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Inspection, Corrosion & RBI

Inspection, Corrosion & RBI

Identify credible damage, screen CUI and SCC, rank qualitative risk, structure inspection records and carry traceable assumptions into Remaining Life.

Calculator handoff

Prepare a traceable Remaining Life preset

These fields populate screening assumptions only. Thickness readings, tmin value and design basis remain required in the calculator.

Future corrosion allowance is not the original design corrosion allowance. SCC and other crack-like damage require a separate flaw assessment.

Open Remaining Life
Metal loss

General / uniform thinning

API RP 571

Corrosive liquid or wet-gas exposure distributed over a broad area.

Susceptible materials

Carbon steelLow-alloy steel

Indicators

Consistent UT lossScale or general rustingRising long- and short-term corrosion rate

Likely locations

Straight runsVessels and headersLow points

Inspection methods

UT grid / automated UTProfile RTVisual examination

Mitigation

Chemistry controlMaterial upgradeCoating/liningInspection trending
External corrosion

Corrosion under insulation (CUI)

API RP 583

Water ingress beneath insulation, cycling temperature and contaminants.

Susceptible materials

Carbon steelAustenitic stainless steel

Indicators

Damaged jacketingWet insulationRust stainingLocalized external loss or chloride cracking

Likely locations

PenetrationsSupports and shoesLow pointsTerminations and weather seals

Inspection methods

Targeted insulation removalPulsed eddy current screeningProfile RTUT / surface examination

Mitigation

Weatherproof jacketingDrainage and sealingCUI-resistant coatingRisk-based inspection locations
Localized metal loss

Erosion-corrosion

API RP 571

High velocity, turbulence, entrained solids/droplets or flashing service.

Susceptible materials

Carbon steelCopper alloysSoft or passive alloys under impingement

Indicators

Directional groovesSmooth scalloped lossRate increase after operating change

Likely locations

ElbowsReducersDownstream of valves/orificesTees and injection points

Inspection methods

UT scanningProfile RTVisual / borescope

Mitigation

Velocity controlGeometry changeWear-resistant materialRemove solids/liquid carryover
Environment-assisted cracking

Chloride stress-corrosion cracking

API RP 571

Chlorides, tensile stress and susceptible metal temperature/condition.

Susceptible materials

Austenitic stainless steel

Indicators

Branched transgranular cracksLeaks with little general thinningSalt deposits

Likely locations

Hot insulated stainless pipingEvaporation pointsWeld heat-affected zones

Inspection methods

PTEddy currentAngle-beam UTMetallography

Mitigation

Chloride controlKeep insulation dryStress/material reviewTemperature control
Localized metal loss

Microbiologically influenced corrosion (MIC)

API RP 571

Stagnant or low-flow water with biofilm and nutrients.

Susceptible materials

Carbon steelStainless steelCopper alloys

Indicators

TuberculationDeep isolated pitsBiofilm/slimeRapid local leaks

Likely locations

DeadlegsLow-flow branchesFirewater and cooling waterHydrotest water hold points

Inspection methods

UT mappingVisual / borescopeDeposit and microbiological sampling

Mitigation

Drain/dryBiocide and water treatmentFlush velocityRemove deadlegs
High-temperature corrosion

High-temperature sulfidation

API RP 571

Sulfur-containing hydrocarbon streams at elevated metal temperature.

Susceptible materials

Carbon steelLow-alloy steels

Indicators

Relatively uniform internal thinningScale morphologyStrong alloy-composition sensitivity

Likely locations

Furnace transfer linesHot crude/vacuum circuitsMix points

Inspection methods

UT thickness surveyProfile RTPositive material identification

Mitigation

Alloy verification/upgradeTemperature and chemistry controlCircuit-based inspection
Metallurgical damage

High-temperature hydrogen attack (HTHA)

API RP 571

Hydrogen partial pressure and metal temperature in a susceptible regime.

Susceptible materials

Carbon steelC-0.5Mo and Cr-Mo steels

Indicators

Internal decarburization/fissuringProperty lossLate-stage cracking

Likely locations

Hot hydrogen service pipingWelds and heat-affected zonesReactors and exchangers

Inspection methods

Advanced UT techniquesMetallography/replicationEngineering review of operating history

Mitigation

Materials and operating-window reviewSpecialized inspection programReplace susceptible material
Localized electrochemical corrosion

Galvanic corrosion

API RP 571

Conductive electrolyte bridging metals with different corrosion potentials.

Susceptible materials

Dissimilar electrically connected metals

Indicators

Preferential loss near dissimilar-metal junctionAttack focused on anodic material

Likely locations

Flange transitionsSmall anodic attachmentsWet external interfaces

Inspection methods

Visual examinationUT mappingElectrical isolation check

Mitigation

Electrical isolationArea-ratio reviewCoating and drainageCompatible material selection
Environment-assisted cracking

Caustic stress-corrosion cracking

API RP 571

Concentrated caustic plus tensile stress at susceptible temperature.

Susceptible materials

Carbon steelLow-alloy steelSelected stainless steels

Indicators

Intergranular crackingCracks near welds/stress raisersConcentration at evaporation points

Likely locations

Heat-traced linesInjection pointsDeadlegsWeld HAZ

Inspection methods

WFMT / MTAngle-beam UTMetallography

Mitigation

Concentration/temperature controlStress relief where qualifiedMaterial selectionWater wash/design change
Environment-assisted cracking

Amine stress-corrosion cracking

API RP 571

Aqueous amine service combined with tensile or weld residual stress.

Susceptible materials

Carbon steelLow-alloy steel

Indicators

Intergranular cracksCracking near non-PWHT weldsLittle accompanying wall loss

Likely locations

Welds and HAZAttachmentsHigh-stress geometryRich/lean amine piping

Inspection methods

WFMT / MTAngle-beam UTMetallography

Mitigation

Qualified PWHT strategyChemistry and temperature controlStress reductionTargeted weld inspection
Environment-assisted cracking

Carbonate stress-corrosion cracking

API RP 571

Alkaline carbonate/bicarbonate environment with tensile stress.

Susceptible materials

Carbon steelLow-alloy steel

Indicators

Intergranular branched cracksCracks at weld toes and HAZLocalized surface scale

Likely locations

FCC wet-gas circuitsWelds and attachmentsStagnant alkaline locations

Inspection methods

WFMT / MTAngle-beam UTMetallography

Mitigation

Environment controlPWHT where qualifiedBarrier coatingFocused weld inspection
Environment-assisted cracking

Polythionic acid stress-corrosion cracking

API RP 571

Sulfur scale, moisture and oxygen during shutdown or exposure.

Susceptible materials

Sensitized austenitic stainless steel

Indicators

Intergranular crackingShutdown-related failuresCracks near sensitized weld HAZ

Likely locations

Hot sulfur-service pipingFurnace and reactor circuitsWeld heat-affected zones

Inspection methods

PTAngle-beam UTMetallography

Mitigation

Dry nitrogen protectionApproved neutralization washStabilized/low-carbon materialShutdown controls
Environment-assisted cracking

Ammonia stress-corrosion cracking

API RP 571

Ammonia-containing environment with tensile stress and susceptible metallurgy.

Susceptible materials

Copper alloysCarbon steel in selected ammonia services

Indicators

Branched crackingCracks at cold-worked regionsLeakage with limited general corrosion

Likely locations

Copper-alloy tubingWelded ammonia pipingCold-worked components

Inspection methods

PTEddy currentAngle-beam UT

Mitigation

Material selectionStress reductionEnvironment and oxygen control
Environment-assisted cracking

Wet H₂S cracking (HIC / SOHIC / SSC)

API RP 571

Aqueous hydrogen-sulfide service capable of hydrogen charging.

Susceptible materials

Carbon steelLow-alloy steelHigh-strength steels

Indicators

Blisters or stepwise crackingThrough-thickness SOHICCracks at hard weld zones

Likely locations

Wet sour pipingWelds and HAZLow points and water-wet sections

Inspection methods

Shear-wave UTPAUT / TOFDWFMT / MTMetallography

Mitigation

Sour-service material controlHardness controlWater/chemistry managementQualified PWHT
External corrosion

Atmospheric corrosion

API RP 571

Moisture, salts, industrial pollutants and coating breakdown on uninsulated surfaces.

Susceptible materials

Carbon steelLow-alloy steel

Indicators

Coating failureRust scalePitting at crevices and supports

Likely locations

Pipe supportsMarine exposureCrevicesPoorly drained areas

Inspection methods

Visual examinationUT spot/gridProfile RT

Mitigation

Coating maintenanceDrainageSupport redesignWashdown
External corrosion

Soil-side corrosion

API RP 571

Contact with conductive soil, groundwater or failed coating with inadequate cathodic protection.

Susceptible materials

Buried carbon steel

Indicators

Coating holidaysExternal pittingLow pipe-to-soil potential

Likely locations

Soil-to-air interfacesRoad crossingsWet/clay soilsSleeves

Inspection methods

Close-interval surveyDCVG/ACVGExcavation and UTGuided-wave UT

Mitigation

Cathodic protectionCoating repairDrainageElectrical interference control
Localized metal loss

Hydrochloric acid corrosion

API RP 571

Aqueous hydrochloric acid or chloride salt hydrolysis, often near dew points.

Susceptible materials

Carbon steelLow-alloy steelSelected stainless steels

Indicators

Rapid localized thinningAcid dew-point attackIron chloride deposits

Likely locations

Overhead systemsInjection and mix pointsCondensing zones

Inspection methods

UT scanningProfile RTProcess sampling

Mitigation

Water wash and neutralization controlAlloy/material reviewMixing designTemperature control
Metal loss

Sour-water corrosion

API RP 571

Water containing H₂S, ammonia, cyanides or other refinery contaminants.

Susceptible materials

Carbon steelLow-alloy steel

Indicators

General or localized thinningDeposits and foulingDamage changes with chemistry

Likely locations

Overhead linesSour-water pipingLow pointsInjection locations

Inspection methods

UT surveyProfile RTChemistry monitoring

Mitigation

Chemistry controlWash-water managementVelocity controlMaterial upgrade
Mechanical damage

Mechanical / vibration fatigue

API RP 571

Cyclic mechanical stress from vibration, pressure pulsation or repeated displacement.

Susceptible materials

All piping materials

Indicators

Cracks at weld toesSmall-bore connection failuresRepeat leakage

Likely locations

Small-bore branchesCompressor/pump pipingSupportsDiscontinuities

Inspection methods

Visual examinationPT / MTAngle-beam UTVibration monitoring

Mitigation

Dynamic stress reductionSupport modificationGeometry improvementVibration monitoring
Mechanical damage

Thermal fatigue

API RP 571

Repeated temperature gradients, mixing or cycling that generate cyclic thermal stress.

Susceptible materials

Carbon steelLow-alloy steelStainless steel

Indicators

Network/circumferential cracksCracks near mixing interfacesCycling-related leaks

Likely locations

Mixing teesQuench pointsBypassesIntermittent services

Inspection methods

PT / MTAngle-beam UTThermal monitoring

Mitigation

Reduce mixing gradientsOperational controlsGeometry/material reviewIOW monitoring
High-temperature metallurgical damage

Creep and stress rupture

API RP 571

Long-term operation in a material-dependent elevated-temperature creep regime.

Susceptible materials

Carbon steelLow-alloy steelAustenitic stainless steel

Indicators

BulgingCreep cavitationWeld crackingDimensional change

Likely locations

Hot pipingWelds and HAZFurnace outlet systems

Inspection methods

Replication/metallographyDimensional surveyAdvanced UTHardness testing

Mitigation

Temperature controlLife assessmentMaterial upgradeWeld-specific monitoring
Metallurgical / fracture

Brittle fracture

API RP 571

Low metal temperature, high stress and insufficient material toughness or crack-like flaws.

Susceptible materials

Carbon steelLow-alloy steel

Indicators

Sudden fractureLittle plastic deformationInitiation at a flaw or stress concentration

Likely locations

Cold startupsHydrotest conditionsThick or old componentsWeld discontinuities

Inspection methods

Material verificationFracture-mechanics reviewUT for crack-like flaws

Mitigation

Minimum metal temperature controlToughness verificationPressure-temperature procedureFlaw assessment