API RP 571 & Advanced Damage Mechanisms and Material Investigation in the Refining, Petrochemical & Petroleum Industries

What are the Goals?

By the end of this API RP 571 & Advanced Damage Mechanisms and Material Investigation training course, participants will learn to:

• Understand general damage mechanisms applicable to the industry and be able to identify their features and function
• Recognize and be aware of the mechanical and metallurgical failure mechanisms related to the brittle fracture and material embrittlement, creep and stress rupture, thermal and mechanical fatigue, as well as most prevalent problems such as corrosion
• Identify refining industry damage mechanisms on uniform or localized loss thickness and explain the various types of corrosion related to it
• Be aware of the conditions for and morphology of high-temperature damage mechanisms such as oxidation, sulfidation, carburization, metal dusting, high temperature hydrogen attack (HTHA) and decarburization, among others
• Understand the document background, scope, organization and limitation in use of API RP 571.
• Appreciate the need of further in-depth study for each damage mechanism for the practical implementation in the day-to-day-work

Who is this Training Course for?

• Experienced Maintenance Personnel
• Corrosion/Material Engineers; Corrosion Managers/Technicians
• Asset Integrity Engineers
• Maintenance Managers
• Mechanical and Process Engineers
• Inspectors
• Designers

Daily Agenda

Day One: Introduction, Materials Refining, Basics of Corrosion

• API RP 571 and links to ASME PCC-3, API 580/581
• Materials of construction and their applicability
• Steels -- Carbon Steel; Cast Iron; C-Mo Steel; Cr-Mo Steels
• Stainless Steels and Duplex steels
• Material Selection process
• Materials, damage mechanisms, barriers
• xxStandards and other references; Terms, symbols and abbreviations;
• Refining Processes
• Types of corrosion
• Basic mechanisms

Day Two: Corrosion

• Galvanic Corrosion
• Concentration Cell Corrosion
• Erosion/Erosion - Corrosion
• Cavitation
• Atmospheric Corrosion
• Corrosion Under Insulation (CUI)
• Cooling Water Corrosion
• Boiler Water Condensate Corrosion
• Oxygenated Water Corrosion (Non-Boiler)
• Brine Corrosion
• Microbiologically Influenced Corrosion (MIC)
• Soil Corrosion
• Dealloying
• Graphitic Corrosion
• CO2 Corrosion
• Caustic Corrosion
• HCl Corrosion
• Workshop: Corrosion assessment CO2 corrosion
• Workshop: HCl Corrosion

Day Three: Refining and High Temperature Corrosion

• Sour Water Corrosion (Acidic)
• Ammonium Bisulfide Corrosion (Alkaline Sour Water)
• Amine Corrosion
• Ammonium Chloride Corrosion
• Aqueous Organic Acid Corrosion
• Hydrofluoric (HF) Acid Corrosion
• Sulfuric Acid Corrosion
• Phenol (Carbolic Acid) Corrosion
• Phosphoric Acid Corrosion
• Oxidation
• Sulfidation
• High Temperature H2/H2S Corrosion
• Napthenic Acid Corrosion
• Carburization
• Metal Dusting
• Decarburization
• Nitriding
• Flue-Gas Dew-Point Corrosion
• Fuel Ash Corrosion
• Workshop: Damage mechanisms filtering ASME PCC-3 using ASME PCC-3 table

Day Four: Embrittlement and High Temperature Damage Mechanisms

• Brittle Fracture
• Temper Embrittlement
• 885°F (475°C) Embrittlement
• Sigma Phase Embrittlement
• Hydrogen embrittlement
• Liquid metal embrittlement
• Titanium Hydriding
• Graphitization
• Spheroidization (Softening)
• Strain Aging
• Creep and Stress Rupture
• Short Term Overheating – Stress Rupture including Steam Blanketing
• High Temperature Hydrogen Attack
• Dissimilar Metal Weld (DMW) Cracking
• Stress Relaxation Cracking (Reheat Cracking)
• Refractory Degradation
• Gaseous Oxygen-Enhanced Ignition and Combustion
• Thermal Fatigue
• Thermal Shock
• Mechanical Fatigue including Vibration-Induced Fatigue
• Corrosion Fatigue

Day Five: Environmental Assisted Cracking, Process PFDs, IOWs

• Chloride Stress Corrosion Cracking (Cl-SCC)
• Polythionic Acid Stress Corrosion Cracking
• Wet H2S Damage
• Caustic Stress Corrosion Cracking (Caustic Embrittlement)
• Amine Stress Corrosion Cracking
• Carbonate Stress Corrosion Cracking
• Ethanol Stress Corrosion Cracking (SCC)
• Ammonia Stress Corrosion Cracking
• Hydrogen Stress Cracking - HF
• Hydrofluoric Acid SCC of Nickel Alloys
• Workshop: Assessing susceptibility to Cl-SCC
• Wrap-up of Refining Damage mechanisms; comparison and coverage in API 581
• Process Unit PFDs
• Proposed IOWs, link to the damage mechanisms
• Workshop: API 571 test quiz