API RP 571: Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

Introduction

This course prepares the student for the API RP 571 examination (Damage Mechanisms Affecting Fixed Equipment in the Refining and Petrochemical Industries). The course is an intensive one week course covering the 64 corrosion mechanisms documented in the API 571. It will also review basic refinery flow as needed to understand how the flow affects corrosion mechanisms.

This API 571 Supplemental Inspection Certification Program (ICP) is designed to train inspectors on damage mechanisms affecting fixed equipment in the refining industry. The objective of the ICP is to provide documented evidence of advanced knowledge and expertise (above the basic core API 510, 570 & 653 examinations) in the area of Corrosion and Materials based on the information contained in API RP 571. Completion of the API

ICP 571 will add significant value to your professional credentials. It will show your employers and clients that you have obtained a high level of proficiency and understanding in this important field. The importance of the API 571 certification is that it is a key first step in safely and reliably. Proper identification of damage mechanisms is important when:

• Implementing the API Inspection Codes (API 510, 570 & 653).
• Conducting risk-based inspection per API 580 / 581.
• Methodologies for Risk-Based Inspection (RBI) depend on the accurate prediction and determination of active mechanisms.
• Performing a fitness-for-service assessment using API 579. The damage mechanisms need to be understood and need to be considered when evaluating the remaining life.
• Setting up effective inspection plans requires an in-depth understanding of what kind of damage to look for and how to identify it.
• Conducting a MOC. An effective Management of Change (MOC) process needs to consider the effect of proposed changes on future degradation. Many problems can be prevented or eliminated if the precursors to damage are observed and monitored so that any potential damage is mitigated.

Objectives

To improve safety, reliability, and minimize the liability of fixed equipment by learning common damage mechanisms in the refining and petrochemical industry as covered in API 571. The roles of the engineer and inspector in identifying affected materials and equipment, critical factors, the appearance of damage, prevention and mitigation, inspection, and monitoring will be covered to introduce the concepts of service-induced deterioration and failure modes. This course is intended for anyone interested in gaining a fundamental understanding of damage mechanisms in metals. The course provides participants with the knowledge necessary to:

• Successfully pass the API RP 571 ICP exam.
• Understand the subject matter on the API 571 exam. (Steel-Solutions guarantee).
• Have a detailed background on the scope, organization, and use of API RP 571.
• Understand the relationship between various corrosion mechanisms and associated metallurgy.
• Identify various inspection techniques for the different metallurgies and corrosion mechanisms.
• Comprehend how various corrosion mechanisms react in specific environments (how they can be rate controlled).
• Understand general damage mechanisms applicable to the refining industry and be able to identify their features & functions.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

Engineers, inspectors, designers, and experienced maintenance personnel who are involved in designing, operating, maintaining, repairing, inspecting and analyzing pressure vessels, piping, tanks, and pipelines for safe operations in the refining, petrochemical and other related industries. (Interconnected with API 579, API 580 and API 571)

Course Outline

Section 1:

• Introduction
• Scope
• Organization and Use
• References
• Definitions of Terms
• Technical
• Inquires

Section 2:

• Standards
• Other References

Section 3

• Terms
• Symbols and Abbreviations

Section 4: General

Mechanical and Metallurgical Failure Mechanisms

• Graphitization
• Softening (Spheroidization)
• Temper Embrittlement 
• Strain Aging 
• 885°F (475oC) Embrittlement 
• Sigma Phase Embrittlement 
• Brittle Fracture
• Creep and Stress Rupture
• Thermal Fatigue
• Short Term Overheating – Stress Rupture
• Steam Blanketing
• Dissimilar Metal Weld (DMW) Cracking
• Thermal Shock
• Erosion/Erosion – Corrosion
• Cavitations
• Mechanical Fatigue
• Vibration-Induced Fatigue
• Refractory Degradation
• Reheat Cracking
• Gaseous Oxygen-Enhanced Ignition and Combustion

Uniform or Localized Loss of Thickness

• Galvanic Corrosion
• Atmospheric Corrosion
• Corrosion under Insulation (CUI)
• Cooling Water Corrosion
• Boiler Water Condensate Corrosion
• CO2 Corrosion
• Flue-Gas Dew-Point Corrosion
• Microbiologically Induced Corrosion (MIC)
• Soil Corrosion
• Caustic Corrosion
• Dealloying
• Graphitic Corrosion

High-Temperature Corrosion [>400°F (204°C)]

• Oxidation
• Sulfidation
• Carburization
• Decarburization
• Metal Dusting
• Fuel Ash Corrosion
• Nitriding

Environment – Assisted Cracking

• Chloride Stress Corrosion Cracking (Cl SCC)
• Corrosion Fatigue
• Caustic Stress Corrosion Cracking (Caustic Embrittlement)
• Ammonia Stress Corrosion Cracking
• Liquid Metal Embrittlement (LME)
• Hydrogen Embrittlement (HE)
• Ethanol Stress Corrosion Cracking (SCC)
• Sulfate Stress Corrosion Cracking

Section 5: General

• Uniform or Localized Loss in Thickness Phenomena
• Amine Corrosion
• Ammonium Bisulfide Corrosion (Alkaline Sour Water)
• Ammonium Chloride Corrosion
• Hydrochloric Acid (HCl) Corrosion
• High Temp H2/H2S Corrosion
• Hydrofluoric (HF) Acid Corrosion
• Naphthenic Acid Corrosion (NAC)
• Phenol (Carbolic Acid) Corrosion
• Phosphoric Acid Corrosion
• Sour Water Corrosion (Acidic)
• Sulfuric Acid Corrosion
• Aqueous Organic Acid Corrosion

Environment-Assisted Cracking

• Polythionic Acid Stress Corrosion Cracking (PASCC)
• Amine Stress Corrosion Cracking
• Wet H2S Damage (Blistering/HIC/SOHIC/SSC) 5.1.2.4 Hydrogen Stress Cracking - HF
• Carbonate Stress Corrosion Cracking (ACSCC)

Other Mechanisms

• High-Temperature Hydrogen Attack (HTHA)
• Titanium Hydrating

Process Unit PFD’s