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PCMS RBI Technical Manual

This document outlines the rules and models used to calculate risk in the PCMS Risk Based Inspection (RBI) Technical Manual. It details the PCMS risk matrix and thresholds. It also provides guidelines for evaluating the consequences of failure including economic, environmental, health and safety impacts. Further, it describes methods for calculating the probability of failure based on generic failure frequencies, technical subfactors, and inspection effectiveness. Models are presented for analyzing internal and external thickness loss, as well as environmental assisted cracking and mechanical/metallurgical failures. Appendices provide internal corrosion rate tables and guidelines for atmospheric storage tanks.

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100% found this document useful (2 votes)

903 views69 pages

PCMS RBI Technical Manual

Uploaded by

Febri Ramdani Nugraha

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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RBI Technical Manual

Rules for Calculation of Risk

PCMS RBI Technical Manual
Rules for Calculation of Risk

Contents
1. Introduction .................................................................................................................................... 5

2. References ...................................................................................................................................... 5

3. PCMS Risk Matrix ............................................................................................................................ 6

3.1. Risk Threshold ......................................................................................................................... 7

4. Process Fluid Data ........................................................................................................................... 7

5. Evaluation of Consequences of Failure ........................................................................................... 8

5.1. Economic Consequences......................................................................................................... 8

5.2. Environmental Consequences ................................................................................................ 9

5.3. Health and Safety Consequences.......................................................................................... 10

5.3.1. Toxic Release Scenario .................................................................................................. 10

5.3.2. Fire Scenario.................................................................................................................. 11

5.3.3. Vapor Cloud Explosion Scenario ................................................................................... 12

5.4. Release Quantity Calculation ................................................................................................ 13

6. Probability of Failure ..................................................................................................................... 14

6.1. Generic Failure Frequency .................................................................................................... 14

6.2. Technical Subfactor ............................................................................................................... 16

6.3 Inspection Effectiveness ................................................................................................... 17

7. Internal Thickness Loss ................................................................................................................. 18

7.1. Initial Screening..................................................................................................................... 19

7.2. Initial Probability Calculation ................................................................................................ 23

7.3. Internal Thickness Loss Models ............................................................................................ 25

7.3.1. Amine Corrosion ........................................................................................................... 26

7.3.2. Ammonium Bisulfide (Alkaline Sour Water) Corrosion ................................................ 27

7.3.3. CO2 Corrosion Model .................................................................................................... 27

7.3.4. High Temperature H2/H2S Corrosion ............................................................................ 27

7.3.5. High Temperature Sulfur Corrosion .............................................................................. 27

October, 2012 Page 2

The contents of this document are confidential and shall not be reproduced, loaned or given away without specific permission of
PCMS a member of MISTRAS Group Inc.
PCMS RBI Technical Manual
Rules for Calculation of Risk

7.3.6. HF Acid Corrosion.......................................................................................................... 28

7.3.7. Low Temperature Wet H2S Corrosion Model ............................................................... 28

7.3.8. Naphthenic Acid Corrosion ........................................................................................... 28

7.3.9. Non-modeled Internal Corrosion Mechanisms............................................................. 28

7.4. Target Date ........................................................................................................................... 29

8. External Thickness Loss ................................................................................................................. 30

8.1. Screening............................................................................................................................... 31

8.2 External Thickness Loss Models ............................................................................................ 31

8.2.1 CUI or General External Corrosion ................................................................................ 31

8.2.2 High Temperature Oxidation ........................................................................................ 33

8.2.3 Fuel Ash Corrosion ............................................................................................................... 34

8.3 Target Date ........................................................................................................................... 34

9 Environmental Assisted Cracking .................................................................................................. 35

9.1 Initial Screening..................................................................................................................... 35

9.2 Initial Susceptibility Evaluation ............................................................................................. 38

9.3 Environment Assisted Cracking Models................................................................................ 40

9.3.1 Amine Stress Corrosion Cracking .................................................................................. 40

9.3.2 Chloride SCC .................................................................................................................. 41

9.3.3 Caustic SCC .................................................................................................................... 42

9.3.4 High Temperature Hydrogen Attack ............................................................................. 42

9.3.5 Hydrogen Stress Cracking (HF) ...................................................................................... 43

9.3.6 Polythionic Acid Stress Corrosion Cracking................................................................... 43

9.3.7 Wet H2S Damage (HIC/SOHIC/ Hydrogen Blistering) .................................................... 44

9.3.8 Wet H2S Damage (SSC) .................................................................................................. 44

10 Mechanical and Metallurgical Failure ....................................................................................... 45

10.1 Initial Screening..................................................................................................................... 46

10.2 Initial Susceptibility Evaluation ............................................................................................. 48

October, 2012 Page 3

10.3 Mechanical and Metallurgical Failure Models ...................................................................... 48

10.3.1 Lining ............................................................................................................................. 48

Appendix 1 - Internal Corrosion Rate Tables ........................................................................................ 52

Appendix 2 – Atmospheric Storage Tanks ............................................................................................ 65

October, 2012 Page 4

1. Introduction
The RBI module for PCMS Version 7 has been developed using a 5x5 risk matrix and features
from API 581, RIMAP Petrochemicals, and Tischuk T-OCA methods of RBI. The module is
designed to give similar results to API 581 with less effort and less use of external experts. The
RBI module uses all of the damage mechanisms described in API 571.

An RBI calculator has been added to PCMS which uses the physical and chemical properties of
the process streams, operating conditions and materials of construction to calculate probability
and consequences of failure. A key feature in this is the addition of a process stream data table.

The API 581 generic probabilities of failure are used together with modification factors based on
damage rates or susceptibility to calculate the probability of failure.

Consequences of failure are based on evaluation of business, health and safety and
environmental consequences. The total consequences of failure is expressed in dollars or may
be configured to dimensionless consequences units if required. This is multiplied by the
probability of failure to give a risk value expressed in dollars or consequences units.

The risk calculation rules and the screening and modeling rules described in this document are
the initial configuration of the PCMS RBI module. Like other PCMS functions, the configuration
may be changed by the user.

2. References
API 571 Damage Mechanisms

API 581 Base Resource Document

RIMAP Petrochemical Workbook

October, 2012 Page 5

3. PCMS Risk Matrix

The PCMS risk matrix is shown below.

Consequences Category

A B C D E

Probability < $10,000 $10,000 to $100,000 to $1,000,000 >

to $10,000,000
Category $100,000 $1,000,000
$10,000,000

-1
(10 to 1)

4
-2 -1
(10 to 10 )

-3 -2
(10 to 10 )

-4 -3
(10 to 10 )

-4
(<10 )

Risk Rank

High Medium- Medium Low

High

October, 2012 Page 6

3.1. Risk Threshold

The Risk Threshold, indicated by the blue line in the RBI Matrix, is the Maximum Risk desired at a
facility. PCMS provides two options for setting the Risk Threshold: Probability Category and Risk
Amount. Probability Category is the 1-5 Probability Rank; the Risk Amount is the result of the
Risk Calculation (Probability x Consequence). Both are designated per Consequence Category.
For each susceptible Damage Mechanism, PCMS will calculate a Target Date, the date that the
Risk Threshold would be exceeded if no further inspection is performed.

4. Process Fluid Data

Definition of the process stream composition is key to the working of the PCMS RBI module. The
consequences assessments are based on fluid properties held in a reference table. The
probability screening and some of the failure probability calculations are also based on values in
the process stream composition table.

Table 4.1 Process Stream Composition

Process Stream 01-Crude Oil Feed

Component Percent
Crude Oil 90.0
Sulfur 6.0
Water 3.0
Hydrogen Sulfide 0.01

It is important to use a current mass balance or obtain assistance from a process engineer to get
the process streams defined accurately. The data should be entered in mole percent.

The PCMS Fluid Property reference table contains values that are used in the consequences
calculations as shown in the example below:

Table 4.2 Component Properties

Toxic Enviro Boiling Flash Auto Liquid

Component Gas SG
Potential Toxicity Point Point Ignition SG
BUTANE 2 Low 30 -76 761 0.58 2.01
CARBON DIOXIDE 3 Low -79 9999 9999 0.83 1.52
CHLORINE 4 High -31 9999 9999 1.41 5.35
CRUDE OIL 2 Medium 122 23 410 0.9 2.84
DEAERATED
SEAWATER 1 Low 212 9999 9999 1.04 0.62
DIESEL 2 Medium 446 151 640 0.85 3.9
GASOLINE 2 Medium 120 -51 536 0.74 3.4
HYDROGEN SULFIDE 4 Low -76 23 500 0.79 1.18

October, 2012 Page 7

5. Evaluation of Consequences of Failure

PCMS RBI evaluates three consequences of failure, economic, health and safety and
environmental. All consequences are expressed in dollars. The total consequences of failure is
the sum of the three consequences.

Total consequences = Economic + Health and Safety + Environmental.

The consequences calculations are simple compared to the dispersion model used in API 581.
They are based on consequences evaluations in the RIMAP Petrochemical Workbook and the
consequences assessments of several companies’ in-house RBI procedures.

Users may configure PCMS to work with either Total consequences or the worst case individual
value from Economic, Health and Safety and Environmental Consequences.

Users can override or apply a multiplier to each Consequence Scenario using the Consequence
Consideration picklist.

5.1. Economic Consequences

Economic consequences are dominated by lost production rather than the direct cost of repair
except in cases where there is no production lost.

At unit level store the value of daily product from the unit.

At circuit and equipment level ask and store the number of days lost production required to
repair and Reduced Repair Rate.

Economic Consequences = days for repair x value of daily production x reduced repair rate

Users may choose not to include Economic consequences in their RBI assessment. I this case
leave the values at zero.

Repair cost is directly input on the RBI consequences form.

October, 2012 Page 8

5.2. Environmental Consequences

The Environment Consequences is evaluated by PCMS from the contained fluid and the
inventory. PCMS looks up the environmental toxicity for each fluid in the process stream in the
component reference table.

Table 5.2.1 Environmental Toxicity

Rating Description

High Harmful and Toxic

Medium Harmful but not Toxic (Most Alkanes)
Low Not Harmful to the Environment

Inventory or the calculated released quantity is calculated:

Volume of equipment x density of component from reference table x percentage in the stream

Note: The Volume of equipment is adjusted by the Release Quantity Multiplier of the
Damage Mechanism most likely to occur. When the Release Quantity Multiplier is not
populated, full release is assumed.

An Inventory vs. Environmental Toxicity Matrix is used to determine the Consequences Value:

Table 5.2.2 Environmental Consequences Value

Environmental Impact
Inventory Rating
Low Medium High
>50 tons $5,000 $5,000,000 $5,000,000
5 to 50
tons $500 $500,000 $5,000,000
0.5 to 5
tons $0 $50,000 $500,000
< 0.5 tons $0 $5,000 $50,000

PCMS first groups all of the components in the process stream by rating, totals the release
quantities for each of the low, medium, and high rating groups, and then runs the calculations to
determine the consequence values.

One final consideration is whether the leak could get out of the plant. If something leaks within
the plant boundary and is contained by the plant systems, there is no environmental impact.
This can be adjusted by the user in the RBI consequences window by manually overwriting the
calculated value.

October, 2012 Page 9

5.3. Health and Safety Consequences

Health and Safety Consequences is the worst case of three scenarios, Toxic Release, Fire and
Vapor Cloud Explosion.

5.3.1. Toxic Release Scenario

The Toxic Release Scenario is evaluated by PCMS from the contained fluid and the
concentration. Where a stream contains multiple components, PCMS calculates the toxic
release scenario for each component, adds them and stores the total dollar value.

Table 5.3.1.1 Toxic Potential

Rating Description
5 Extremely Toxic (HF and HCN)
4 Highly Toxic (H2S, Cl2, NH4)
3 Medium Toxicity (Benzene, CO)
Harmful but not Toxic (Most
2 Hydrocarbons)
1 Inert, not Toxic

A Concentration vs Toxic Potential Matrix is used to determine the Toxic Consequences

Value:

Table 5.3.1.2 Toxic Scenario Value

Concentration Toxic Potential Rating

1 2 3 4 5
>10% $0 $5,000 $500,000 $5,000,000 $5,000,000
1 to 10% $0 $500 $50,000 $500,000 $5,000,000
0.1 to 1% $0 $0 $5,000 $50,000 $500,000
< 0.1%(1000ppm) $0 $0 $500 $5,000 $50,000

October, 2012 Page 10

5.3.2. Fire Scenario

The Fire Scenario is by PCMS evaluated based on the flammability and inventory of the
process fluid. Where a stream contains multiple components, PCMS first groups all of the
components in the process stream by rating, totals the release quantities for each of the
low, medium, and high rating groups, and then calculates the flammability scenarios.
Table 5.3.2.1 Flammability Rating

Rating Description
Flammable and Operating Temperature >
High Autoignition Temperature
Flammable and Flash Point < Operating
Medium Temperature < Autoignition Temperature
Flammable and Flash Point > Operating
Low Temperature

None Not Flammable

The Fire Scenario for each fluid component is calculated as follows:

1. Inventory = Volume of equipment x density of fluid x concentration of fluid

Note: The Volume of equipment is adjusted by the Release Quantity Multiplier of

the Damage Mechanism most likely to occur. When the Release Quantity Multiplier
is not populated, full release is assumed.

2. An Inventory vs. Flammability Matrix is used to determine the Fire Scenario Value:

Table 5.3.2.2 Fire Scenario Value

Flammability
Inventory Rating
None Low Medium High
>50 tons $0 $500,000 $5,000,000 $5,000,000
5 to 50 tons $0 $50,000 $500,000 $5,000,000
0.5 to 5 tons $0 $5,000 $50,000 $500,000
< 0.5 tons $0 $0 $5,000 $50,000

October, 2012 Page 11

5.3.3. Vapor Cloud Explosion Scenario

The Vapor Cloud Explosion (VCE) Scenario is evaluated by PCMS flammability and inventory
of the process fluid. Where a stream contains multiple components, PCMS first groups all of
the components in the process stream by rating, totals the release quantities for each of the
low, medium, and high rating groups, and then calculates the VCE scenarios.

Table 5.3.3.1 VCE Potential

Rating Description
Flammable and Liquid and Boiling Point <
High
50o F
Flammable and Liquid and Operating
Medium Temperature > Boiling Point
None – Fluid is not flammable or Fluid is in
Low the vapor state (phase) or Fluid is liquid
and Operating Temperature < Boiling Point

Inventory or the calculated released quantity is calculated:

1. Volume of equipment x density of fluid x concentration of fluid

Note: The Volume of equipment is adjusted by the Release Quantity Multiplier of

the Damage Mechanism most likely to occur. When the Release Quantity Multiplier
is not populated, full release is assumed.

2. An Inventory vs VCE Potential Matrix is used to determine the VCE Scenario Value:

Table 5.3.3.2 VCE Scenario Value

VCE Potential
Inventory Rating
Low Medium High
>5 tons $0 $500,000 $5,000,000
0.5 to 5
tons $0 $50,000 $500,000
< 0.5 tons $0 $5,000 $50,000

October, 2012 Page 12

5.4. Release Quantity Calculation

PCMS computes a Release Quantity for each stream component. The Equipment Volume is split
by the percentage of each stream component. A mass is then calculated for both the Liquid and
Vapor portions (split per the Liquid/Vapor ratio).

Liquid Mass = Volume (ft3) * Component Liquid Specific Gravity * 62.428 (weight of water lbs/ft3)

Vapor Mass (using Ideal Gas Law) =

Volume * Component Gas Specific Gravity * Atmospheres * Abs. Temp * Density of Air

October, 2012 Page 13

6. Probability of Failure
PCMS uses failure probability calculations based on the generic probabilities of failure from API
581. These are modified by technical factors in a similar way to API 581 to result in a numeric
probability of failure factor. The probability categories are shown on the PCMS risk matrix in
Section 3.

6.1. Generic Failure Frequency

Since the PCMS consequence model does not consider different hole sizes, we have taken the
generic failure frequency database from API 581 and selected the highest frequency for each
equipment type. We have also set a default piping length of 100 feet to calculate the generic
failure frequency for piping.

Table 6.1.1 Failure Frequencies

Equipment Type Leak

Frequency
(per year)
Centrifugal Pump, single seal 3.06 x 10-5
Centrifugal Pump, double seal 3.06 x 10-5
Column 3.06 x 10-5
Compressor, Centrifugal 3.06 x 10-5
Compressor, Reciprocating 3.06 x 10-5
Filter 3.06 x 10-5
Fin/Fan Coolers 3.06 x 10-5
Heat Exchanger, Shell 3.06 x 10-5
Heat Exchanger, Tube Side 3.06 x 10-5
Piping, .75" diameter 3.06 x 10-5
Piping, 1" diameter 3.06 x 10-5
Piping, 2" diameter 3.06 x 10-5
Piping, 4" diameter 3.06 x 10-5
Piping, 6" diameter 3.06 x 10-5
Piping, 8" diameter 3.06 x 10-5
Piping, 10" diameter 3.06 x 10-5
Piping, 12" diameter 3.06 x 10-5
Piping, 16" diameter 3.06 x 10-5
Piping, > 16" diameter 3.06 x 10-5
Pressure Vessels 3.06 x 10-5
Reactor 3.06 x 10-5
Reciprocating Pumps 3.06 x 10-5
Atmospheric Storage Tank – Floor 7.2 x 10-4

October, 2012 Page 14

Equipment Type Leak

Frequency
Atmospheric Storage Tank – Shell ( x 10-4 )
1.0
Atmospheric Storage Tank – Roof 1.0 x 10-4

October, 2012 Page 15

6.2. Technical Subfactor

In API 581, the Equipment Modification is the product of four subfactors:

FT*FU* FM*FP
Where,

FT – Technical Subfactor

FU – Universal Subfactor

FM – Mechanical Subfactor

FP – Process Subfactor

PCMS only uses the Technical Subfactor. The PCMS Technical Subfactor is based on the Damage
Mechanisms described in API 571. Some detailed models from API 581 are used and some
detailed models from Tischuk T-OCA are also used. The Damage Mechanisms are grouped into 4
Failure Mode categories:

FIT – Internal Thickness Loss

FET – External Thickness Loss

FEC – Environmentally Assisted Cracking

FMF – Metallurgical and Mechanical Failure

PCMS will calculate a factor for each of the Failure Mode categories. Within each Failure Mode,
PCMS will filter the damage mechanisms and will then calculate a technical factor for any
thatremain. The highest factor within a failure mode will be used as the factor for that failure
mode.

The Technical Module factor FT is the Maximum of the 4 failure mode factors:

FT = Max (FIT, FET, FEC, FMF)

The final probability of failure value will be Generic Frequency x FT.

For example for a column, the Generic Frequency is 2 x 10-4. This is probability category 2. If FT
is 100 the probability is 2 x 10-2. This is probability category 4.

October, 2012 Page 16

6.3 Inspection Effectiveness

The inspection effectiveness portion of PCMS is completely configurable by the users in terms of
both the effectiveness ca-tegory of each type of inspection and in the amount of reduction in
Subfactor.

We have added some initial data and programmed the reduction in Subfactor according to the
RIMAP Petrochemical workbook. In PCMS, the risk reduction factor by an inspection is reduced
by 10 percent (user configurable) each year after the inspection. This means that after 10 years,
there is no risk reduction from an individual inspection but that other inspections have a
cumulative effect.

1
2000 2002 2004 2006 2008 2010
Class A Inspection
0.1
Class B Inspection
Class C Inspection
0.01

0.001

0.0001

Failure Probability with Inspection Baseline Failure Probability

Standard Inspection Effectiveness (Class C) - Divide Subfactor by 10

Examples

Piping - TMLs located on 10% of components

Equipment – TMLs located on shell and heads

Medium Inspection or Mitigation Effectiveness (Class B) – Divide Subfactor by 100

Examples

Piping - TMLs located on 50% of components, corrosion rate estimated by statistical method
Equipment – Manual scanning, corrosion rate estimated by statistical method

High Inspection or Mitigation Effectiveness (Class A) – Divide Subfactor by 1000

Examples:

Piping - TMLs located on 100% of components, corrosion rate estimated by statistical method
Equipment – Automated scanning, corrosion rate estimated by statistical method
Equipment – Internal Inspection

October, 2012 Page 17

Table 6.3.1 Default Inspection Effectiveness Subfactor Divisor

Inspection Effectiveness
Failure Mode
Standard (C) Medium (B) High (A)
Internal
Thickness Loss 10 100 1000
External
Thickness Loss 10 100 1000
Environmental
Assisted
Cracking 3 10 30
Mechanical
and
Metallurgical
Failure 3 10 30

7. Internal Thickness Loss

PCMS includes all the damage mechanisms from API 571. We have divided the high
temperature corrosion mechanisms between internal thickness loss and external thickness loss
because these failure modes match with inspection methods.

PCMS includes the following damage mechanisms for internal thickness loss from API 571:

Amine Corrosion (45)

Ammonium Bisulfide (Alkaline Sour Water) Corrosion (7)
Ammonium Chloride Corrosion (8)
Boiler Water Condensate Corrosion (50)
Cooling Water Corrosion (49)
Caustic Corrosion (19)
CO2 Corrosion (42)
Dealloying (41)
Flue Gas Dew Point Corrosion (38)
Galvanic Corrosion (53)
Graphitic Corrosion (15)
Hydrochloric Acid Corrosion (9)
High Temperature H2/H2S Corrosion (4)
High Temperature Sulfur Corrosion (1)
HF Acid Corrosion (37)
Low temperature H2S Corrosion (13)
Metal Dusting (59)
Microbial Induced Corrosion (51)
Naphthenic Acid Corrosion (6)
Phenol corrosion (63)
Phosphoric Acid Corrosion (62)
Sour Water Corrosion (13)
Sulfuric Acid Corrosion (36)

October, 2012 Page 18

() indicates API 571 Reference NumberPCMS has an additional mechanism for Unspecified
Internal Thickness Loss. This is used when PCMS has calculated a corrosion rate, but the
screening process has not been able to detect any other specific damage mechanism.

To calculate the Internal Thickness Loss Subfactor, PCMS takes the following steps:

• Initial Screening

• Calculate Specific Models

• Import measured rate from thickness monitoring data

• Evaluate in the circuit window

• Apply inspection effectiveness factor in the event window after the Initial assessment is
complete.

7.1. Initial Screening

Most of the internal corrosion mechanisms are specific to fluid and material combinations.
Some simple screening allows PCMS to eliminate many mechanisms from most circuits. .
Screening criteria for all of the mechanisms are listed below.

Amine Corrosion

If Material is not Carbon Steel

Exclude Amine Corrosion
If Process Fluid does not contain Rich Diglycolamine
Or Rich Diethanolamine
Or Rich Diisopropanolamine
Or Rich Methyldiethanolamine
Or Rich Monoethanolamine
Or Rich Sulfolane
Or Diglycolamine
Or Diethanolamine
Or Diisopropanolamine
Or Methyldiethanolamine
Or Monoethanolamine
Or Sulfolane
Exclude Amine Corrosion
Ammonium Bisulfide (Alkaline Sour Water) Corrosion

If Material is not Carbon Steel

Exclude Ammonium Bisulfide Corrosion
If Process Fluid does not contain H2S and Ammonia and water
or Ammonium Bisulfide and water
or Sour ater
Exclude Ammonium Bisulfide Corrosion

October, 2012 Page 19

Ammonium Chloride Corrosion

If Process Fluid does not include Water and Ammonia/Ammonium and Chlorides
Exclude Ammonium Chloride Corrosion

Boiler Water Condensate Corrosion

If Process Fluid does not contain Boiler Water Condensate

Exclude Boiler Water Condensate Corrosion

Caustic Corrosion

If Process Fluid does not contain Sodium Hydroxide and Water

Exclude Caustic Corrosion
Minimum Temperature is 150 F

Cooling Water Corrosion

If Process Fluid does not contain Cooling Water

Exclude Cooling Water Corrosion

CO2 Corrosion

If Process Fluid does not include Water and CO2

Exclude CO2 Corrosion
If material is not Carbon Steel
Exclude CO2 Corrosion
Maximum Temperature is 284 F

Dealloying

If Material is not Copper Alloy or Cast Iron

Exclude Dealloying

Flue Gas Dew Point Corrosion

If Process Fluid does not contain Flue Gas

Exclude Flue Gas Dew Point Corrosion
Maximum Temperature is 350 F

Galvanic Corrosion

If Process Fluid does not include water

Exclude Galvanic Corrosion

October, 2012 Page 20

If Equipment does not have Dissimilar Metals

Exclude Galvanic Corrosion

Graphitic Corrosion

If Material is not Cast Iron

Exclude Graphitic Corrosion

High Temperature H2/H2S Corrosion

If Process Fluid does not include H2S

Exclude High Temperature H2/H2S Corrosion
If Operating Temperature Less than 400 F
Exclude High Temperature H2/H2S Corrosion

High Temperature Sulfur Corrosion

If Process Fluid does not include Sulfur

Exclude High Temperature Sulfur Corrosion
If Operating Temperature Less than 400 F
Exclude High Temperature Sulfur Corrosion

HF Acid Corrosion

If Process Fluid does not contain Hydrofluoric Acid

Exclude HF Acid Corrosion

Hydrochloric Acid Corrosion

If Process Fluid does not contain Hydrochloric Acid

Exclude Hydrochloric Acid Corrosion

Low Temperature Wet H2S Corrosion

If Process Fluid does not include Water and H2S

Exclude Low Temperature Wet H2S Corrosion
If Material is not Carbon Steel
Exclude Low Temperature Wet H2S Corrosion

Naphthenic Acid Corrosion

If Process Fluid does not include Naphthenic Acid

Exclude Naphthenic Acid Corrosion
Minimum Temperature is 400 F
October, 2012 Page 21
The contents of this document are confidential and shall not be reproduced, loaned or given away without specific permission of
PCMS a member of MISTRAS Group Inc.
PCMS RBI Technical Manual
Rules for Calculation of Risk

Phenol Corrosion

If Process Fluid does not include Phenol

Exclude Phenol Corrosion

Phosphoric Acid Corrosion

If Process Fluid does not include Phosphoric Acid

Exclude Phosphoric Acid Corrosion

Sour Water Corrosion

If Process Fluid does not include Refinery Sour Water

Exclude Sour Water Corrosion

Sulfuric Acid Corrosion

If Process Fluid does not include Sulfuric Acid

Exclude Sulfuric Acid Corrosion

Metal Dusting

If Operating Temperature is not in the range 900 F to 1500 F

Exclude Metal Dusting

October, 2012 Page 22

7.2. Initial Probability Calculation

The initial probability calculation is carried out without assessment of inspection effectiveness.
After the initial calculation, the analysis moves to review mode and the probability calculation
will be modified by assessment of inspection effectiveness, measured corrosion rates, measured
remaining thickness and expert evaluation of corrosion mechanisms that are not possible to
calculate.

Calculate ar/t

The initial value of ar/t is based on:

• The piping or equipment age in years (a) calculated from date built and date now.

• The corrosion rate (r) from the applicable models.

• The nominal wall thickness of the piping or equipment (t).

Once thickness monitoring has been done to give a measured corrosion rate, the current value
of ar/t is determined by the corrosion data and Rate Method selected to compute RBI:

• For the Rate Methods of Calculated Avg. Rate and Formula Adjusted Rate:

o a = Equipment age from date built

o r = CAR or FAJ

o t = Minimum Nominal Thickness in the Circuit

• For the Rates Methods Max Long Rate, Max Short Rate, Worst Case( Long/Short) Rate,
and Worst Case (Long/Short) Retirement Date

o a = Time between Initial Reading of the driving rate and now

o r = Long or Short Rate

o t = Thickness of First Reading used to determine driving rate

The Internal Thickness loss Subfactor is based on the table below:

Table 7.2.1 Thickness Loss Subfactor

ar/t Thickness Loss ar/t Thickness Loss Subfactor

Subfactor
< 0.08 1 0.25 to 0.30 650
0.08 to 0.10 2 0.30 to 0.35 750
0.10 to 0.12 6 0.35 to 0.40 900
0.12 to 0.14 20 0.40 to 0.45 1050

October, 2012 Page 23

ar/t Thickness Loss ar/t Thickness Loss Subfactor

Subfactor
0.14 to 0.16 90 0.45 to 0.50 1200
0.16 to 0.18 250 0.50 to 0.55 1350
0.18 to 0.20 400 0.55 to 0.60 1500
0.20 to 0.25 520 >0.60 1900

Cladding

For Equipment with Cladding, the Cladding Material is used for RBI Screening and Rate
Modeling.

Lining

For Equipment with Lining, the Technical Subfactor is divided by 100

October, 2012 Page 24

7.3. Internal Thickness Loss Models

Of the damage mechanisms classified under Internal Thickness Loss, 8 have models, the
remaining must be evaluated in the circuit window by the user.

Table 7.3.1 Process Stream Composition

Evaluated by PCMS Models Evaluated by the User

Amine Caustic

Ammonium Bisulfide (Alkaline Cooling Water

Sour Water)

Carbon Dioxide Dealloying

High Temperature Flue Gas Dew Point

Hydrogen/Hydrogen Sulfide

High Temperature Sulfur Galvanic

Hydrofluoric Acid Graphitic

Low Temperature Wet Hydrochloric Acid

Hydrogen Sulfide

Naphthenic Acid Microbial

Phenol

Phosphoric Acid

Sulfuric Acid

Sour Water (Acid)

Boiler Water Condensate

Ammonium Chloride

Metal Dusting

Unspecified

The models are described in detail in the sections below. User evaluated mechanisms are
identified on the circuit window probability form and require a user input of susceptibility.

October, 2012 Page 25

7.3.1. Amine Corrosion

API 581 models amine corrosion in a complex way with inputs required for amine type, acid
gas loading, undesirable salts and velocity. Since most users will not have these values, the
model has been simplified by taking median values for the different inputs and selecting the
corrosion rates from the API 581 table.

Table 7.3.1.1 Corrosion Rates for Carbon Steel in Rich Amine

Temperature Corrosion Rate (mpy)

(F)

<190 6

190-210 10

211-230 20

231-250 45

251-270 70

>270 90

Table 7.3.1.2 Corrosion Rates for Carbon Steel in Lean Amine

Temperature Corrosion Rate (mpy)

(F)

<190 1

190-210 2

211-230 5

231-250 10

251-270 15

>270 20

October, 2012 Page 26

7.3.2. Ammonium Bisulfide (Alkaline Sour Water) Corrosion

When H2S and NH3 are present in the stream:

• Calculate Kp = %H2S x %NH3.

• Look up Corrosion Rate based on Kp in Table 7.3.2.1.

When NH4SH is present in the stream:

• Look up Corrosion Rate based on Weight % NH4SH in Table 7.3.2.1.

When Sour Water is in the stream, 25 mpy is used for the Corrosion Rate.

Table 7.3.2.1 Corrosion Rates for Carbon Steel in Alkaline Sour Water

Kp NH4HS (wt%) Corrosion Rate (mpy)

<0.07 2 5

0.07 to 0.235 5 15

0.235 to 0.70 14 30

>0.70 20 300

7.3.3. CO2 Corrosion Model

For Carbon Dioxide corrosion of carbon steel, the deWaard and Milliams equation is used to
calculate the corrosion rate:

Calculate operating temperature in degrees C (Maximum allowable temperature is 140 F)

Calculate operating pressure in bar absolute
Calculate corrosion rate in millimeters per year:

CR = 10^(5.8 -(1710/MIN(333,Op TemperatureC+273))+(0.67log(0.01CO2*(1+Op

Pressure bara))/2.301))
Multiply CR by 39.37 to get corrosion rate in mpy

7.3.4. High Temperature H2/H2S Corrosion

The high temperature H2 / H2S model is based on Couper-Gorman. Tables G-27 through G-
32 in Appendix 1 are derived from API 581 but simplified to eliminate dependence on the
hydrocarbon type.

7.3.5. High Temperature Sulfur Corrosion

The high temperature sulfur corrosion model is based on modified McConomy. Tables for
different materials are listed in Appendix 1. These Tables G-17 through G-24 are directly
from API 581 and are combined with naphthenic acid corrosion.

October, 2012 Page 27

7.3.6. HF Acid Corrosion

The HF acid model contains data for carbon steel and monel 400. Any other materials in HF
service should be evaluated in the event window. Tables G-42 and G-43 are located in
Appendix 1.

7.3.7. Low Temperature Wet H2S Corrosion Model

The following graph shows corrosion rate vs. concentration curves for wet H2S for Carbon
Steel at different temperatures from ambient to 150C (300F). Remember that percent is
10,000 x ppm.

Wet H2S Corrosion

50
Corrosion Rate (mpy)

40 25

60
30
95

120
20
150

0
0 1 2 3 4 5

Percent H2S

7.3.8. Naphthenic Acid Corrosion

High temperature sulfur and naphthenic acid corrosion rate tables for different materials are
listed in Appendix 1. These Tables G-17 through G-24 are directly from API 581.

7.3.9. Non-modeled Internal Corrosion Mechanisms

Where we do not have a technical model for a corrosion mechanism, for example, galvanic
corrosion, the user must define susceptibility. The default rates are:

Table 7.3.9.1 User Defined Corrosion Rates

Rating Corrosion Rate (mpy)

Negligible 0

Low 2

October, 2012 Page 28

Rating Corrosion Rate (mpy)

Medium 10

High 50

These settings may be changed by the user.

7.4. Target Date

PCMS calculates the Target Date, the date the Risk would rise above the Risk Threshold. For
Internal Loss Damage Mechanisms, the Age is increased until the Risk Calculation (Probability x
Consequence) exceeds the Risk Threshold. For each increment of Age, Damage Factor is
recalculated with adjustments made to both ar/t and Inspection Effectiveness.

October, 2012 Page 29

8. External Thickness Loss

PCMS contains four damage mechanisms for external thickness loss:

CUI of Carbon and Low Alloy Steels (46)

Atmospheric External Corrosion of Carbon and Low Allow Steels (47)
High Temperature Oxidation (11)
Fuel Ash corrosion of Boiler and Furnace Tubes (44)

() indicates API 571 Reference Number

PCMS will conduct screening to determine whether any of the damage mechanisms apply. If none
apply, the External Thickness Loss Subfactor will be zero. For example, no external thickness loss
damage mechanisms would apply to an austenitic stainless line operating at ambient temperature.

Calculate ar/t

The initial value of ar/t is based on:

• The piping or equipment age in years(a) calculated from date built and now
• The corrosion rate (r) from the applicable models
• The nominal wall thickness of the piping or equipment (t)

The current value of ar/t is based on:

• Age is the minimum of:

• The time elapsed in years (a) from the Last Inspection (Date Built is used if inspection
has not been done) and now
• The time in which an applied coating has been determined to be ineffective; the Coating picklist
contains an Interval to add to the Coating Installation Date to determine this date.The measured
corrosion rate (r) from the Circuit window (the modeled rate is used if a measured rate is not
present).
• The nominal wall thickness of the piping or equipment (t)

To calculate the External Thickness Loss Subfactor, PCMS takes the following steps:

• Initial Screening

• Calculate Specific Models

• Import measured rate from inspection data

• Evaluate in the circuit window

• Apply inspection effectiveness factor in the event window after the Initial assessment is
complete.

October, 2012 Page 30

8.1. Screening

CUI or Atmospheric External Corrosion

If material is not carbon or low alloy steel

Exclude CUI and
Exclude External Corrosion
If Material is not CS .5 Moly
Exclude CUI

High Temperature Oxidation

If operating temperature less than 900 F

Exclude High Temperature Oxidation

Fuel Ash Corrosion

If operating temperature less than 1000 F

Exclude Fuel Ash Corrosion

8.2 External Thickness Loss Models

8.2.1 CUI or General External Corrosion

Base Corrosion Rates can be found in the RBI EXTERNAL CORROSION RATE picklist table. The table
contains suggested rates by process environment and temperature range, for Insulated and non-
Insulated equipment. The default values are from API 581 2nd Edition (2008) Tables 16.3 (External
Corrosion) and 17.3 (CUI). The Corrosion Rate used in the model will be the Maximum Corrosion
Rate found in the table using both Operating Temperature and Temperature Out on the circuit. CUI
Potential on Circuit is an override for the temperature range.

October, 2012 Page 31

The following adjustment factors (or rate multipliers) are then applied to the Base Corrosion
Rate:
• Insulation Type (CUI Only)
The Insulation Type adjustment factors are in the Insulation Type picklist.
Default values are from API 581 2nd Edition (2008) Table 17.4. The value used is
determined by the Insulation Type on the circuit.

Table 8.2.1.1 Insulation Type Adjustment Factor

Insulation Type Adjustment Factor
None 1.0
Foamglass 0.75
Pearlite 1.0
Fiberglass 1.25
Mineral Wool 1.25
Calcuim Silicate 1.25
Asbestos 1.25

• Complexity (CUI Only)

Complexity is the number of design features (branch connections, nozzles, pipe
supports, etc.) that would promote the collection of moisture. The adjustment
factors are in the Complexity picklist. The value used is determined by the
Complexity on the circuit. Suggested values from API 581 2nd Edition (2008)
Section 17.6.3 are:

Table 8.2.1.2 Complexity – CUI Only

Complexity Adjustment
Factor
Below Average (none) 0.75
Average (some) 1.0
Above Average (many) 1.25

• Insulation Condition (CUI Only)

Insulation Condition is based on the external visual of the jacketing condition.
The adjustment factor is in the Insulation Condition. The value used is
determined by the Insulation Condition on the circuit. Suggested values from
API 581 2nd Edition (2008) Section 17.6.3 are:

Table 8.2.1.3 Complexity - Insulation Condition CUI Only

Complexity Adjustment
Factor
Below Average (heavy damagene) 1.25
Average (good jacketing with some areas of failed 1.0
weatherproofing)

October, 2012 Page 32

Above Average (no signs of damage or standing water) 0.75

• Pipe Supports and Interfaces

o The Rate is multiplied by 2 if piping has a configuration that does not allow
for proper coating maintenance or if it has an interface that enters either
soil or water.

Table 8.2.1.4 Corrosion Rates for Calculation of the Damage Factor - CUI

Table 8.2.1.5 Corrosion Rates for Calculation of the Damage Factor - General
External Corrosion

8.2.2 High Temperature Oxidation

If the pipe or equipment has an operating temperature greater than 900 F, the high
temperature oxidation table, Table 4-6 from API 571 is used to determine the corrosion rate.

October, 2012 Page 33

Table 8.2.2.1 High Temperature Oxidation

Corrosion Rate (mpy)

Maximum Metal Temperature °F (oC)
Material of 900 -950 951 - 1001 - 1051 - 1101 - 1151 - 1201 - 1251 - 1301 - 1351 - 1401 - 1451 -
(482- 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500
Construction 570oC) (511- (538- (566- (594- (622- (649- (677- (705- (733- (761- (788-
538oC) 566oC) 593oC) 621oC) 649oC) 677oC) 704oC) 732oC) 760oC) 788oC) 816oC
)
CS 2 4 6 9 14 22 33 48 – – – –
1¼ Cr 2 3 4 7 12 18 30 46 – – – –
2¼ 1 1 2 4 9 14 24 41 – – – –
5Cr 1 1 1 2 4 6 15 35 65 – – –
7Cr 1 1 1 1 1 2 3 6 17 37 60 –
9Cr 1 1 1 1 1 1 1 2 5 11 23 40
12 Cr 1 1 1 1 1 1 1 1 3 8 15 30
304SS 1 1 1 1 1 1 1 1 1 2 3 4
309SS 1 1 1 1 1 1 1 1 1 1 2 3
310 SS/HK 1 1 1 1 1 1 1 1 1 1 1 2
800H/HP 1 1 1 1 1 1 1 1 1 1 1 2

Table 8.2.2.2 High Temperature Oxidation

Corrosion Rate (mpy)

Maximum Metal Temperature °F (oC)
Material of 1501 - 1551 - 1601 - 1651 - 1701 - 1751 - 1801 - 1851 - 1901 - 1951 - 2001 - 2051 - 2101 -
1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 2050 2100 2150
Construction (816- (844- (872- (899- (927- (955- (983- (1011- (1038- (1067- (1094- (1122- (1149-
843oC) 871oC) 899oC) 927oC) 954oC) 982oC) 1010oC) 1038oC) 1066oC) 1093oC) 1121o 1149o 1177o
C) C) C)
CS – – – – – – – – – – – – –
1¼ Cr – – – – – – – – – – – – –
2¼ – – – – – – – – – – – – –
5Cr – – – – – – – – – – – – –
7Cr – – – – – – – – – – – – –
9Cr 60 – – – – – – – – – – – –
12 Cr 50 – – – – – – – – – – – –
304SS 6 9 13 18 25 35 48
309SS 4 6 8 10 13 16 20 30 40 50 – – –
310 SS/HK 3 4 5 7 8 10 13 15 19 23 27 31 37
800H/HP 3 4 6 8 10 13 17 21 27 33 41 50 60

8.2.3 Fuel Ash Corrosion

If the pipe or equipment has an operating temperature greater than 1000 F, PCMS will not filter Fuel
Ash Corrosion. The user will be able to make a direct assessment in the circuit window.

8.3 Target Date

PCMS calculates the Target Date, the date the Risk would rise above the Risk Threshold. For each
External Loss Damage Mechanism, the Age is increased until the Risk Calculation (Probability x
Consequence) exceeds the Risk Threshold. For each increment of Age, Damage Factor is
recalculated with adjustments made to both ar/t and Inspection Effectiveness.

October, 2012 Page 34

9 Environmental Assisted Cracking

API 571 includes the following damage mechanisms for environmental assisted cracking:

Amine Stress Corrosion Cracking (22)

Ammonia Stress Corrosion Cracking (48)
Carbonate Stress Corrosion Cracking (21)
Caustic Stress Corrosion Cracking (Caustic Embrittlement) (18)
Chloride Stress Corrosion Cracking – External (23)
Chloride Stress Corrosion Cracking – Internal (23)
High Temperature Hydrogen Attack (10)
Hydrogen Stress Cracking (HF) (40)
Hydrogen SC (HF) HIC/SOHIC (40)
Liquid Metal Embrittlement (52)
Polythionic Acid Stress Corrosion Cracking (5)
Titanium Hydriding (57)
Wet H2S Damage (HIC/SOHIC/ Hydrogen Blistering) (2)
Wet H2S Damage (Sulfide Stress Cracking - SSC) (2)

() indicates API 571 Reference Number

PCMS will screen the environmental assisted cracking damage mechanisms, and then evaluate
the Subfactor for any remaining by model or by direct assessment. For most circuits, no
mechanisms will apply and the Subfactor should be 0. In most of the remainder only one
damage mechanism will apply. If more than one apply, PCMS will use the highest Subfactor.

To calculate the Environmental Assisted Cracking Subfactor, PCMS takes the following steps:

• Initial Screening

• Calculate Specific Models

• Evaluate in the Circuit window

• Apply Aging Factor from Install Date or Last Inspection Date.

• Apply Inspection Effectiveness factor in the Event window after the Initial assessment is
complete.

9.1 Initial Screening

The environmental assisted cracking damage mechanisms are specific to fluid and material
combinations. Some simple screening allows PCMS to eliminate many mechanisms from most
circuits. Screening criteria for all of the mechanisms are listed below:

October, 2012 Page 35

Amine Stress Corrosion Cracking

If Process Fluid does not include Diglycolamine or Diethanolamine or Diisopropanolamine or

Monoethanolamine or Sulfolane or Methyldiethanolamine
Exclude Amine Stress Corrosion Cracking
If Material is not Carbon Steel
Exclude Amine Stress Corrosion Cracking
If Heat Treatment is Stress Relief
Exclude Amine Stress Corrosion Cracking

Ammonia Stress Corrosion Cracking

If Process Fluid does not include Ammonia

Exclude Ammonia Stress Corrosion Cracking

Carbonate Stress Corrosion Cracking

If Process Fluid does not include Refinery Sour Water, H2S, and CO2
Exclude Carbonate Stress Corrosion Cracking
If Material is not Carbon steel
Exclude Carbonate Stress Corrosion Cracking
If Heat Treatment is Stress Relief or PWHT
Exclude Carbonate Stress Corrosion Cracking
If H2S < 50 ppm
Exclude Carbonate Stress Corrosion Cracking
If Material is not CS .5 Moly
Exclude Carbonate Stress Corrosion Cracking
Maximum temperature is 250 F

Caustic Stress Corrosion Cracking (Caustic Embrittlement)

If Process Fluid does not include Sodium Hydroxide

Exclude Caustic Stress Corrosion Cracking (Caustic Embrittlement)
Caustic and Potassium Hydroxide are included as optional fluids
If Material is not Carbon Steel or Austenitic SS
Exclude Caustic Stress Corrosion Cracking (Caustic Embrittlement)
If Heat Treatment is Stress Relief or PWHT
Exclude Caustic Stress Corrosion Cracking (Caustic Embrittlement)
If Material is not CS or 300 SS
Exclude Caustic Stress Corrosion Cracking
Minimum Temperature is 150 F

Chloride Stress Corrosion Cracking - External

If Material is not Austenitic or Duplex Stainless

October, 2012 Page 36
The contents of this document are confidential and shall not be reproduced, loaned or given away without specific permission of
PCMS a member of MISTRAS Group Inc.
PCMS RBI Technical Manual
Rules for Calculation of Risk

Exclude Chloride Stress Corrosion Cracking - External

If Operating Temperature < 100 F
Exclude Chloride Stress Corrosion Cracking - External
If Operating Temperature > 400 F
Exclude Chloride Stress Corrosion Cracking – External
If not CUI Potential
Exclude Chloride Stress Corrosion Cracking - External

Chloride Stress Corrosion Cracking - Internal

If Material is not Austenitic or Duplex Stainless

Exclude Chloride Stress Corrosion Cracking - Internal
If Process Fluid does not include Chlorides
Exclude Chloride Stress Corrosion Cracking - Internal
If Operating Temperature < 100 F
Exclude Chloride Stress Corrosion Cracking - Internal
If CUI Potential
Exclude Chloride Stress Corrosion Cracking – Internal

High Temperature Hydrogen Attack

If Process Fluid does not include Hydrogen

Exclude High Temperature Hydrogen Attack
If Operating Temperature < 400F
Exclude High Temperature Hydrogen Attack
If Material is not Carbon Steel, Chrome Moly Alloy steel, or CS .5 Moly
Exclude High Temperature Hydrogen Attack

Hydrogen Stress Cracking (HF)

If Process Fluid does not include HF Acid

Exclude Hydrogen Stress Cracking (HF)
If Material is not Carbon Steel or Chrome Moly Alloy
Exclude Hydrogen Stress Cracking (HF)
If Heat Treatment is PWHT
Exclude Hydrogen Stress Cracking (HF)

Hydrogen SC (HF) HIC/SOHIC

If Process Fluid does not include HF Acid
Exclude Hydrogen Stress Cracking (HF)
If Material is not Carbon Steel or Chrome Moly Alloy
Exclude Hydrogen Stress Cracking (HF)

October, 2012 Page 37

Liquid Metal Embrittlement

If Process Fluid does not include Mercury

Exclude Liquid Metal Embrittlement

Polythionic Acid Stress Corrosion Cracking

If Material is not Austenitic Stainless or Alloy 600 or Alloy 800

Exclude Polythionic Acid Stress Corrosion Cracking
If Process Fluid does not include Sulfur or H2S
Exclude Polythionic Acid Stress Corrosion Cracking
If Operating Temperature is less than 700 F
Exclude Polythionic Acid Stress Corrosion Cracking

Titanium Hydriding

If Material is not Titanium

Exclude Titanium Hydriding

Wet H2S Damage (HIC/SOHIC/ Hydrogen Blistering)

If Material is not Carbon Steel or Chrome Moly Alloy

Exclude Wet H2S Damage (HIC/SOHIC)
If Process Fluid does not include H2S and (Water or Refinery Sour Water)
Exclude Wet H2S Damage (HIC/SOHIC)
If Operating Temperature > 300 F
Exclude Wet H2S Damage (HIC/SOHIC)

Wet H2S Damage (Sulfide Stress Cracking – SSC)

If Material is not Carbon Steel or Chrome Moly Alloy

Exclude Wet H2S Damage (Sulfide Stress Cracking - SSC)
If Process Fluid does not include H2S and (Water or Refinery Sour Water)
Exclude Wet H2S Damage (Sulfide Stress Cracking - SSC)
If Operating Temperature > 180 F
Exclude Wet H2S Damage (Sulfide Stress Cracking - SSC)
If PWHT
Exclude Wet H2S Damage (Sulfide Stress Cracking - SSC)

9.2 Initial Susceptibility Evaluation

Where possible, the models calculate a high, medium or low value of susceptibility. This is
converted to a Subfac=tor value by Table 9.2 which is based on API 581. Some API 571 damage
mechanisms are not included in API 581 and were estimated by PCMS and included in Table 9.2.

The Subfactor value will later be modified by inspection and monitoring effectiveness. Where
there is no susceptibility to any of the damage mechanisms, the Environmental Assisted Cracking
Subfactor will be zero.
October, 2012 Page 38
The contents of this document are confidential and shall not be reproduced, loaned or given away without specific permission of
PCMS a member of MISTRAS Group Inc.
PCMS RBI Technical Manual
Rules for Calculation of Risk

Table 9.2.1 Environmental Assisted Cracking Subfactor from Initial Susceptibility

Damage Mechanism High Medium Low Negligible

Amine SCC 1000 100 10 0

Ammonia SCC 1000 100 10 0

Carbonate SCC 1000 100 10 0

Caustic SCC 5000 500 50 0

Chloride SCC – External 5000 500 50 0

Chloride SCC – Internal 5000 500 50 0

High Temp Hydrogen Attack 2000 200 20 0

Hydrogen Stress Cracking (HF) 100 10 1 0

Hydrogen SC (HF) HIC/SOHIC 100 10 10 0

Liquid Metal Embrittlement 1000 100 10 0

Polythionic Acid SCC 5000 500 50 0

Titanium Hydriding 1000 100 10 0

Wet H2S Damage (HIC/SOHIC 100 10 1 0

Hydrogen Blistering)
Wet H2S Damage (SSC) 100 10 1 0

October, 2012 Page 39

9.3 Environment Assisted Cracking Models

The models are designed to return a susceptibility value of High, Medium, Low or None for each
of the damage mechanisms.

9.3.1 Amine Stress Corrosion Cracking

PCMS models Amine SCC for 6 amines:

Diglycolamine
Diethanolamine
Diisopropanolamine
Methyldiethanolamine
Monoethanolamine
Sulfolane

If contents includes “Rich”,

Susceptibility = None
If contents = Monoethanolamine or Diisopropanolamine and operating temperature > 180F
Susceptibility = High
If contents = Monoethanolamine or Diisopropanolamine and operating temperature > 100F
Susceptibility = Medium
If contents = Monoethanolamine or Diisopropanolamine and operating temperature < 100F
Susceptibility = Low
If contents = Diethanolamine and operating temperature > 180F
Susceptibility = Medium
If contents = Diethanolamine and operating temperature > 140F
Susceptibility = Low
If contents = Diethanolamine and operating temperature < 140F
Susceptibility = None
If contents = Diglycolamine or Methyldiethanolamine or Sulfolane and operating
temperature > 180F
Susceptibility = Low
If contents = Diglycolamine or Methyldiethanolamine or Sulfolane and operating
temperature < 180F
Susceptibility = None

October, 2012 Page 40

9.3.2 Chloride SCC

Chloride SCC may occur in austenitic or duplex stainless steels on either the process side or
the external side.

Two models must be used, one for process side and one for the external side.

Process Side Chloride SCC

The initial susceptibility is determined from the following table:

Table 9.3.2.1 Initial Susceptibility

Operating <10ppm 10-100 ppm 100-1000 ppm >1000ppm

Temperature (F)

100-150 Low Medium Medium High

150-200 Medium Medium High High

200-400 Medium High High High

If Operating Temperature < 100F

Susceptibility = None
If Operating Temp > 400F
Susceptibility = None

External side Chloride SCC

External side Chloride SCC is the Corrosion Under Insulation equivalent for austenitic and
duplex stainless steel. The initial susceptibility is determined from the following table:

Table 9.3.2.2 Initial Susceptibility

Operating Insulated Not Insulated

Temperature (F)

100-150 Low Low

150-220 High Medium

>220 Medium Low

If Operating Temperature < 100F

Susceptibility = None

October, 2012 Page 41

9.3.3 Caustic SCC

The caustic service limits for Carbon Steel that is not stress relieved are according to the
table below (Referred as Area A in API 581):

Table 9.3.3.1 Caustic Service Limits

Caustic Concentration (%) Temperature (F)

>5 180

5-15 170

15-25 155

25-35 140

35-45 125

>45 115

Use Table 9.3.3.1 to determine the limit temperature from the caustic concentration in
contents.

If operating temperature > limit temperature and caustic concentration > 5%

Susceptibility = High
If operating temperature > limit temperature and caustic concentration < 5%
Susceptibility = Medium
If operating temperature < limit temperature
Susceptibility = None

9.3.4 High Temperature Hydrogen Attack

First Calculate the value of Pv

Pv = log(PH2) + 3.09 x 10-4( T)(log(t)+14)

Where,

PH2 = Partial pressure of hydrogen in units of kgf/cm2 = %hydrogen in fluid x operating

pressure

T = Temperature in oK = oC + 273

t = time in service in hours (today – unit start date convert to hours)

October, 2012 Page 42

The initial susceptibility is determined from the Table 9.3.4.1 below:

Table 9.3.4.1 Initial Susceptibility

Material High Medium Low None

Carbon Steel Pv>4.70 4.70>Pv>4.61 4.61>Pv>4.53 Pv<4.53

0.5 Mo Pv>4.95 4.95>Pv>4.87 4.87>Pv>4.78 Pv<4.78

0.5 Cr 0.5 Mo Pv>5.40 5.40>Pv>5.31 5.31>Pv>5.23 Pv<5.23

1 Cr 0.5 Mo Pv>5.80 5.80>Pv>5.71 5.71>Pv>5.63 Pv<5.63

1.25 Cr 0.5 Pv>6.00 6.00>Pv>5.92 5.92>Pv>5.83 Pv<5.83

2 Cr 0.5 Mo Pv>6.25 6.25>Pv>6.16 6.16>Pv>6.07 Pv<6.07

2.25 Cr 1 Mo Pv>6.53 6.53>Pv>6.45 6.45>Pv>6.36 Pv<6.36

9.3.5 Hydrogen Stress Cracking (HF)

If Heat Treatment = None
Susceptibility = High
If Heat Treatment = PWHT or stress Relief
Susceptibility = Medium

9.3.6 Polythionic Acid Stress Corrosion Cracking

Polythionic Acid Stress Corrosion Cracking occurs during shutdown rather than in service
unless preventative actions are taken. The initial susceptibility is determined from Table
9.3.6.1

Table 9.3.6.1 Initial Susceptibility

Material Operating Operating

Temperature Temperature
< 800F >800F

300 Series Medium High

Stainless

Alloy 600 and Medium High

Alloy 800

Alloy 625, Alloy Low Medium

October, 2012 Page 43

Material Operating Operating

Temperature Temperature
< 800F >800F

825, Alloy 20

9.3.7 Wet H2S Damage (HIC/SOHIC/ Hydrogen Blistering)

Wet H2S Damage (HIC/SOHIC) is caused by atomic hydrogen passing through the steel and
accumulating at inclusions and causing internal pressure forming blisters in susceptible steel.
Stepwise cracks then form at the ends of the blisters and eventually link. In PCMS we
calculate initial susceptibility from the H2S concentration using the table below:

Table 9.3.7.1 Initial Susceptibility

H2S Susceptibility
Concentration
parts per
million (ppm)

<50 Low

50-10,000 Medium

>10,000 High

PCMS users may reduce the initial susceptibility if resistant grades of steel are used in
construction.

9.3.8 Wet H2S Damage (SSC)

Wet H2S Damage (SSC) is sulfide stress cracking. This is a form of stress corrosion cracking
requiring a susceptible material and a specific corrosive environment. In PCMS we calculate
initial susceptibility from the H2S concentration using the table below:

October, 2012 Page 44

Table 9.3.8.1 Initial Susceptibility

H2S Susceptibility
Concentration
parts per million
(ppm)

<50 Low

50-1000 Medium

>1000 High

Note that the limits are different in the SSC table from HIC/SOHIC and Hydrogen Blistering.
PCMS users may reduce the susceptibility to SSC if hardness control to NACE MR-01-75 has been
applied during equipment or piping fabrication.

9.4 Aging Factor

The initial damage factor determined by the models is increased by an annual aging factor for
the time between now and the last inspection for the damage mechanism. The annual aging
factor is a % determined by the Risk Level determined by the models. Those values are 20% for
High, 10% for Medium, and 5% for Low. Those factors are configurable per Damage Mechanism.

9.5 Target Date

PCMS calculates the Target Date, the date the Risk would rise above the Risk Threshold. For
each Cracking Damage Mechanism, the Age is increased until the Risk Calculation (Probability x
Consequence) exceeds the Risk Threshold. For each increment of Age, the Damage Factor is
recalculated with adjustments for the Aging Factor and Inspection Effectiveness.

10 Mechanical and Metallurgical Failure

API 571 includes the following damage mechanisms for mechanical and metallurgical failure.

Brittle Fracture (31)

Carburization (24)
Cavitation (28)
Creep (3)
Dissimilar Weld Metal Cracking (39)
Erosion (20)
Fatigue – Mechanical (54)
Fatigue – Thermal (12)
Refractory Damage
Reheat Cracking (35)

October, 2012 Page 45

Lining

() indicates API 571 Reference Number

There are several other metallurgical damage mechanisms described in API 571. These include
885 oF Embrittlement, Graphitization, Sigma Phase Embrittlement , Spheroidization, Strain Aging,
Temper Embrittlement. They are undetectable by inspection and have been excluded.

API 571 also includes Carburization and Nitriding as High Temperature corrosion mechanisms.
These are included in PCMS as mechanical and metallurgical failure mechanisms.

API 571 also includes Short Term Overheating and Steam Blanketing. These are damage
mechanisms that apply to furnace and boiler tubes under non optimal operating conditions.
They have been excluded from PCMS.

PCMS has screening and then direct evaluation by the user in the circuit window for the
Mechanical and Metallurgical Failure mechanisms, only Lining has a model. PCMS will use the
highest subfactor evaluated for the mechanical and metallurgical failure Subfactor. For most
circuits, no mechanisms will apply and the Subfactor will be zero.

To calculate the Mechanical and Metallurgical Failure Subfactor, PCMS takes the following steps:

• Initial Screening

• Evaluate in the Circuit window

• Apply Aging Factor from Install Date or Last Inspection Date.

• Apply inspection effectiveness factor in the event window after the Initial assessment is
complete.

10.1 Initial Screening

Some simple screening allows PCMS to eliminate many mechanical and metallurgical damage
mechanisms from most circuits.

Brittle Fracture

If Material not Carbon Steel or Alloy Steel

Exclude Brittle Fracture

Carburization

If Operating Temperature is less than 1100 F

Exclude Carburization

October, 2012 Page 46

Cavitation

PCMS will not contain any data to screen for Cavitation

Set Initial susceptibility as None
Evaluate in circuit window to modify

Creep

If Operating Temperature is less than the Creep Temperature in Materials Properties Table
Exclude Creep

Dissimilar Weld Metal Cracking

PCMS will not contain any data to screen for Dissimilar Weld Metal Cracking
Set Initial susceptibility as None
Evaluate in circuit window to modify

Erosion

PCMS will not contain any data to screen for Erosion

Set Initial susceptibility as None
Evaluate in circuit window to modify

Mechanical Fatigue

PCMS will not contain any data to screen for Mechanical Fatigue
Set Initial susceptibility as None
Evaluate in circuit window to modify

Thermal Fatigue

PCMS will not contain any data to screen for Thermal Fatigue
Set Initial susceptibility as None
Evaluate in circuit window to modify

Reheat Cracking

PCMS will not contain any data to screen for Reheat Cracking
Set Initial susceptibility as None
Evaluate in circuit window to modify

October, 2012 Page 47

Lining

If no Lining then
Exclude Lining

10.2 Initial Susceptibility Evaluation

When the PCMS user evaluates susceptibility to a mechanical and metallurgical damage
mechanism as High, Medium or Low, PCMS converts susceptibility to a Subfactor value by use of
Table 10.2.1. The subfactor value will later be modified by inspection and monitoring
effectiveness.

The initial probability Subfactor table was derived from API 581. Not all API 571 damage
mechanisms are included in API 581. Probability subfactor values were adopted for these
mechanisms based on the most similar mechanism in API 581.

Table 10.2.1 Initial Probability Subfactor

Damage Mechanism High Medium Low None
Brittle Fracture 1000 100 10 0
Carburization 500 50 5 0
Cavitation 1000 100 10 0
Creep 1000 100 10 0
Dissimilar Weld Metal Cracking 1000 100 10 0
Erosion 1000 100 10 0
Mechanical Fatigue 500 50 5 0
Thermal Fatigue 500 50 5 0
Reheat Cracking 1000 100 10 0
Nitriding 500 50 5 0
Lining 3000 300 30

10.3 Mechanical and Metallurgical Failure Models

10.3.1 Lining

Lining Damage Factors per Material are in the RBI LINING DAMAGE FACTOR picklist.
The default values in the picklist are based on API 581 Table M-5A- Lining Failure
Factors and M-5B – Lining Failure Factors – Organic Coatings.

October, 2012 Page 48

Table 10.3.1.1 Lining Damage Factors

Years Since Damage Factor as a Function of Inorganic Lining Type

Last
Internal Strip Lined Castable Castable Glass Acid Fiberglass
Visual Alloy Refractory Refractory Lined Brick
Inspection (Resistant) Severe
Conditions

1 0.3 0.5 9 3 0 1

2 0.5 1 40 4 0 1

3 0.7 2 146 6 0 1

4 1 4 428 7 0 1

5 1 9 1017 9 1 1

6 2 16 1978 11 1 1

7 3 30 3000 13 1 2

8 4 53 3000 16 1 3

9 6 89 3000 20 2 7

10 9 146 3000 25 3 13

11 12 230 3000 30 4 26

12 16 351 3000 36 5 47

13 22 518 3000 44 7 82

14 30 738 3000 53 9 139

15 40 1017 3000 63 11 228

16 53 1358 3000 75 15 359

17 69 1758 3000 89 19 548

18 89 2209 3000 105 25 808

19 115 2697 3000 124 31 1151

20 146 3000 3000 146 40 1587

21 184 3000 3000 170 50 2119

October, 2012 Page 49

Years Since Damage Factor as a Function of Inorganic Lining Type

Last
Internal Strip Lined Castable Castable Glass Acid Fiberglass
Visual Alloy Refractory Refractory Lined Brick
Inspection (Resistant) Severe
Conditions

22 230 3000 3000 199 63 2743

23 286 3000 3000 230 78 3000

24 351 3000 3000 266 97 3000

25 428 3000 3000 306 119 3000

Table 10.3.1.2 Time Damage Factors

Damage Factor as a Function of Time Since the Last Inspection

Years in Service
Inspected More Inspected 3 to 6 Inspected Within
Than 6 years ago years ago Last 3 years

1 30 1 0

2 89 4 0

3 230 16 0

4 518 53 0

5 1017 146 0.2

6 1758 351 1

7 2697 738 4

8 3000 1358 16

9 3000 2209 53

10 3000 3000 146

11 3000 3000 351

12 3000 3000 738

13 3000 3000 1358

October, 2012 Page 50

Damage Factor as a Function of Time Since the Last Inspection

Years in Service
Inspected More Inspected 3 to 6 Inspected Within
Than 6 years ago years ago Last 3 years

14 3000 3000 2209

15 3000 3000 3000

16 3000 3000 3000

17 3000 3000 3000

18 3000 3000 3000

19 3000 3000 3000

20 3000 3000 3000

21 3000 3000 3000

22 3000 3000 3000

23 3000 3000 3000

24 3000 3000 3000

25 3000 3000 3000

10.4 Aging Factor

The initial damage factor determined by the models is increased by an annual aging factor for the
time between now and the last inspection for the damage mechanism. The annual aging factor is a
% determined by the Risk Level determined by the models. Those values are 20% for High, 10% for
Medium, and 5% for Low. Those factors are configurable per Damage Mechanism.

Note: This does not apply to Lining.

10.5 Target Date

PCMS calculates the Target Date, the date the Risk would rise above the Risk Threshold. For each
Mechanical and Metallurgical Failure Damage Mechanism, the Age is increased until the Risk
Calculation (Probability x Consequence) exceeds the Risk Threshold. For each increment of Age, the
Damage Factor is recalculated with adjustments for the Aging Factor and Inspection Effectiveness.

October, 2012 Page 51

Appendix 1 - Internal Corrosion Rate Tables

High Temperature Sulfur and Naphthenic Acid Corrosion Tables

Table G-17 - Estimated Corrosion Rates for Carbon Steel (mpy)

Sulfur TAN Temperature

(wt %) mg/g <450 451-500 501-550 551-600 601-650 651-700 701-750 >750
<=0.2 <=0.3 1 3 7 15 20 35 50 60
0.31-1.0 5 15 25 35 45 55 65 75
1.1-2.0 20 25 35 65 120 150 180 200
2.1-4.0 30 60 60 120 150 160 240 240
>4.0 40 80 100 180 180 200 280 300
0.21-0.6 <=0.5 1 4 10 20 30 50 70 80
0.51-1 5 10 15 25 40 60 80 90
1.1-2.0 8 15 25 35 50 75 90 110
2.1-4.0 10 20 35 50 70 100 120 130
>4.0 20 30 50 70 90 120 140 160
0.61-1.0 <=0.5 1 5 10 25 40 60 90 100
0.51-1 5 10 15 30 50 80 110 130
1.1-2.0 10 185 30 50 80 100 130 150
2.1-4.0 15 30 50 80 100 120 140 170
>4.0 25 40 60 100 120 150 180 200
1.1-2.0 <=0.5 2 5 15 30 50 80 110 130
0.51-1 7 10 20 35 55 100 130 50
1.1-2.0 15 20 35 55 100 120 140 170
2.1-4.0 20 30 55 85 110 150 170 200
>4.0 30 45 75 120 140 180 200 260
2.1-3.0 <=0.5 2 7 20 35 55 95 130 150
0.51-1 7 10 30 45 60 120 140 170
1.1-2.0 15 20 40 60 75 140 170 200
2.1-4.0 20 35 60 90 120
>4.0 35 50 80 120 150 200 260 280
>3.0 <=0.5 2 8 20 40 60 100 140 160
0.51-1 8 15 25 45 65 120 150 170
1.1-2.0 20 25 35 65 120 150 180 200
2.1-4.0 30 60 60 120 150 160 240 240
>4.0 40 80 100 160 180 200 280 300

October, 2012 Page 52

Table G-18 - Estimated Corrosion Rates for 1.25 and 2.25 Cr Steel
(mpy)
Sulfur TAN Temperature
(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=0.3 1 1 4 7 13 21 25 30
0.31-1.0 3 8 15 20 25 30 35 40
1.1-2.0 10 15 20 30 60 75 90 100
2.1-4.0 15 30 30 60 75 85 120 120
>4.0 20 40 50 80 100 120 140 160
0.21-0.6 <=0.5 1 2 5 10 20 30 35 40
0.51-1 3 5 8 15 20 30 40 45
1.1-2.0 4 8 15 20 25 40 45 55
2.1-4.0 5 10 20 25 35 50 60 65
>4.0 10 15 25 35 45 60 70 80
0.61-1.0 <=0.5 1 3 6 15 25 40 45 50
0.51-1 3 5 8 20 30 45 55 60
1.1-2.0 5 8 15 25 40 50 65 75
2.1-4.0 7 15 25 40 50 60 70 85
>4.0 12 20 30 50 60 75 90 100
1.1-2.0 <=0.5 2 3 8 15 30 50 55 65
0.51-1 4 5 10 20 40 55 65 75
1.1-2.0 6 10 20 30 50 65 70 80
2.1-4.0 10 15 30 45 60 75 85 100
>4.0 15 20 35 60 75 90 100 130
2.1-3.0 <=0.5 2 4 9 20 35 55 65 75
0.51-1 4 5 15 25 40 60 70 80
1.1-2.0 7 10 20 30 45 70 80 100
2.1-4.0 10 15 30 45 60 80 100 120
>4.0 15 25 40 60 80 100 120 140
>3.0 <=0.5 2 4 10 20 35 60 70 80
0.51-1 5 8 15 25 40 70 75 85
1.1-2.0 10 15 20 30 60 75 90 100
2.1-4.0 15 30 30 60 75 85 120 120
>4.0 20 40 50 80 100 120 140 160

October, 2012 Page 53

Table G-19 - Estimated Corrosion Rates for 5% Cr Steel (mpy)

Sulfur TAN Temperature

(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=0.7 1 1 2 4 6 8 10 15
0.7-1.5 2 3 4 6 10 10 15 20
1.6-2.0 7 10 15 20 25 35 45 50
2.1-4.0 10 15 20 30 40 45 50 60
>4.0 15 20 30 40 50 60 70 80
0.21-0.6 <=0.7 1 2 3 5 8 10 15 20
0.7-1.5 2 3 4 6 10 15 20 25
1.6-2.0 4 6 8 10 15 20 25 30
2.1-4.0 4 6 8 10 15 20 30 35
>4.0 6 8 10 10 20 25 35 40
0.61-1.0 <=0.7 1 2 4 6 10 15 23 25
0.7-1.5 2 4 6 8 15 20 25 30
1.6-2.0 4 6 8 10 15 20 30 35
2.1-4.0 6 8 10 10 20 25 35 40
>4.0 8 10 10 15 20 30 40 50
1.1-2.0 <=0.7 1 2 5 8 15 20 30 35
0.7-1.5 3 5 10 15 20 30 35 40
1.6-2.0 5 10 15 20 30 35 40 45
2.1-4.0 10 15 20 30 35 40 45 50
>4.0 15 20 30 35 40 50 60 70
2.1-3.0 <=0.7 1 3 6 9 15 20 35 40
0.7-1.5 5 7 10 15 20 25 40 45
1.6-2.0 7 10 15 20 25 35 45 50
2.1-4.0 10 15 20 30 40 45 50 60
>4.0 15 20 30 40 50 60 70 80
>3.0 <=0.7 2 3 6 10 15 25 35 40
0.7-1.5 5 7 10 15 20 30 40 45
1.6-2.0 7 10 15 20 25 35 45 50
2.1-4.0 10 15 20 30 40 45 50 60
>4.0 15 20 30 40 50 60 70 80

October, 2012 Page 54

Table G-20 - Estimated Corrosion Rates for 7% Cr Steel (mpy)

Sulfur TAN Temperature

(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=0.7 1 1 1 2 4 6 7 8
0.7-1.5 1 2 3 5 7 8 10 15
1.6-2.0 4 7 10 15 20 25 30 35
2.1-4.0 7 10 15 20 25 30 35 45
>4.0 10 15 20 25 30 35 45 60
0.21-0.6 <=0.7 1 1 2 4 5 8 10 15
0.7-1.5 1 2 4 5 8 10 15 15
1.6-2.0 2 4 5 6 10 15 15 20
2.1-4.0 3 5 6 9 12 15 20 20
>4.0 4 6 9 10 15 20 20 25
0.61-1.0 <=0.7 1 1 3 4 6 10 15 15
0.7-1.5 2 3 4 6 10 15 15 20
1.6-2.0 3 4 6 10 12 15 20 25
2.1-4.0 4 6 10 12 15 20 25 30
>4.0 5 10 12 15 20 25 30 35
1.1-2.0 <=0.7 1 2 3 6 8 15 15 20
0.7-1.5 2 3 6 10 15 15 20 25
1.6-2.0 3 6 10 15 20 20 25 30
2.1-4.0 6 10 15 20 20 25 30 35
>4.0 10 15 20 20 25 30 35 45
2.1-3.0 <=0.7 1 2 4 6 9 15 20 25
0.7-1.5 6 7 9 10 15 20 25 30
1.6-2.0 7 9 10 15 20 25 30 35
2.1-4.0 9 10 15 20 30 35 35 40
>4.0 10 15 20 30 35 470 50 55
>3.0 <=0.7 1 2 4 7 10 15 20 25
0.7-1.5 2 4 7 10 15 20 25 30
1.6-2.0 4 7 10 15 20 25 30 35
2.1-4.0 7 10 15 20 25 30 35 45
>4.0 10 15 20 25 30 35 45 60

October, 2012 Page 55

Table G-21 - Estimated Corrosion Rates for 9% Cr Steel (mpy)

Sulfur TAN Temperature

(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=0.7 1 1 1 2 3 4 5 6
0.71-1.5 1 2 2 4 4 5 6 8
1.6-2.0 2 4 5 8 10 15 15 20
2.1-4.0 3 6 10 12 15 20 20 25
>4.0 5 8 12 15 20 25 30 30
0.21-0.6 <=0.7 1 1 2 3 4 6 7 15
0.71-1.5 1 1 2 4 5 7 8 10
1.6-2.0 2 2 3 5 8 8 10 10
2.1-4.0 3 3 5 8 10 10 12 15
>4.0 4 5 8 10 10 12 15 15
0.61-1.0 <=0.7 1 1 2 3 5 8 9 10
0.71-1.5 1 2 3 5 8 10 10 10
1.6-2.0 2 3 5 8 10 10 10 15
2.1-4.0 3 5 8 10 10 15 15 15
>4.0 5 8 10 10 15 15 20 20
1.1-2.0 <=0.7 1 1 2 4 6 10 10 15
0.71-1.5 1 2 3 5 7 10 15 15
1.6-2.0 2 4 4 6 8 12 15 20
2.1-4.0 3 6 5 8 10 15 20 20
>4.0 5 8 10 12 15 20 20 25
2.1-3.0 <=0.7 1 1 3 5 7 10 15 15
0.71-1.5 1 2 4 6 8 10 15 15
1.6-2.0 2 4 5 8 10 15 15 20
2.1-4.0 3 6 10 12 15 20 20 25
>4.0 5 8 12 15 20 25 30 30
>3.0 <=0.7 1 1 2 5 8 10 15 15
0.71-1.5 2 3 5 8 10 15 15 20
1.6-2.0 3 5 10 12 15 20 20 25
2.1-4.0 5 8 12 15 20 25 30 30
>4.0 7 9 15 20 25 30 35 40

October, 2012 Page 56

Table G-22 - Estimated Corrosion Rates for 12% Cr Steel

(mpy)
Sulfur TAN Temperature
(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=0.7 1 1 1 1 1 1 2 2
0.71-1.5 1 1 1 1 1 2 4 5
1.6-2.0 2 2 2 4 4 5 8 10
2.1-4.0 5 10 15 20 25 30 25 40
>4.0 10 15 20 25 30 25 40 45
0.21-0.6 <=0.7 1 1 1 1 1 2 3 3
0.71-1.5 1 1 1 1 1 2 3 3
1.6-2.0 1 2 2 2 2 4 5 5
2.1-4.0 2 3 3 3 3 5 10 15
>4.0 3 4 5 8 10 12 15 20
0.61-1.0 <=0.7 1 1 2 3 5 2 3 4
0.71-1.5 1 1 1 1 1 2 3 4
1.6-2.0 2 2 4 5 6 6 7 8
2.1-4.0 3 3 5 8 10 12 15 20
>4.0 4 5 5 8 10 15 20 25
1.1-2.0 <=0.7 1 1 1 1 2 3 4 5
0.71-1.5 1 1 1 1 2 3 4 5
1.6-2.0 2 2 3 5 7 8 10 10
2.1-4.0 3 3 5 8 10 12 15 20
>4.0 5 8 10 12 15 20 25 30
2.1-3.0 <=0.7 1 1 1 1 2 3 5 6
0.71-1.5 1 1 1 1 2 3 5 6
1.6-2.0 2 5 7 9 10 12 15 15
2.1-4.0 3 8 10 15 20 20 25 30
>4.0 5 10 15 20 25 30 35 40
>3.0 <=0.7 1 1 1 1 2 3 5 6
0.71-1.5 1 1 1 1 2 4 5 6
1.6-2.0 3 5 7 9 10 12 15 15
2.1-4.0 4 8 10 15 20 20 25 30
>4.0 5 10 15 20 25 30 35 40

October, 2012 Page 57

Table G-23 - Estimated Corrosion Rates for Austenitic SS without Mo (mpy)

(304,321,347,etc)
Sulfur TAN Temperature
(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=1.0 1 1 1 1 1 1 1 1
1.1-2.0 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 1 2 3 4 4
>4.0 1 1 1 2 3 4 5 6
0.21-0.6 <=1.0 1 1 1 1 1 1 1 1
1.1-2.0 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 1 2 3 4 4
>4.0 1 1 1 2 3 4 5 6
0.61-1.0 <=1.0 1 1 1 1 1 1 1 1
1.1-2.0 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 2 3 4 5 6
>4.0 1 2 2 4 6 8 10 12
1.1-2.0 <=1.0 1 1 1 1 1 1 1 1
1.1-2.0 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 2 3 4 5 6
>4.0 1 2 2 4 6 8 10 12
2.1-3.0 <=1.0 1 1 1 1 1 1 1 1
1.1-2.0 1 1 1 1 1 1 1 1
2.1-4.0 1 2 2 4 6 8 10 12
>4.0 1 2 4 7 10 14 17 20
>3.0 <=1.0 1 1 1 1 1 1 1 2
1.1-2.0 1 1 1 1 1 2 2 2
2.1-4.0 1 2 2 4 6 8 10 12
>4.0 1 2 4 7 10 14 17 20

October, 2012 Page 58

Table G-24 - Estimated Corrosion Rates for 316 SS with < 2.5% Mo (mpy)

Sulfur TAN Temperature

(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <=0.2 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 1 1 2 2 2
>4.0 1 1 1 2 4 5 7 10
0.21-0.6 <=0.2 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 1 2 2 2 2
>4.0 1 1 2 3 4 5 7 10
0.61-1.0 <=0.2 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 1 2 2 2 3
>4.0 1 1 2 3 5 5 7 10
1.1-2.0 <=0.2 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 1 3 3 3 4
>4.0 1 1 3 5 5 5 7 10
2.1-3.0 <=0.2 1 1 1 1 1 1 1 1
2.1-4.0 1 1 1 2 3 3 4 5
>4.0 1 1 3 5 5 6 8 10
>3.0 <=0.2 1 1 1 1 1 1 1 2
2.1-4.0 1 1 1 2 4 5 5 6
>4.0 1 2 3 5 5 6 8 10

October, 2012 Page 59

Table G-25 - Estimated Corrosion Rates for 316 SS with >=2.5% Mo and 317 SS
(mpy)
Sulfur TAN Temperature
(wt %) mg/g <450 451- 501- 551- 601- 651- 701- >750
500 550 600 650 700 750
<=0.2 <4.0 1 1 1 1 1 1 1 1
4.1-6.0 1 1 1 1 1 2 4 5
>6.0 1 1 1 2 4 5 7 10
0.21-0.6 <4.0 1 1 1 1 1 1 1 1
4.1-6.0 1 1 1 1 2 4 4 5
>6.0 1 1 2 3 4 5 7 10
0.61-1.0 <4.0 1 1 1 1 1 1 1 1
4.1-6.0 1 1 1 1 2 4 4 5
>6.0 1 1 2 3 4 5 7 10
1.1-2.0 <4.0 1 1 1 1 1 1 1 1
4.1-6.0 1 1 1 1 2 3 5 7
>6.0 1 1 3 5 5 5 7 10
2.1-3.0 <4.0 1 1 1 1 1 1 1 1
4.1-6.0 1 1 1 2 3 4 8 7
>6.0 1 1 3 5 5 6 8 10
>3.0 <4.0 1 1 1 1 1 1 1 2
4.1-6.0 1 1 1 2 3 4 5 7
>6.0 1 2 3 5 5 6 8 10

October, 2012 Page 60

High Temperature Hydrogen/Hydrogen Sulfide Corrosion

Table G-27 - Estimated Corrosion Rates for Carbon, 1.25 and 2.25% Cr Steel
(mpy)
Temperature (F)
H2S 400- 451- 501- 551- 601- 651- 701- 751- 801- 851- 901- 951-
(mol %) 450 500 550 600 650 700 751 800 850 900 950 1000
<0.002 1 1 1 1 2 3 4 6 8 10 14 18
0.002 to 0.005 1 1 2 3 5 7 11 15 21 29 38 50
0.005 to 0.01 1 2 3 4 7 11 16 22 31 41 55 71
0.01 to 0.05 1 2 3 5 9 13 19 27 38 51 67 87
0.05 to 0.1 1 2 4 7 10 16 23 33 46 62 82 110
0.1 to 0.5 2 3 6 10 15 23 34 48 66 90 120 150
0.5 to 1 2 4 7 11 17 26 38 45 75 100 130 170
>1 3 5 8 13 21 32 47 67 93 130 170 220

Table G-28 - Estimated Corrosion Rates for 5% Cr Steel

(mpy)
Temperature (F)
H2S 400- 451- 501- 551- 601- 651- 701- 751- 801- 851- 901- 951-
(mol %) 450 500 550 600 650 700 751 800 850 900 950 1000
<0.002 1 1 1 1 2 3 4 6 8 10 11 14
0.002 to 0.005 1 1 1 2 3 5 7 9 13 18 23 30
0.005 to 0.01 1 1 2 2 4 6 9 12 17 23 31 40
0.01 to 0.05 1 2 3 4 7 10 15 22 30 41 54 70
0.05 to 0.1 1 2 3 5 8 13 19 27 37 50 66 85
0.1 to 0.5 1 3 5 8 12 18 27 39 53 72 95 120
0.5 to 1 2 3 5 9 14 21 31 44 60 81 110 140
>1 2 4 7 11 17 26 38 54 75 100 130 170

October, 2012 Page 61

Table G-29 - Estimated Corrosion Rates for 7% Cr

Steel (mpy)
Temperature (F)

H2S 400- 451- 501- 551- 601- 651- 701- 751- 801- 851- 901- 951-
(mol %) 450 500 550 600 650 700 751 800 850 900 950 100
0
<0.002 1 1 1 1 1 2 3 4 6 8 10 13
0.002 to 0.005 1 1 1 2 3 4 6 9 12 16 21 28
0.005 to 0.01 1 1 1 2 4 5 8 11 16 21 28 37
0.01 to 0.05 1 1 2 4 6 10 14 20 28 37 49 64
0.05 to 0.1 1 2 3 5 8 12 17 24 34 46 60 78
0.1 to 0.5 1 2 4 7 11 17 25 35 49 66 87 110
0.5 to 1 2 3 5 8 13 19 28 40 55 74 98 130
>1 2 3 6 10 16 24 35 49 68 92 120 160

Table G-30 - Estimated Corrosion Rates for 9% Cr

Steel (mpy)
Temperature (F)

H2S 400- 451- 501- 551- 601- 651- 701- 751- 801- 851- 901- 951-
(mol %) 450 500 550 600 650 700 751 800 850 900 950 100
0
<0.002 1 1 1 1 1 2 3 4 5 7 9 12
0.002 to 0.005 1 1 1 2 2 4 6 8 11 15 17 25
0.005 to 0.01 1 1 1 2 3 5 7 10 14 20 26 34
0.01 to 0.05 1 1 2 4 6 9 13 18 25 34 45 59
0.05 to 0.1 1 2 3 4 7 11 16 22 31 42 55 72
0.1 to 0.5 1 2 4 7 10 16 23 32 45 61 80 100
0.5 to 1 1 3 4 7 12 18 26 37 51 68 90 120
>1 2 3 6 9 14 22 32 45 63 85 110 150

October, 2012 Page 62

Table G-31 - Estimated Corrosion Rates for 12% Cr

Steel (mpy)
Temperature (F)
H2S (mol%) 400- 451- 501- 551- 601- 651- 701- 751- 801- 851- 901- 951-
450 500 550 600 650 700 751 800 850 900 950 100
0
<0.002 1 1 1 1 2 3 4 5 6 9 11 14
0.002 to 0.005 1 1 1 1 2 3 4 6 8 11 14 18
0.005 to 0.01 1 1 1 2 2 4 5 7 9 12 15 19
0.01 to 0.05 1 1 1 2 3 4 6 9 12 15 19 25
0.05 to 0.1 1 1 1 2 3 5 7 10 13 17 22 27
0.1 to 0.5 1 1 2 3 4 6 9 12 16 21 27 34
0.5 to 1 1 1 2 3 5 7 10 13 18 23 30 38
>1 1 2 3 4 7 10 13 18 25 32 42 53

Table G-32 - Estimated Corrosion Rates for 300 Series Stainless

Steel (mpy)
Temperature (F)
H2S (mol%) 400- 451- 501- 551- 601- 651- 701- 751- 801- 851- 901- 951-
450 500 550 600 650 700 751 800 850 900 950 100
0
<0.002 1 1 1 1 1 1 1 1 1 1 2 2
0.002 to 0.005 1 1 1 1 1 1 1 1 1 2 2 3
0.005 to 0.01 1 1 1 1 1 1 1 1 2 2 3 3
0.01 to 0.05 1 1 1 1 1 1 1 1 2 3 3 4
0.05 to 0.1 1 1 1 1 1 1 1 1 2 3 4 5
0.1 to 0.5 1 1 1 1 1 1 1 1 3 4 5 6
0.5 to 1 1 1 1 1 1 1 1 2 3 4 5 6
>1 1 1 1 1 1 1 2 2 4 5 7 9

October, 2012 Page 63

HF Acid Corrosion

Table G-42 Estimated Corrosion

Rates (mpy) for Carbon Steel
HF-in-Water
Concentration
Temp (F)
0-1% 2-5% 6-63% 64- >80%
80%
<80 20 999 999 50 20
80-130 100 999 999 300 50
130-150 100 999 999 300 100
151-160 999 999 999 999 200
161-175 999 999 999 999 500
176-200 999 999 999 999 700
>200 999 999 999 999 999

Table G-43 - Estimated Corrosion Rates (mpy) for

Alloy 400
Temp (F) HF-in-Water Concentration
Aerated 0-1% 2-5% 6-63% 64-80% >80%
<80 NO 1 1 10 1 2
YES 10 10 25 10 15
80-150 NO 1 1 15 5 3
YES 10 10 30 20 15
151-200 NO 5 5 20 10 5
YES 20 20 100 50 20
>200 NO 10 10 20 20 10
YES 100 100 200 200 100

October, 2012 Page 64

Appendix 2 – Atmospheric Storage Tanks

1. Introduction
An RBI process for atmospheric storage tanks has been developed for PCMS. It includes the
some modifications to the standard consequences of failure. It also includes a selection of the
piping and equipment damage mechanisms and with some storage tank specific damage
mechanisms added.

2. References
API 653

API 581 Second Edition

API 581 First Edition Appendix O

3. Consequences of Failure
For storage tanks, the standard consequence calculations are slightly altered based on whether
the circuit is a tank floor, shell or roof.

3.1. Economic Consequences

No change to this calculation, see PCMS RBI Technical Manual Paragraph 5.1

3.2. Environmental Consequences

3.2.1. Tank Roof

Environment Consequences for the Roof will default to 0.

3.2.2. Tank Shell

The standard Environmental Consequence calculation will apply, see PCMS RBI
Technical Manual Paragraph 5.2

3.2.3. Tank Floor

Environment Consequences will default to 0 when a Protective Barrier is present. If

there is no Protective Barrier, the standard Environmental Consequence calculation
will apply, see PCMS RBI Technical Manual Paragraph 5.2

3.3. Health and Safety Consequences

3.3.1. Tank Roof

The standard Health and Safety Consequence calculations will apply, see PCMS RBI
Technical Manual Paragraph 5.3

October, 2012 Page 65

3.3.2. Tank Shell

The standard Health and Safety Consequence calculations will apply, see PCMS RBI
Technical Manual Paragraph 5.3

3.3.3. Tank Floor

Because any product release from the Tank Floor will be into the ground, the Health
and Safety Consequences will default to 0.

4. Probability of Failure
PCMS uses failure probability calculations based on the generic probabilities of failure from API
581. These are modified by technical factors in a similar way to API 581 to result in a numeric
probability of failure factor.

4.1. Generic Failure Frequency

PCMS uses the Generic Failure Frequencies for Storage Tanks from API 581, as shown below.
API does not have a GFF for the Tank Roof, PCMS applies the same GFF as the Tank Shell.

Circuit Type Leak

Frequency
(per year)
Tank Bottom 7.2 x 10-4
Tank Shell 1 x 10-4
Tank roof 1 x 10-4

5. Internal Thickness Loss

PCMS includes the following damage mechanisms for Internal Thickness Loss on Storage Tanks:

Amine Corrosion

Caustic Corrosion

Low Temperature H2S Corrosion

Microbial Induced Corrosion

Sour Water Corrosion

Unspecified Internal Corrosion

5.1. Initial Screening

Screening rules for Internal Thickness Loss Damage Mechanisms on Storage Tank follow the
rules found in the PCMS RBI Technical Manual Paragraph 7.1

Microbial Induced Corrosion is User Entered

October, 2012 Page 66

Unspecified Internal Corrosion is triggered by PCMS when a Corrosion Rate is detected, but
Microbial Induced Corrosion is not present

5.2. Probability Calculation

The Probability Calculation for Internal Thickness Loss Damage Mechanisms on Storage
Tanks follows the same method as Internal Thickness Loss Damage Mechanisms on other
equipment types, see PCMS RBI Technical Manual Paragraph 7.2. For Tank Floors, the
following Damage Factor table is used with ar/t:

ar/t Thickness Loss ar/t Thickness Loss Subfactor

Subfactor
< 0.05 4 0.50 to 0.55 420
0.05 to 0.10 14 0.55 to 0.60 500
0.10 to 0.15 32 0.60 to 0.65 587
0.15 to 0.20 56 0.65 to 0.70 681
0.20 to 0.25 87 0.70 to 0.75 782
0.25 to 0.30 125 0.75 to 0.80 890
0.30 to 0.35 170 0.80 to 0.85 1005
0.35 to 0.40 222 0.85 to 0.090 1126
0.40 to 0.45 281 .090 to 0.95 1255
0.45 to 0.50 347 >0.95 1390

Inspection Effectiveness is then applied as described in PCMS RBI Technical Manual

Paragraph 6.3. PCMS allows for a different Annual Reduction Factor for Tanks.

5.3. Target Date

The Target Date calculation for Internal Thickness Loss Damage Mechanisms on Storage
Tanks follows the same calculation as Internal Thickness Loss Damage Mechanisms in the
PCMS RBI Technical Manual Paragraph 7.4

6. External Thickness Loss

PCMS includes the following damage mechanisms for External Thickness Loss on Storage Tanks:

CUI of Carbon and Low Alloy Steels

External Corrosion of Carbon and Low Alloy Steels

Soil Corrosion

6.1. Initial Screening

The screening for External Thickness Loss Damage Mechanisms includes the part of the Tank.

October, 2012 Page 67

6.1.1. Tank Roof

CUI and External Corrosion follow PCMS RBI Technical Manual paragraph 8.

Soil Corrosion is not applicable.

6.1.2. Tank Shell

CUI and External Corrosion follow PCMS RBI Technical Manual paragraph 8.

Soil Corrosion is not applicable.

6.1.3. Tank Floor

CUI and External Corrosion are not applicable.

The Floor is susceptible to Soil Corrosion.

6.2. Soil Corrosion Model

The Expected Corrosion Rate for Soil Corrosion is defaulted to 5 mpy.

The Actual Corrosion Rate can be entered on the Circuit Window, if known.

6.3. Probability Calculation

The Probability Calculation for External Thickness Loss Damage Mechanisms on Storage
Tanks follows the same method as Internal Thickness Loss Damage Mechanisms on other
equipment types, see PCMS RBI Technical Manual Paragraph 7.2

Inspection Effectiveness is then applied as described in PCMS RBI Technical Manual

Paragraph 6.3

6.4. Target Date

The Target Date calculation for External Thickness Loss Damage Mechanisms on Storage
Tanks follows the same calculation as External Thickness Loss Damage Mechanisms on other
equipment types, see PCMS RBI Technical Manual Paragraph 8.3

7. Environmental Assisted Cracking

PCMS includes the following damage mechanisms for Environmental Assisted Cracking on
Storage Tanks:

Amine Stress Corrosion Cracking

Caustic Stress Corrosion Cracking

Chloride Stress Corrosion Cracking – Internal and External

Hydrogen Stress Cracking (HF)

Wet H2S (HIC/SOHIC/Blistering)

Wet H2S (Sulfide Stress Cracking)

October, 2012 Page 68

The Initial Screening and Probability calculations are described in PCMS RBI Technical Manual
Paragraph 9

8. Mechanical and Metallurgical Failure

PCMS includes the following damage mechanisms for Mechanical and Metallurgical Failure:

Accidental Damage

Brittle Fracture

Lining

Service Damage

Settlement Damage

8.1. Lining
The Initial Screening and Probability calculations are described in PCMS RBI Technical
Manual Paragraph 10

October, 2012 Page 69

The contents of this document are confidential and shall not be reproduced, loaned or given away without specific permission of
PCMS a member of MISTRAS Group Inc.

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