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Cracked High Pressure Steam Superheater Alloy 800 Piping Of A Thermal Oxidizer From A Gas Plant SRU

Cracked High Pressure Steam Superheater Alloy 800 Piping Of A Thermal Oxidizer From A Gas Plant SRU
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Caustic soda (sodium hydroxide) is one of the most widely used inorganic chemicals in water treatment process. Improper injection rate or concentration have led to many failures in the industry. These failures have been mostly identified as Caustic Stress Corrosion Cracking (CSCC).

Caustic Stress Corrosion Cracking (CSCC) is a form of Environment Assisted Cracking (EAC), characterized by surface-initiated cracks that occur in materials exposed to caustic environment. EAC is defined as a cracking process caused by the synergistic effects of stress, and environment on a specific material. All three factors–stress, aggressive environment, and susceptible material are necessary for EAC. The environment aggressiveness escalates with increase of caustic concentration and metal temperature, in case of CSCC. 

Product Number: 51322-17922-SG
Author: Yousif A. Al Rabie, Iyad Al-Buraiki
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings
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A failure was reported in an alloy 800 (UNS N08800) high pressure steam superheater piping downstream of a thermal oxidizer in a Sulfur Recovery Unit of a Gas Plant. Unexpected cracking on the circumference was observed. No evidence of corrosion was found on the piping. A metallurgical failure analysis investigation established that the piping had failed due to intergranular environmental stress corrosion cracking (IGSCC), specifically Caustic Stress Corrosion Cracking (CSCC) cracking. The cracks most probably originated as a result of unexpected wet conditions and caustic carryover. It was recommended to review the water treatment program, prevent water condensation and inspect the rest of the piping for similar cracks. 

A failure was reported in an alloy 800 (UNS N08800) high pressure steam superheater piping downstream of a thermal oxidizer in a Sulfur Recovery Unit of a Gas Plant. Unexpected cracking on the circumference was observed. No evidence of corrosion was found on the piping. A metallurgical failure analysis investigation established that the piping had failed due to intergranular environmental stress corrosion cracking (IGSCC), specifically Caustic Stress Corrosion Cracking (CSCC) cracking. The cracks most probably originated as a result of unexpected wet conditions and caustic carryover. It was recommended to review the water treatment program, prevent water condensation and inspect the rest of the piping for similar cracks. 

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External corrosion in uninsulated pipelines is normally able to be prevented by cathodic protection (CP). Generally, external corrosion on buried pipelines cannot occur if CP current is getting onto the pipe. CP is an electrochemical means of corrosion control in which the oxidation reaction in a galvanic cell is concentrated at the anode and suppresses corrosion of the cathode (pipe) in the same cell. For instance, to make a pipeline a cathode, an anode is attached to it.
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