA is dependent on temperature,hydrogen partial pressure, time and stress. Service exposure timeis cumulative.

    HTHA is preceded by a period of time when no noticeable changeis detectable by normal inspection techniques.

    API RP 941 provides material resistance curves.

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    High Temperature Hydrogen AttackAPI RP 941 provides material resistance curves.

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    High Temperature Hydrogen Attack

    Prevention Use alloy steels with

    chromium and molybdenumto increase carbide stability

    thereby minimizing methaneformation. Other carbide

    stabilizing elements includetungsten and vanadium.

    300 Series SS, as well as

    5Cr, 9Cr and 12Cr alloys, arenot susceptible to HTHA at

    conditions normally seen in

    refinery units.HTHA to a Boiler Tube

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    High Temperature Hydrogen Attack One employee sustained a minor injury.

    NPS 8 carbon steel elbow ruptured after operating for only 3 months. The escaping hydrogen gas from the ruptured elbow quickly ignited.

    HTHA to a Boiler Tube

    A maintenancecontractor

    accidentallyswitched a

    carbon steelelbow with an

    alloy steelelbow during ascheduled heat

    exchangeroverhaul.

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    API 571

    Graphitization

    Softening (Spheroidization)

    Temper Embrittlement

    Strain Aging

    885F Embrittlement

    Sigma Phase Embrittlement

    Brittle Fracture

    Creep / Stress Rupture

    Thermal Fatigue

    Short Term Overheating -Stress Rupture

    Steam Blanketing

    Dissimilar Metal Weld (DMW)Cracking

    Thermal Shock

    Erosion / Erosion-Corrosion

    Cavitation

    Mechanical Fatigue

    Vibration-Induced Fatigue

    Refractory Degradation

    Reheat Cracking

    Galvanic Corrosion

    Atmospheric Corrosion

    Much of the information presented on deterioration of metals is taken

    from API 571 Damage Mechanisms Affecting Fixed Equipment in theRefining Industry API 571 addresses all of the following mechanisms:

    BECHTENGINEERING COMPANY, INC. Materials - 88

    API 571 Corrosion Under Insulation

    (CUI)

    Cooling Water Corrosion

    Boiler Water CondensateCorrosion

    CO2 Corrosion

    Flue Gas Dew Point Corrosion

    Microbiologically InducedCorrosion (MIC)

    Soil Corrosion

    Caustic Corrosion

    Dealloying

    Graphitic Corrosion

    Oxidation

    Sulfidation

    Carburization

    Decarburization

    Metal Dusting

    Fuel Ash Corrosion

    Nitriding

    Chloride Stress CorrosionCracking (CI-SCC)

    Corrosion Fatigue

    Caustic Stress CorrosionCracking (CausticEmbrittlement)

    Ammonia Stress CorrosionCracking

    Liquid Metal Embrittlement(LME)

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    API 571

    Hydrogen Embrittlement (HE) Amine Corrosion

    Ammonium Bisulfide Corrosion(Alkaline Sour Water)

    Ammonium Chloride Corrosion

    Hydrochloric Acid (HCI)Corrosion

    High Temp H2/H2S Corrosion

    Hydrofluoric (HF) AcidCorrosion

    Naphthenic Acid Corrosion(NAC)

    Phenol (Carbonic Acid)Corrosion

    Phosphoric Acid Corrosion Sour Water Corrosion (Acidic)

    Sulfuric Acid Corrosion Polythionic Acid Stress

    Corrosion Cracking (PASCC)

    Amine Stress CorrosionCracking

    Wet H2S Damage

    Hydrogen Stress Cracking HF

    Carbonate Stress CorrosionCracking

    High Temperature HydrogenAttack

    Titanium Hydriding