BROADLY CLASSIFIED AS : LOW TEMPERATURE CORROSION ---- CORROSION AT ROOM TEMPERATURE AND BELOW HIGH TEMPERATURE CORROSION ----

ELEVATED TEMPERATURE CORROSION INCLUDING THAT BY MOLTEN METALS

TWO IMPORTANT CORROSIONS TYPES ENCOUNTERED BY US ARE COVERED:

SSCC : SULPHIDE STRESS CORROSION CRACKING IGC : INTERGRANULAR CORROSION

MEDIA ONE OF THE MOST IMPORTANT FACTORS. PROCESS FLUIDS CONTAMINANTS SOLVENTS CATALYSTS ETC.

HIC -HYDROGEN INDUCED CRACKING SSCC --A CRACKING PROCESS THAT REQUIRES SIMULTANEOUS ACTION OF A CORRODENT AND SUSTAINED TENSILE STRESS.

EXCLUDED :
FAILURES DUE TO REDUCED SECTION AS A RESULT OF CORROSION FAILURES DUE TO INTER - CRYSTALLINE OR TRANS - CRYSTALLINE CORROSION

MEDIA : WATER : FUNCTIONS AS ELECTROLYTE HYDROLYSES INORGANIC SALTS COMBINATION OF AIR & WATER IS DANGEROUS --AIR SUPPLIES O2 WATER ACTS AS ELECTROLYTE SOURCES : ALMOST EVERY PART OF PROCESS

H2S SOUR WATER COMMON SOURCES : CRUDE OIL DECOMPOSITION OF ORGANIC COMPOUNDS OF SULPHUR PROCESS WATER CARRYING H2S WITH NH3 HCN ETC. H2S REACTS WITH STEEL TO GIVE A BLACK SULPHIDE FILM C.S. HAS GOOD RESISTANCE TO AQUEOUS SULPHIDE CORROSION

SOUR WATER
COMMON SOURCES PROCESS WATER CARRYING H2S WITH NH3 HCN ETC

AQUEOUS H2S C.S. AND LAS ARE USED AQUEOUS H2S + NH3 ETC CONDITION MORE SEVERE C.S. & LAS NOT USED DEPENDING ON SEVERITY S.S OR TITANIUM USED

HIC

NACE STANDARD

TM - 02 84 TM - 01 77

SSCC NACE STANDARD

HIC TESTING : SPECIMEN SIZE : 20 X 20 X 100 mm SOLUTION : A -- SODIUM CHLORIDE + ACETIC ACID ( pH 2.7 ) SATURATED WITH H2S B -- SYNTHETIC SEA WATER ( AS PER ASTM D 1141 ) pH 8.1 - 83 SATURATED WITH H2S TEST DURATION : 96 HOURS ( 4 DAYS ) FINAL pH SOLUTION A -- 4.0 SOLUTION B -- 4.8 - 5.4

TEST RESULT : THREE SECTIONS OBSERVED BLISTERS SHALL BE NIL CSR , CLR AND CTR SHALL BE WITHIN SPECIFIED LIMITS CSR =100 [ (a x b)

( W x T) ]

CLR =100 [ a / ( W x T) ] CTR =100 [ b

( W x T) ]

a = CRACK LENGTH b = CRACK AREA THICKNESS W = SECTION WIDTH T = TEST SPECIMEN THICKNESS

SSCC TESTING : SPECIMEN SIZE : ROUND BAR TENSILE SPECIMEN GAUGE DIA. 6.35 mm GAUGE LENGTH 25.4 mm ( OVERALL LENGTH 200 mm) SOLUTION : A -- SODIUM CHLORIDE + ACETIC ACID ( pH 2.6 - 2.8 ) SATURATED WITH H2S

B -- SODIUM CHLORIDE + SODIUM ACETATE + ACETIC ACID ( pH 3.4 - 3.6 ) SATURATED WITH H2S
TEST DURATION : 720 HOURS ( 30 DAYS )

TEST LOAD : GENERALLY LOADED TO 72% OF STANDARD METAL YIELD STRENGTH. THIS MAY BE CHANGED BY CUSTOMER FINAL pH SOLUTION A -- 4.0 SOLUTION B -- 4.0 TEST IS DEEMED PASSED IF SPECIMEN DOES NOT BREAK EXAMINATION AT 10 X DOES NOT REVEAL CRACKS

SUSCEPTIBLE MATERIALS : STAINLESS STEELS PROCESS : CORROSION RESISTANCE OF STAINLESS STEELS IS DERIVED FROM Cr + O2 --------> Cr2O3

FROM METAL

FROM ATMOSPHERE

Cr2O3 FORMS A TENACIOUS FILM ON THE SURFACE.

MINIMUM 12 % Cr IS NEEDED TO MAKE STEEL STAINLESS WHEN S.S. PASSES THROUGH THE TEMPERATURE RANGE OF 425O C TO 850O C WE HAVE : C + Cr -----> Cr23C6

THE REACTION OCCURS AT GRAIN BOUNDARIES

THUS THERE IS A BAND AT THE GRAIN BOUNDARIES WHERE Cr IS LESS THAN 12% THIS AREA IS NO MORE STAINLESS

THE PROCESS FLUIDS AND CONTAMINANTS CAN ATTACK IN THIS AREA. THERE ARE A LOT OF PROCESSES OF MANUFACTURING THAT TAKE SS IN THIS RANGE EG. WELDING ; CUTTING ; HOT/WARM FORMING SERVICE TEMPERATURE CAN ALSO BE IN THIS RANGE THUS THERE IS A NEED TO TEST THE SUSCEPTABILITY TO IGC THIS NEED IS GOVERNED BY SERVICE CONDITIONS APPLICABLE STD. ASTM A262

THERE ARE 5 PRACTICES

PRACTICE A SOLUTION OXALIC ACID ETCH TEST APPLICATION RAPID IDENTIFICATION OF MATERIALS WHICH WILL FAIL B FERRIC SULPHATE + SULPHURIC ACID DETECTS IGC BUT NOT SIGMA PHASE SUSCEPTABILITY DETECTS IGC BUT AND SIGMA PHASE SUSCEPTABILITY DETECTS IGC BUT NOT SIGMA PHASE SUSCEPTABILITY DETECTS IGC BUT NOT SIGMA PHASE SUSCEPTABILITY

65 % NITRIC ACID

Cu +CuSO4 + 16 % H2SO4

Cu +CuSO4 + 50 % H2SO4

PRACTICE A

TEST CONDITIONS ETCHING AND EXAMIN AT 250 x AND 500 x BOILING SOLUTION 120 HOURS BOILING SOLUTION 240 HOURS

BOILING SOLUTION 24 HOURS BOILING SOLUTION 120 HOUR

NORMALLY PRACTICE B ; C AND E ARE USED

IN PRACTICE B AND C WEIGHT LOSS IS MEASURED. THE CORROSION RATE IS GIVEN BY THE WEIGHT LOSS THIS IS NOT THE CORROSION RATE IN ACTUAL SERVICE. THE RESULT IS A RELATIVE MEASURE IN PRACTICE E SPECIMEN IS BENT THROUGH 180O OVER A FORMER OF 1T RADIUS.

THE BENT SURFACE IS EXAMINED AT 100 x AND 250 x

TEST IS PASSED IF THERE ARE NO CRACKS. CRACKS FROM EDGE , WRINKLES AND ORANGE PEEL EFFECT ARE DISREGARDED.

PRACTICE B EVALUATION 7290 x W

Millimeter Per Month =

Axdxt W A t d = Weight Loss in gms. = Total Area of the Sample in cm2 = Time of Exposure in hours = Density of sample in gms / cc

Millimeter Per Month x 0.04 = Inches Per Month

Millimeter Per Month x 0.47 = Inches Per Year

Millimeter Per Month x 12 = Millimeter Per Year Millimeter Per Month x 472 = mpy Millimeter Per Month x Density / 3 = Milligram Per Square Decimeter Per Day

PRACTICE C EVALUATION MPY = 3440880 (W) (A) ( d ) ( t )

W= Weight loss ( gms) A= Total Specimen area (cm2 ) d= Density of sample ( gms / cm3 ) t = Time of exposure ( hrs)

PRACTICE E EVALUATION

FAILED

MARGINAL ( DOUBTFUL )

PASSED

STEP

DUAL

DITCH

PARENT METAL As Received 100 x

After exposure 100 x

After bending 100 x

HAZ

Before exposure

After exposure

WELD

Before exposure

After exposure

PASSED

FAILED