Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

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SECTION 1.0 Introduction and scope 简介及范围
1.1 Introduction 序言 ASME 和 API 加压设备的设计规范和标准 - 提供设计 , 制造 , 检验和测试 “ 新的 ” 压力容器 , 管道系统和储罐的规则 . 这些规范不解决设备在服务期间设备的老化 , 腐蚀 , 损坏等的考虑 . 这 RP 主要针对在役设备上述信息 . 在执行适用性评价 (FFS), 基于风险的检验 (RBI), 也提供需要的信息 . 因为 : • 进行 FFS/ API RP 579- FFS 评估第一步是确定 (1) 缺陷类型和 (2) 损坏的原因 . • 基于风险的检验 (RBI) 第一个步骤也是正确的识别系统设备损伤机理或其他形式的恶化原因 .
Page 1 and 2: Damage Mechanisms Affecting Fixed E
Page 3 and 4: 印度支那不就是 “Indo
Page 6 and 7: Speaker: Fion Zhang 2013/7/4
Page 8: Ctrl + Shift + S = save a copy Ctrl
Page 11: For API 570 ICP - API RP 571, Damag
Page 14 and 15: API RP 571, Damage Mechanisms Affec
Page 16: API RP 571, Damage mechanisms Affec
Page 19 and 20: Mechanical and Metallurgical Failur
Page 21 and 22: High Temperature Corrosion [>400 o
Page 23 and 24: FOREWORD 前言 The overall purpos
Page 25 and 26: This publication contains guidance
Page 27: Table of contents 目录 1.0 Intro
Page 31 and 32: 当设备观察到的缺陷
Page 33 and 34: 基于外观或形态 , 损
Page 35 and 36: General and local metal loss/ 均
Page 41 and 42: Surface connected cracking
Page 53 and 54: SCC or fatigue cracks nucleate at s
Page 55 and 56: subsurface cracking
Page 57 and 58: subsurface cracking
Page 59 and 60: Microfissuring/microvoid formation
Page 61 and 62: Microfissuring/microvoid formation
Page 63 and 64: Metallurgical changes
Page 65 and 66: Metallurgical changes
Page 67 and 68: Each of these general types of dama
Page 69 and 70: API571, 此规范对石油化
Page 71 and 72: a) Description of Damage - a basic
Page 73 and 74: Damage mechanisms that are common t
Page 75 and 76: SECTION 2.0 REFERENCES 2.1 Standard
Page 77 and 78: ASM • Metals Handbook Volume 1, P
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WRC • Bulletin 32 Graphitization
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SECTION 3.0 DEFINITION OF TERMS AND
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3.1.4 Di-ethanolamine 二乙醇
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The 1949 Schaeffler diagram
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The 1949 Schaeffler diagram
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3.1.9 Hydrogen Induced Cracking (HI
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3.1.12 Martensitic stainless steel
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3.2 Symbols and Abbreviations 3.2.1
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3.2.31 HP - high pressure. 3.2.32 H
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SECTION 4.0 GENERAL DAMAGE MECHANIS
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GENERAL DAMAGE MECHANISMS - ALL IND
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4.2 Mechanical & Metallurgical Fail
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4.4 High Temperature Corrosion 高
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4.2 Mechanical & Metallurgical Fail
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2013- API570 Examination Par. 3 - D
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Exam Damage Mechanism Temperatures
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4.2.1 Graphitization 石墨化 (
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4.2.1 Graphitization 石墨化 4.
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Graphitization Location: Areas with
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4.2.1.3 Critical Factors a) The mos
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f) The second and more damaging typ
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eyebrow! Type2 Graphitization 焊
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eyebrow! Type 2 Graphitization 焊
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4.2.1.4 Affected Units or Equipment
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4.2.1.5 Appearance or Morphology of
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Figure 4-2 - High magnification pho
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4.2.1.7 Inspection and Monitoring a
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Creep Type: Microvoid formation & j
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Typical ferrite-pearlite structure
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Figure 13: Lower bainite generated
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Random graphitization
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Graphitization of A Cast Iron Main
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石墨化 , 学习重点 : 1.
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Spheroidization Prolong Exposure 85
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Figure 9: The microstructures near
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Spheroidization 球化 in physical
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http://www.matter.org.uk/steelmatte
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Spheroidization affect Cr-Mo low ca
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Susceptibility to Spheroidization
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Spheroidization is a change in the
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650 o F~ 1070 o F API510-Exam
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API510-Exam 4.2.3 Temper Embrittlem
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API510-Exam 4.2.3.2 Affected Materi
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[Embrittlement temperature 650°F~1
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[Embrittlement temperature 650°F~1
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韧脆转变温度向上移
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API510-Exam SEM fractographs of tem
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API510-Exam 4.2.3.3 Critical Factor
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API510-Exam 4.2.3.4 Affected Units
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API510-Exam
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API510-Exam
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Intergranular Cracking API510-Exam
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API510-Exam 4.2.3.6 Prevention / Mi
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API510-Exam Existing Material: De-e
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API510-Exam Susceptibility to tempe
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API510-Exam 4.2.3.7 Inspection and
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API510-Exam
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API510-Exam irreversible temper bri
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回火脆化学习重点 : 1
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Intermediate temperature
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4.2.4 Strain Aging 伸张时效
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韧性减低 / 抗拉曾强
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拉力 AISC- Guide to Design Crite
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d) Strain aging effects are observe
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Bessemer Process
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Bessemer Process
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Open hearth Process
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Open hearth Process 平炉炼钢
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Basic Oxygen Process
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Metallurgy for Dummies http://metal
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4) Rimmed Steel 沸腾钢 , 不
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4.2.5 885°F (475°C) embrittlement
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Graphitisation Spheroidization Temp
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885°F (475°C) embrittlement Embri
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• The existence of 885°F embritt
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d) Since 885°F embrittlement can o
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Fig. 3—Oxalic acid etched microst
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Impact energy and brinell hardness
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http://www.sciencedirect.com/scienc
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4.2.6 Sigma-Phase Embrittlement “
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885°F embrittlement Sigma phase em
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Sigma-Phase Embrittlement 西格
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e) The 300 Series SS can exhibit ab
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Σ(σ)phase in austenitic matrix
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σ 相脆化 - 缺乏韧性
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FCC (fluidized catalytic cracking )
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Stainless steel heater tubes
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tube-to-tubesheets attachment
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tube-to-tubesheets attachment
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设备 : 催化裂化再生
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d) For the 10% sigmatized specimen,
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Table 2. Impact testing (Test Metho
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Fig. 2. Micrograph showing carburiz
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Fig. 4. Micrograph showing sigma fo
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Fig. 6. Micrograph showing sigma ph
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Fig. 8a. SEM fractography showing t
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4.2.6.6 Prevention / Mitigation a)
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What causes knife-line attack? For
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4.2.6.7 Inspection and Monitoring
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http://www.metalconsult.com/failure
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http://www.metalconsult.com/failure
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http://www.industrialheating.com/ar
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Table 4: Chemical composition of fe
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Improperly etched specimen showing
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Oxalic acid etched- Duplex SS
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4.2.7 Brittle Fracture 脆性破
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No shear lip, little micro void coa
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API510/570-Exam 4.2.7.3 Critical Fa
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API510/570-Exam Definition of Britt
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API510/570-Exam
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API510/570-Exam Figure 7: The fract
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Figure 4: The fracture on the Case
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API510/570-Exam Various stages duri
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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http://www.wermac.org/misc/pressure
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API510/570-Exam c) Most processes r
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The main material property that API
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Figure UCS 66.1 Coincident Ratio Th
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Steps: 1. Determine material group.
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Steps: 5. If the coincident ratio i
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UCS-66 (b2) For minimum design meta
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API510/570-Exam 4.2.7.5 Appearance
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Crack propagation (cleavage) in bri
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API510/570-Exam 4.2.7.6 Prevention
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API510/570-Exam 4.2.7.7 Inspection
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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Microvoid due to plastid yielding &
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API510/570-Exam Further reading: ht
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4.2.8 Creep & Stress Rupture 蠕
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Graphitisation Spheroidization Temp
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http://www.ejsong.com/mdme/me mmods
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c) The level of creep damage is a f
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不是所有的蠕变失效
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c) Low creep ductility failures hav
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c) Creep damage is not reversible.
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4.2.8.8 Related Mechanisms 相关
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Figure 4-18 - Creep rupture of an H
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a b Figure 4-19 - Creep Failure of
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4.2.9 Thermal Fatigue 热疲劳 A
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API510/570-Exam Graphitisation Sphe
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API510/570-Exam 4.2.9.3 Critical Fa
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API510/570-Exam 4.2.9.4 Affected Un
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Figure 4-21 - Bulging in a skirt of
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Figure 4-23 - Thermal fatigue of 30
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API510/570-Exam Figure 4-25 - Older
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API510/570-Exam
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API510/570-Exam 4.2.9.5 Appearance
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API510/570-Exam Figure 4-27 - Photo
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API510/570-Exam b) Designs should i
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam 571-4 Charlie Chong
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API510/570-Exam
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API510/570-Exam
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热疲劳学习重点 : a)
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Short Term Overheating Stress Ruptu
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4.2.10.3 Critical Factors 关键
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4.2.10.5 Appearance or Morphology o
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短期过热应力开裂学
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Steam Blanketing Local over-heating
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individual bubbles join to form a s
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Heat transfer and mass transfer dur
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4.2.11.4 Affected Units or Equipmen
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蒸汽封学习重点 : a)
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4.2.12 Dissimilar Metal Weld (DMW)
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Table 4-4: Coefficients of Thermal
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d) Thermal cycling aggravates the p
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g) Dissimilar metal welds on a ferr
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Environmental Cracking - Ambient se
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High temperature service Blister Fi
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High temperature service Figure 4-4
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Intergranular liquid metal embrittl
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• Alloy transitions inside fired
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4.2.12.6 Prevention / Mitigation
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Figure 4-34 - Schematic of typical
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异种钢焊接开裂学习
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4.2.13 Thermal Shock 温度突
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f) Fracture is related to constrain
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高温突变学习重点 : a
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API510/570-Exam 4.2.14 Erosion/Eros
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API510/570-Exam e) For each environ
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API510/570-Exam c) Hydroprocessing
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API510/570-Exam 4.2.14.6 Prevention
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API510/570-Exam 4.2.14.7 Inspection
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Figure 4-44 - Erosion of a 9Cr-1Mo
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定义 : Corrosion 腐蚀 - 化
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam Flow Direction
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Flow Direction API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam 冲蚀 / 冲蚀 -
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4.2.15 Cavitation 4.2.15.1 Descript
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c) Attack is accelerated by the mec
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气穴腐蚀学习重点 : a
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API510/570-Exam 4.2.16 Mechanical F
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API510/570-Exam b) Metallurgical Is
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API510/570-Exam
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API510/570-Exam 4.2.16.4 Affected U
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API510/570-Exam b) Mechanical Loadi
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Figure 4-50 - Schematic of a fatigu
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Figure 4-52 - Higher magnification
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Figure 4-54 - Fatigue crack in a 16
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Figure 4-56 - The surface of the fr
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam The signature mark
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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API510/570-Exam
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530.352 Materials Selection Lecture
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Examples of Fatigue Failures Plasti
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Examples of Fatigue Failures Railwa
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Types of Fatigue: Fatigue of cracke
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Basic Fatigue Terminology: + max
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Low Cycle Fatigue • Apply control
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Miner’s s Rule Rule of Accumulati
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Crack initiation Cracks start at:
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Crack Growth Striation indicating s
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Real world comparisons: log da/dN t
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Fracture Surfaces: Initiation site
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4.2.17 Vibration Induced Fatigue
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API 570-Exam 4.2.17.4 Affected Unit
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API 570-Exam 4.2.17.6 Prevention /
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API 570-Exam 4.2.17.8 Related Mecha
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Figure 4-58 - Cross-sectional view
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API 570-Exam
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4.2.18 Refractory Degradation 耐
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4.2.18.3 Critical Factors a) Refrac
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耐火材料退化学习重
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4.2.19 Reheat Cracking 4.2.19.1 Des
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4.2.19.3 Critical Factors Important
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http://www.hydrocarbonprocessing.co
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http://www.staff.ncl.ac.uk/s.j.bull
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Figure 4-60 - Samples removed from
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Figure 4-62 - Cross-section through
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http://www.staff.ncl.ac.uk/s.j.bull
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4.2.20 GOX-Enhanced Ignition & Comb
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4.2.20.2 Affected Materials a) Carb
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4.2.20.3 Critical Factors a) Many f
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e) Impingement areas such as sharp
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g) A thorough review is needed befo
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Figure 4-64 - Thermal combustor on
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Figure 4-66 - Same as figure above
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Figure 4-68 - Photograph illustrati
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气化氧 - 增强燃烧学
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