Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

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Speaker: Fion Zhang 2013/7/4
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Page 1 and 2: Damage Mechanisms Affecting Fixed E
Page 3 and 4: 印度支那不就是 “Indo
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 and 28: Table of contents 目录 1.0 Intro
Page 29 and 30: 1.1 Introduction 序言 ASME 和 A
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
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subsurface cracking
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subsurface cracking
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Microfissuring/microvoid formation
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Microfissuring/microvoid formation
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Metallurgical changes
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Metallurgical changes
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Each of these general types of dama
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API571, 此规范对石油化
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a) Description of Damage - a basic
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Damage mechanisms that are common t
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SECTION 2.0 REFERENCES 2.1 Standard
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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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Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

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