API Bulletin 9399 -E

Identiffication
n, Repair, and Mitigattion of C
Crackin
ng of Stteel
Equip
pment in
n Fuel Ethano
E
l Servicce
SECOND ED
DITION | AUGU
UST 2013 | 42 PAGES
P
| $160.0
00 | PRODUCT NO. C939E02

Usage of fue
el ethanol as an
a oxygenate additive in gassoline
blends is increasing both in the United States and
internationa
ally. This document discusse
es stress corro
osion
cracking (SC
CC) of carbon steel tanks, piping, and
equipment exposed to fue
el ethanol as a consequencce of
being in the
e distribution system,
s
at etha
anol distributio
on
facilities, orr end user (EU) facilities whe
ere the fuel eth
hanol
is eventuallyy added to gassoline. Such equipment
e
inclludes
but is not lim
mited to:
storage
e tanks,
piping and
a related ha
andling equipm
ment, and
pipeline
es
that are use
ed in distribution, handling, storage, and
blending of fuel ethanol. However, data
a for pipelines in
ethanol servvice is limited and caution should
s
be used
d
when applying guidelines from this doccument that ha
ave
been derive
ed mainly from
m applications involving pipin
ng
and tanks in
n ethanol storage and blend
ding facilities. SCC
of other me
etals and alloyss is beyond the scope of thiss
document, as
a is the corro
osion of steel in this service..
It is realized
d that SCC of steel
s
in fuel ethanol is a topic
where know
wledge of the subject
s
is activvely growing
through doccumentation of
o recent experrience and thrrough
research in progress. Thiss document de
eals with hand
dling
of cracks in existing equip
pment and red
duction of SCC
C
occurrence in new equipm
ment as a resu
ult of exposure
e to
fuel ethanol per ASTM D4
4806 (or otherr international
specifications), ethanol fu
uel blends, and pipeline
transmixes involving fuel ethanol and conventional
c
hydrocarbon
n fuels (gasoline, diesel, or jet
j fuel). It includes
guidelines for
f carbon stee
el construction
n materials,
including th
heir fabrication
n, inspection, and
a repair to help
h
assure safe
e and reliable operations.
o

www.api.org

ng practices
Thiss document is based on currrent engineerin
and
d insights from
m recent industrrial experience
e and research..
Old
der equipment may not confo
orm exactly to tthe information
n
con
ntained herein,, but this does not imply that such
equ
uipment is bein
ng operated in an unsafe or u
unreliable
maanner. It is also recognized tha
at facilities ma
ay vary and mayy
neeed to be modified dependingg on specific op
perating
con
nditions, inspecction, and main
ntenance expe
erience. Each
useer company is u
ultimately resp
ponsible for its own safe and
reliable operation
ns.
Thee steels referreed to in this doccument are de
efined by the
ASTTM or API desiggnation system
ms or equivalen
nt steel grades
con
ntained in otheer recognized ccodes or standa
ards. Welded
con
nstruction is coonsidered the p
primary method
d of fabrication
n
in eequipment exp
posed to fuel etthanol.
Forr ordering inforrmation:
Onlline: www.apii.org/pubs
Phoone: 1-800-854-7179
(Toll-freee in the U.S. and Canada)
(+1) 303
3-397-7056
(Local an
nd Internationa
al)
Faxx:

(+1) 303
3-397-2740

applicable.
APII members receeive a 30% disscount where a

Contents
Page

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3
3.1
3.2

Terms, Definitions, Acronyms, and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4
4.1
4.2
4.3
4.4
4.5

Background on SCC in Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Description of Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relevant Standards for Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Supply Chain for Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Significance of SCC in Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factors Related to SCC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5
5.1
5.2
5.3
5.4
5.5
5.6
5.7

Guidelines for Fabrication of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fabrication of Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fabrication Guidelines to Minimize SCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specific Guidelines for Minimizing SCC in Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guidelines for PWHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organic Coatings for Internal Protection of Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
15
15
16
16
17
18

6
6.1
6.2
6.3
6.4
6.5

Inspection of Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection After Leakage Caused by SCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Inspection Without Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examination Procedures for Identification of SCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19
19
20
20
20

7
7.1
7.2
7.3
7.4
7.5
7.6

Repair of SCC Damaged Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assessment of Fitness-for-service and Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary Repair by Clamps and Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crack Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stress Relief Heat Treatment Applied to Piping and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23
23
23
23
24
24
25

8
8.1
8.2

Monitoring of Fuel Ethanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Sampling and Analysis of Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Methods for Monitoring and Testing for Corrosion and SCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Annex A (informative) Listing of Reported Cases of SCC in Fuel Ethanol and Remedial Measures. . . . . . . . . 26
Annex B (informative) Form to Submit New Information on SCC in Fuel Ethanol Systems. . . . . . . . . . . . . . . . 32
Annex C (informative) Examples of Typical SCC in Fuel Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Contents
Page

Figures
C.1 SCC in Steel Tank Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.2 SCC in Steel Air Eliminator Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.3 Leak in Piping Resulting from a Crack Adjacent to the Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.4 Characteristics of SCC in Steel Exposed to Fuel Ethanol, Showing Multiple Crack
Initiations and Through-thickness Propagation in Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.5 SCC in Steel Tank Bottom Showing Highly Branched, Intergranular Cracks at 100X . . . . . . . . . . . . . . .
C.6 SCC in Steel Metallographically Prepared with Grain Boundary Etch at 500X . . . . . . . . . . . . . . . . . . . . .
C.7 SCC in Steel Pipe from a Loading Rack Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.8 Cracking of Another Pipe Sample from Same Situation as Noted in the Previous Figure. . . . . . . . . . . .
C.9 SCC of Steel Piping in a Fuel Ethanol System Return Line/Tank Transfer Line . . . . . . . . . . . . . . . . . . . .
C.10 Same SCC Incidence Shown in Previous Figure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34
35
36
36
37
37
38
39
40
41

Tables
1
Quality Specification for Fuel Ethanol per ASTM D4806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2
Generally Compatible and Incompatible Polymeric Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

vi