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4.5 Environment - Assisted Cracking

4.5.1 Chloride Stress Corrosion Cracking (el SeC)

4.5.1.1 Description of Damage

Surface initiated cracks caused by environmental cracking of 300 Series SS and some nickel base alloys under the combined action of tensile stress, temperature and an aqueous chloride environment. The presence of dissolved oxygen increases propensity for cracking.

4.5.1.2 Affected Materials

a) All 300 Series SS are highly susceptible.

b) Duplex stainless steels are more resistant.

c) Nickel base alloys are highly resistant.

4.5.1.3 Critical Factors

a) Chloride content, pH, temperature, stress, presence of oxygen and alloy composition are critical factors.

b) Increasing temperatures increase the susceptibility to cracking.

c) Increasing levels of chloride increase the likelihood of cracking.

d) No practical lower limit for chlorides exists because there is always a potential for chlorides to concentrate.

e) Heat transfer conditions significantly increase cracking susceptibility because they allow chlorides to concentrate. Alternate exposures to wet-dry conditions or steam and water are also conducive to cracking.

f) see usually occurs at pH values above 2. At lower pH values, uniform corrosion generally predominates. SCC tendency decreases toward the alkaline pH region.

g) Cracking usually occurs at metal temperatures above about 140DF (60°C), although exceptions can be found at lower temperatures.

h) Stress may be applied or residual. Highly stressed or cold worked components, such as expansion bellows, are highly susceptible to cracking.

i) Oxygen dissolved in the water normally accelerates SCC but it is not clear whether there is an oxygen concentration threshold below which chloride SCC is impossible.

j) Nickel content of the alloy has a major affect on resistance. The greatest susceptibility is at a nickel content of 8% to 12%. Alloys with nickel contents above 35°,1) are highly resistant and alloys above 45% are nearly immune.

k) Low-nickel stainless steels, such as the duplex (ferrite-austenite) stainless steels, have improved resistance over the 300 Series 5S but are not immune.

I) Carbon steels, low alloy steels and 400 Series SS are not susceptible to CI·SCC

4.5.1.4 Affected Units or Equipment

a) All 300 Series S8 piping and pressure vessel components in any process units are susceptible to CI· sec.

b) Cracking has occurred in water-cooled condensers and in the process side of crude tower overhead condensers.

c) Drains in hydroprocessing units are susceptible to cracking during startup/shutdown if not properly purged.

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d) Bellows and instrument tubing, particularly those associated with hydrogen recycle streams contaminated with chlorides, can be affected.

e} External CI-SCC has also been a problem on insulated surfaces when insulation gets wet. f) Cracking has occurred in boiler drain lines.

4.5.1.5 Appearance or Morphology of Damage

a} Surface breaking cracks can occur from the process side or externally under insulation (Figure 4-77).

b) The material usually shows no visible signs of corrosion.

c) Characteristic stress corrosion cracks have many branches and may be visually detectable by a crazecracked appearance of the surface (Figure 4-78, Figure 4-79 and Figure 4-80).

d) Metallography of cracked samples typically shows branched transgranular cracks (Figure 4-81 and Figure 4-82). Sometimes Intergranular cracking of sensitized 300 Series SS may also be seen.

e) Welds in 300 Series SS usually contain some ferrite, producing a duplex structure that is usually more resistant to CI.-SCC.

f) Fracture surfaces often have a brittle appearance.

4.5.1.6 Prevention I Mitigation

a) Use resistant materials of construction.

b) When hydrotesting, use low chloride content water and dry out thoroughly and quickly.

c) Properly applied coatings under insulation.

d) Avoid designs that allow stagnant regions where chlorides can concentrate or deposit.

e) A high temperature stress relief of 300 Series SS after fabrication may reduce residual stresses.

However, consideration should be given to the possible effects of sensitization that may occur, increasing susceptibility to poly thionic SCC, possible distortion problems and potential reheat cracking.

4.5.1.7 Inspection and Monitoring

a) Cracking is surface connected and may be detected visually in some cases.

b) PT or phase analysis EC techniques are the preferred methods.

c) Eddy current inspection methods have also been used on condenser tubes as well as piping and pressure vessels.

d) Extremely fine cracks may be difficult to find with PT. Special surface preparation methods, including polishing or high-pressure water blast, may be required in some cases, especially in high pressure services.

e) UT.

f) Often, RT is not sufficiently sensitive to detect cracks except in advanced stages where a significant network of cracks has developed.

4.5.1.8 Related Mechanisms

Caustic SCC (see 4.5.3) and poly thionic acid SCC (see 5.1.2.1).

4.5.1.9 References

1. C.P. Dillon, "Corrosion Control in The Chemical Process Industries," Materials Technology Institute, MO, 1994, pp. 88-90.

2. "Corrosion Basics - An Introduction," NACE International, Houston, TX, 1984, pp. 111-123.

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Figure 4-77 - Externall cracking of Type :30455 instrument tubing under insuilation.

Figure 4-78 - Crackilng on the shell side, of Type 316L 55 tubes in steam service at 450·F (232cC), showiln'g tubes after Pir inspection, The cracks can be seen in the center tube (arrow).

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Figure 4-79 - Close-up of the tube in Figure 4-78 showing tight cracks with a spider web appearance.

Figure 4-80 - Other fine branching cracks on the surface of 55 that appear more clearly after PT inspection.

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Figure 4-81 - Photomicrograph of a cross-section of sample in Figure 4-79 showing fine branching cracks. (Unetched. Mag. 50x)

Figure 4·82 -Another photomicrograph of a cress-section of a cracked tube illustrating the transgranular mode of cracking initiating on the surface. (Etched)