xGRIDx Reference Refinery Twin Depth register: materials, component decomposition, resources, protection design requirements. Companion to the full-plant register. 250000 DEXPI Specification 2.0 concepts, extended with xGRIDx depth sections (not a validated DEXPI export) Not a validated DEXPI export. See header comment. Carbon steel plate, SA-516 Gr.70 ASME SA-516 Grade 70 (ASTM A516) Column shells, vessel shells and heads, drums, reactor shells in mild service The default pressure-boundary plate of the plant. Normalized for thicker / lower-temperature sections. Carbon steel pipe and forgings, SA-106 / SA-105 ASME SA-106 Gr.B pipe; ASME SA-105 flanges and forgings Process piping, valve bodies, flange facings across carbon-steel line classes Paired with SA-516 plate as the plant carbon steel system. Tank plate, carbon steel (API 650) ASTM A36 / ASME SA-516 Gr.70 shell plate to API 650; SA-283 intermediate grades in older classes Atmospheric storage tank shells, bottoms and roofs Floating and fixed roof tanks. Bottom plates get corrosion allowance and cathodic protection. 1.25Cr-0.5Mo low alloy steel ASME SA-387 Gr.11 plate; SA-335 P11 pipe; SA-182 F11 forgings Hot oil and moderate-temperature hydrogen service: VDU, hot separator and furnace transfer lines Step up from carbon steel where sulfidation and temperature rule carbon steel out. 2.25Cr-1Mo low alloy steel ASME SA-387 Gr.22 plate; SA-335 P22 pipe; SA-182 F22 forgings High-pressure, high-temperature hydrogen service: hydrocracker and hydrotreater reactor shells, hot high-pressure separators Governed by API RP 941 (Nelson curves) for high-temperature hydrogen attack. Often stainless-clad inside. 5Cr-0.5Mo alloy steel ASME SA-335 P5 pipe; SA-387 Gr.5 plate Fired heater tubes and hot transfer lines in crude, vacuum and coker service Sulfidation resistance at temperature where carbon steel and 1.25Cr thin too fast. 9Cr-1Mo alloy steel ASME SA-335 P9 pipe; SA-387 Gr.9 plate Coker and visbreaker hot lines, high-temperature sulfidic service Top of the Cr-Mo ladder used in this reference plant short of stainless. HP-modified cast alloy, reformer tubes ASTM A297 Gr. HP Nb-modified (HP40Nb class) centrifugally cast tubes SMR reformer catalyst tubes at 800-900 C tube metal temperature Creep-governed. Tube life is managed by temperature history and remaining-life assessment, not calendar. Stainless steel 304/304L ASME SA-240 TP304/304L plate; SA-312 TP304L pipe; SA-213 TP304 tubes Cladding, column internals, trays, and moderate corrosive service Chloride stress corrosion cracking is the governing watch item above about 60 C in chloride presence. Stainless steel 316L ASME SA-240 TP316L; SA-312 TP316L; SA-213 TP316L tubes Sour water, amine-adjacent, and aqueous corrosive service; cladding on Cr-Mo reactors Molybdenum grade for pitting resistance over 304L. Stabilized stainless 321 / 347 ASME SA-240 TP321 / TP347; SA-312 TP347 pipe Reformer and FCC high-temperature internals, transfer lines, polythionic-acid-exposed service Stabilization resists sensitization; the standard answer where polythionic acid SCC is credible. Duplex stainless 2205 ASME SA-240 S32205; SA-790 S32205 pipe; SA-789 tubes Crude overhead, desalter brine, cooling-water and chloride services too aggressive for 316L High strength plus chloride SCC resistance; watch 475 C embrittlement range in fabrication and service. High-nickel alloys 825 / 625 ASME SB-424 Alloy 825 plate; SB-443 Alloy 625; weld overlay per ASME IX Weld overlay and solid alloy in the worst sour and high-temperature spots: hydrocracker effluent, SRU and reactor effluent air coolers Used as overlay or cladding on carbon / Cr-Mo substrate, not solid construction, in this reference design. Clad plate, carbon steel + 316L ASME SA-516 Gr.70 substrate with SA-240 TP316L cladding (roll or explosion bonded, SA-263/264 class) Hydrotreater and hydrocracker reactor and vessel internals surfaces Strength from the substrate, corrosion resistance from the clad layer; clad integrity is an inspection item. Monel 400 (Ni-Cu alloy) ASME SB-127 Alloy 400 plate; SB-164 bar; trim and bolting Alkylation acid-service valve trim, pump trim and instrument parts The classic acid-handling trim alloy; used at trim scale, not vessel scale, in this plant. Cast iron / ductile iron, utility service ASTM A126 cast iron; ASTM A536 ductile iron Cooling water, firewater branches, air and low-hazard utility valves and pump casings Utility-only material class; never in hydrocarbon pressure boundary in this design. Erosion-resistant refractory, FCC High-alumina castable (85% Al2O3 class) over hexmesh / hexsteel anchors, API RP 982 inspection class FCC reactor, regenerator, cyclones and transfer lines Erosion by circulating catalyst is the design driver; lining thickness and anchor pattern are the model attributes. High-alumina refractory, SRU reaction furnace High-alumina brick and castable (90% Al2O3 class hot face) with insulating backup layer Claus reaction furnace and waste heat boiler tube sheet protection Hot-face temperatures in the 1,300 C class; sulfur dew point corrosion behind the lining is the hidden watch item. Heater refractory: insulating firebrick + ceramic fiber IFB 2600 class brick; ceramic fiber modules (1,260 C class) on walls and roofs Fired heaters, boilers, SMR furnace box (outside the catalyst tubes) Fiber modules cut heat loss; burner tiles and peep sights are the wear points. Exchanger tubes, carbon steel SA-179 ASME SA-179 seamless cold-drawn carbon steel tubes General hydrocarbon / hydrocarbon preheat and condensing duty Default tube material where neither side is corrosive enough to rule it out. Exchanger tubes, stainless SA-213 ASME SA-213 TP316L / TP321 seamless tubes Corrosive process sides: reactor effluent, sour and high-temperature services Paired with stainless or clad tubesheets to avoid galvanic mismatch. Exchanger tubes, duplex / titanium for cooling water ASME SA-789 S32205 duplex; SB-338 titanium Gr.2 for brackish / seawater class duty Cooling-water condensers and coolers, including CDU overhead service The standard answer to cooling-water-side pitting and MIC; titanium where chlorides are highest. Bolting, B7 studs / 2H nuts ASME SA-193 Gr.B7 studs; ASME SA-194 Gr.2H nuts General flanged joints in carbon and low-alloy steel systems PTFE or anti-seize coated sets in corrosive atmospheres; controlled torque / tensioning is the modeled procedure. Bolting, B8M stainless ASME SA-193 Gr.B8M Class 2 studs; SA-194 Gr.8M nuts Stainless flanged joints and low-temperature / corrosive-atmosphere joints Galling control (lubricant, hardness differential) is the modeled assembly requirement. Gaskets: spiral wound and RTJ ring ASME B16.20 spiral-wound, 316L winding with graphite filler; octagonal RTJ rings, soft iron / 316 by class Spiral wound as the plant default; RTJ metal rings in high-pressure hydrogen and reactor systems Gaskets are single-use sacrificial components in this model: replaced at every joint break. Valve packing: die-formed graphite / PTFE Die-formed flexible graphite sets with carbon-fiber anti-extrusion rings; braided PTFE for light service Rising-stem valve stem sealing, fugitive-emission (low-E) class packing on control and block valves Packing condition is a modeled LDAR attribute, tied to the emissions layer. Mechanical seal faces: SiC / carbon Reaction-bonded silicon carbide vs resin-impregnated carbon graphite faces; tungsten carbide in abrasive duty Pump and compressor shaft sealing (API RP 682 seal plans) Seal face pair is a wear component; seal support system (Plan 52/53/54) is modeled with the pump. Elastomers: FKM, FFKM, EPDM, NBR by service FKM (general hydrocarbon), FFKM (severe chemical / amine), EPDM (steam and water), NBR (mild oil) O-rings and gaskets in seals, instruments and rotating equipment Elastomer selection is by chemical compatibility class in the register; wrong-elastomer is a named failure mode. Insulation: mineral wool and calcium silicate Mineral wool (ASTM C547) and calcium silicate (ASTM C533) with aluminum jacketing Hot piping and equipment conservation; personnel protection; cold service uses cellular glass class Jacketing integrity is the CUI control: damaged jacketing is a modeled condition flag, not a cosmetic item. Coating systems and thermal-spray aluminum High-temperature epoxy / phenolic coating systems; thermal-spray aluminum (TSA) under insulation in CUI-critical service External corrosion protection of carbon steel, especially under insulation and in splash zones Coating system and surface preparation grade are register attributes per line class. Conductors: copper with XLPE / EPR insulation Copper conductors, XLPE or EPR insulation, armored tray cable (IEEE/ICEA class), 600 V and 5-15 kV classes Power and control cabling plant-wide; fiber-optic for command links (see protection layer) Cable insulation class and routing (tray, conduit, buried) are modeled attributes; critical command runs are fiber. Transformer materials: CRGO core, mineral oil / ester Cold-rolled grain-oriented core steel; mineral insulating oil (ASTM D3487) or natural ester fluid Power transformers plant-wide Oil condition (dissolved gas analysis) is the modeled health attribute for transformers. FCC catalyst: USY zeolite (qualitative class) Ultrastable Y zeolite in an alumina / silica-alumina matrix with clay filler; rare-earth exchanged class FCC-600 reactor / regenerator circulating inventory Composition class only. No proprietary formulation is modeled or claimed. Hydrotreating catalyst: CoMo / NiMo on alumina (qualitative class) Cobalt-molybdenum or nickel-molybdenum oxides on gamma-alumina support, sulfided in service NHT-300, DHT-500, HCU-700 first stage, SRU tail-gas hydrogenation Composition class only. No proprietary formulation is modeled or claimed. Hydrocracking catalyst: NiMo / zeolite (qualitative class) Nickel-molybdenum on zeolite / amorphous silica-alumina support classes HCU-700 second stage cracking beds Composition class only. No proprietary formulation is modeled or claimed. Reformer / isomerization catalyst: Pt on alumina (qualitative class) Platinum (with Re or Sn promoter class) on chlorided gamma-alumina; Pt-zeolite class for isomerization second bed REF-400 (continuous regeneration class), ISO-900 Composition class only. No proprietary formulation is modeled or claimed. Claus catalyst: activated alumina / titania (qualitative class) Activated alumina spheres; titania class in the first converter for COS / CS2 hydrolysis SRU-1200 converter beds Composition class only. No proprietary formulation is modeled or claimed. SMR and shift catalysts: Ni, Fe-Cr, Cu-Zn (qualitative class) Nickel on calcium-aluminate (reformer tubes); iron-chromium high-temperature shift; copper-zinc low-temperature shift; PSA adsorbent (activated carbon / molecular sieve) class HGN-1400 reformer, shift section and PSA Composition class only. No proprietary formulation is modeled or claimed. Lubricating oils and greases (material class) ISO VG 46 / 68 turbine and bearing oils (synthetic PAO class for critical machines); EP gear oils; lithium-complex greases Bearings, gearboxes, seal support systems plant-wide Inventories are quantified in the resources layer. Oil analysis is the modeled condition attribute. Shell: SA-516 Gr.70 carbon steel; hot / sour sections 1.25Cr-0.5Mo or 316L clad Crude and vacuum columns on high-TAN slates Hot sections above 260 C Overhead and pumparound circuits Insulated skirt and lower shell External, at supports and nameplate areas 30 API 510 external + internal at turnaround; thickness survey grid on shell courses; tray condition survey 21 columns / towers in the plant register SA-516 Gr.70 / Cr-Mo by section Sulfidation Naphthenic acid corrosion CUI Counted as courses per column, plant average SA-516 Gr.70 Corrosion thinning Fatigue at nozzle junctions Carbon steel skirt; B7 anchor bolts Atmospheric corrosion Anchor bolt corrosion 304L / 316L stainless trays, valves and downcomers Tray fouling Weir corrosion Tray uplift / damage Trays counted individually, plant average per column; the internals layer v1 listed as a gap, now templated 316L / ceramic packing and liquid distributors Packing fouling Distributor plugging 316L stainless Plugging Corrosion SA-105 forgings; B7/2H bolting Flange leakage Nozzle neck cracking Galvanized carbon steel Atmospheric corrosion Mineral wool / calcium silicate, aluminum jacket Jacket damage driving CUI SA-516 Gr.70 carbon steel; 316L clad or solid in sour / aqueous service Sour drums and separators Amine flash and regenerator vessels Insulated vessels Wet gas / condensate vessels 30 API 510; UT thickness grid; wet-H2S vessels get WFMT / HIC scan class inspection 66 vessels / drums / separators in the plant register SA-516 Gr.70 / clad by service Thinning HIC blistering (sour) SA-516 Gr.70 Thinning Carbon steel Support corrosion Fireproofing damage 316L stainless Erosion Fouling 316L mesh / PP in light service Fouling Carryover SA-105; B7/2H Flange leakage CS / 316L with armored glass Glass breakage Bridle plugging Mineral wool, aluminum jacket Jacket damage driving CUI 2.25Cr-1Mo (SA-387 Gr.22) with 316L / 347 cladding in hydrogen service; carbon steel refractory-lined for FCC class Governed by API RP 941 Nelson curves; the reactor class watch item Cr-Mo on long hot service, tracked by J-factor / step-cool class data Sensitized stainless internals at shutdown exposure Hot-wall sections and SMR tubes Feed-effluent hot sections 30 API 510 with HTHA-targeted UT / TOFD class examination; internals survey each turnaround; catalyst bed DP trend as operating condition 24 reactors in the plant register (hydrotreaters, reformer, hydrocracker, FCC pair, coker drums counted as vessels in v1, SRU converters, SMR counted at fired-heater class) SA-387 Gr.22 + 316L clad HTHA Temper embrittlement Clad disbonding SA-387 Gr.22 + clad HTHA Carbon steel, fireproofed Corrosion under fireproofing Catalyst per resources layer (qualitative class) Catalyst deactivation Bed fouling / crusting Hot spots Beds counted per reactor, plant average; catalyst itself is a resource, tracked in the resources layer 347 stainless Polythionic acid SCC Mechanical damage 347 / 316L stainless Erosion Plugging 347 stainless screen Screen damage Inconel-sheathed thermocouples Thermocouple failure masking hot spots F22 forgings; RTJ rings Flange leakage API 650 carbon steel plate (A36 / SA-516 Gr.70); aluminum floating roofs and seals by service Shell and roof external Governed by API 653 floor scans, cathodic protection is the control Water bottoms Product-side floor and first course 40 API 653: external 5 yr, internal / floor MFL scan 10-20 yr class by corrosion rate 60 tanks in the plant register (crude, product, utility, wastewater) API 650 plate, A36 / SA-516 Shell thinning Buckling (wind / vacuum) Courses counted per tank, plant average API 650 plate with corrosion allowance Soil-side corrosion Product-side pitting Carbon steel; aluminum for internal floaters Roof corrosion Pontoon leakage Steel shoe / foam dam with fabric seals Seal gap (emissions) Seal hang-up Applies to floating-roof tanks; seal condition is an emissions (LDAR / fugitive) attribute Carbon steel / stainless Drain plugging Carbon steel impeller, geared drive Gearbox wear Seal leakage The one moving component on a tank; fitted on crude tanks SA-105; B7/2H Flange leakage Anode beds, rectifier, reference electrodes CP failure accelerating floor corrosion Radar gauge; SIL-rated high-high switch class Gauge failure Overfill Reinforced concrete; lined earthen bund Settlement Bund cracking / drainage blockage SA-516 Gr.70 normalized plate, PWHT; SA-537 class in thicker sections Sour LPG service; plate HIC-tested class Legs and equator zones Pressure cycling at leg attachments 30 API 510; full UT / WFMT class examination of welds on sour spheres; leg and fireproofing survey 8 LPG / pressure spheres in the plant register SA-516 Gr.70 N / SA-537 HIC cracking (sour) Thinning Petal plates counted, plant average per sphere Carbon steel, concrete fireproofed Corrosion under fireproofing SA-105; B7/2H Flange leakage 316L / CS Bridle plugging Galvanized carbon steel Nozzle plugging Galvanized carbon steel Atmospheric corrosion Shell SA-516 Gr.70; tubes SA-179 carbon steel default, SA-213 316L / duplex / titanium by service (see tube metallurgy) The condition driver for this class; the twin's E-101C flag lives here, at the tube bundle Hot hydrocarbon shells and tubes Crude / vacuum service Reactor effluent and overhead exchangers High-velocity inlet zones Stainless tubes under insulation / stagnant chloride Water-side tubes 25 API 510 / TEMA class: bundle pull and tube eddy-current / IRIS survey on condition and at turnaround 148 shell-and-tube exchangers in the plant register SA-516 Gr.70 / Cr-Mo by service Sulfidation Thinning SA-516 Gr.70 / clad by service Pass-partition leakage SA-179 CS / SA-213 SS / duplex / Ti by service Fouling Tube wall thinning Vibration wear at baffles Pitting Tubes counted individually at plant-average 600 per bundle; fouling is tracked at this component, which is where the E-101C flag is expressed Carbon steel / stainless by service Baffle corrosion Tube vibration damage SA-266 / clad forgings Tube joint leakage Crevice corrosion Carbon steel / stainless Internal leakage Spiral-wound 316L / graphite; RTJ in HP service Gasket leakage at joint break Sacrificial: replaced at every bundle pull B7/2H; B8M on stainless Bolt corrosion Relaxation Carbon steel; mineral wool + jacket CUI at saddles Carbon steel tubes default; 316L / duplex / Alloy 825 in reactor effluent and sour service; aluminum fan blades Reactor effluent air coolers; velocity and wash-water controlled Dust, salt and debris on fins Fan and belt drive vibration Headers and structure, coastal air 25 API 510 / API RP 661 class: tube UT sampling, fan vibration route, air-side cleaning on DP trend 31 air cooler bays in the plant register CS / 316L / duplex / 825 by service, aluminum fins NH4HS corrosion Fin fouling Tube leaks Tubes counted individually at plant-average per bay SA-516 / alloy by service Plug leakage Header corrosion Aluminum / composite blades, steel hub Blade fatigue Imbalance Cast iron gearbox; synthetic belts Belt wear Gear wear Bearing failure Rolling element bearings, grease / oil lubricated Bearing wear Galvanized carbon steel Atmospheric corrosion Galvanized steel louvres, pneumatic actuator Actuator failure Louvre seizure Carbon steel Freeze damage Corrosion Tubes: carbon steel to 5Cr / 9Cr by outlet temperature; HP-Nb cast in SMR; refractory per heater refractory class Tube life governed by temperature history; skin thermocouples are the control Process-side hot tubes SMR and coker tubes Coker and batch-cycled heaters Convection section cold end, sulfur in fuel Tube external scaling at temperature 25 API RP 573 class: tube UT / remaining-life assessment, skin TC trend review, refractory survey at turnaround 12 fired heaters in the plant register (incl. SMR furnace and SRU reaction furnace counted as heater/reactor pair) CS / 5Cr / 9Cr / HP-Nb by service Creep Sulfidation Carburization Coking inside tubes Tubes counted individually, plant average per heater CS / low alloy, cast fins Dew point corrosion Fin corrosion High-alloy cast supports (25Cr-20Ni class) Support creep / distortion IFB 2600 + ceramic fiber modules Hot spots Brick failure Fiber shrinkage Stainless / cast alloy burner tiles and tips Tip plugging Flame impingement Tile cracking Burners counted per heater, plant average; burners are stationary assemblies with moving registers below Carbon / stainless steel linkages Linkage seizure Damper warping Carbon steel; SIL-rated shutoff class Regulator failure Filter plugging Carbon steel, refractory lined lower section Dew point corrosion Damper seizure Alloy lance, steam driven Lance erosion Drive failure Inconel-sheathed TCs TC drift / failure masking hot tubes Refractory / cast alloy frames Refractory damage SA-516 / SA-387 drums; SA-210 / SA-213 tube steels by pressure class; refractory in furnace zone Water-side chemistry excursion Deaerator / scavenger control is the defense Superheater outlet legs Drum nozzle and header junctions under cycling Economizer cold end 30 ASME / NBIC class statutory inspection; water-side chemistry trending; tube sampling at major outages 5 boilers in the plant register (4 utility + 1 SRU waste-heat) SA-516 Gr.70 / SA-387 Caustic gouging Fatigue at downcomer nozzles SA-516 Gr.70 Sludge accumulation Corrosion SA-210 A1 / SA-213 T11 Fireside corrosion Waterside pitting Tube erosion Tubes counted at plant-average panel equivalent SA-213 T11 / T22 Creep Oxidation SA-210 / SA-213 Dew point corrosion Erosion Cast alloy / stainless burners, moving registers Tip fouling Register seizure IFB + fiber; steel casing Hot spots Carbon steel / stainless Carryover Internal corrosion Chrome-moly bodies, per PSV template Setpoint drift Seat leakage Carbon steel / alloy by class Erosion at continuous blowdown Casing: cast carbon steel SA-216 WCB (API 610 class); impeller / wear rings 12% Cr or 316L; shaft 4140 / 4145 class; severe service duplex Impeller and casing cutwater in solids / high-velocity service NPSH margin is the modeled attribute Shaft at keyways and couplings under misalignment Stagnant and sour services 20 ISO 10816 vibration route + seal leakage monitoring (API RP 682 plans); overhaul on condition 284 pumps in the plant register SA-216 WCB cast steel Erosion-corrosion Casing thinning Cavitation damage Spiral wound / elastomer by service Joint leakage 12% Cr / 316L / duplex by service Erosion Cavitation pitting Balance loss from wear 4140 / 4145 alloy steel Fatigue at keyway Corrosion under sleeve 316L / hard-coated Scoring under packing / seal SiC vs carbon faces; FFKM / FKM elastomers Face wear Dry running Elastomer attack Hang-up The dominant pump failure component plant-wide; seal plan type is a modeled attribute 316L reservoir and tubing Barrier fluid loss Cooler fouling Rolling element, babbitt in large machines Bearing fatigue Lubrication failure Brinelling Cast iron / steel housing Oil contamination Water ingress Steel spacer coupling; steel guard Element fatigue Misalignment wear Fabricated steel, epoxy grout Grout voids (soft foot) Anchor corrosion Per motor template Per motor template Casing: cast / forged carbon or low-alloy steel; internals stainless and precipitation-hardened steels; dry gas seal faces SiC Wet gas inlet stages Rotor and blade / impeller under surge and fouling imbalance Sour gas casings FCC wet gas and coker gas machines 25 API RP 670 machinery protection (vibration, axial position, temperature) continuous; major inspection 5-8 yr class 22 compressors in the plant register (centrifugal and reciprocating classes combined) Cast / forged CS or Cr-Mo Casing corrosion Cylinder wear (recip) Forged alloy steel rotor; PH stainless impellers Fouling imbalance Fatigue Piston ring wear (recip) Aluminum / bronze labyrinth; abradable coatings Seal wear opening clearances SiC faces, spiral-groove class Seal gas contamination Face damage Slow-roll damage Cartridges counted per shaft end Babbitt-lined steel shells Babbitt fatigue Oil whirl (design-controlled) CS / 316L skid Pump failure (auto-start spare is the control) Oil degradation Per vessel / exchanger templates Liquid carryover Per control valve template Valve stiction driving surge Steel spacer coupling Misalignment wear Per driver template Per driver template Casing and rotor: Cr-Mo-V / 12% Cr steels by steam temperature; blades 12% Cr stainless High-pressure rotor and casing at temperature Start / stop cycling Last-stage blades Rotor steels in wet steam zones (disc keyways) 30 Major inspection with rotor NDT 8-10 yr class; continuous API RP 670 protection; steam path audit by efficiency trend 5 steam turbines in the plant register (plus turbine drivers counted inside compressor / generator sets) Cr-Mo / Cr-Mo-V cast steel Creep Casing distortion Joint leakage Forged Cr-Mo-V / 12% Cr Creep Blade fatigue Last-stage erosion 12% Cr stainless blades Erosion Fatigue FOD Rows counted per machine, plant average Cr-Mo bodies, per valve template Valve sticking (the classic trip failure) Bronze labyrinth; carbon ring segments Seal wear raising steam loss Babbitt-lined shells Babbitt fatigue Mechanical / electronic governor class, redundant trip Failure to trip (test interval is the control) CS / 316L skid Oil degradation Geared electric drive Engagement failure Carbon steel Vacuum leakage Carbon steel casing and wheel; stainless in wet / sour gas; aluminum on air cooler fans Dust and catalyst fines in flue gas service Wheel and blade vibration Acid dew point in flue gas below condensation temperature 20 Vibration route monitoring; wheel inspection at turnaround 19 fans / blowers in the plant register (excludes air-cooler fans, counted in that template) Carbon steel Erosion Dew point corrosion Carbon / stainless steel Erosion Fatigue cracking Fouling imbalance Alloy steel Fatigue Rolling element / sleeve by size Bearing wear Lubrication failure Carbon steel with linkage Linkage seizure Steel / synthetic belts Belt wear Per motor template Per motor template Carbon steel Expansion joint failure SA-106 Gr.B carbon steel default; P11 / P22 / P5 low alloy hot and hydrogen lines; 316L and duplex in corrosive classes Hot oil circuits; silicon content of carbon steel is the register attribute The largest piping damage population plant-wide Elbows and tees downstream of control valves and in two-phase service Crude / vacuum transfer lines Hot hydrogen lines inside RP 941 limits by alloy selection Small-bore connections and relief inlet lines 25 API RP 570 piping inspection: CML thickness grids, circuit-based; CUI program with risk-based insulation removal Pipe spools: 60.5 km of above-ground piping at plant-average 10 m spool length (reference derivation) SA-106 B / P11 / P22 / P5 / 316L by line class Sulfidation CUI Erosion at flow changes Matching filler, PWHT by alloy class Weld defect / cracking PWHT omission on Cr-Mo Welds counted per spool end, plant average Carbon steel, galvanized Support corrosion Spring hanger seizure Shoe CUI trap Mineral wool / CaSi, aluminum jacket Jacket damage driving CUI Forged SA-105 Vibration fatigue (the classic small-bore failure) SA-234 WPB carbon steel; WP11 / WP22 / WP5 alloy; WP316L stainless by line class Extrados thinning in two-phase and high-velocity service Hot circuits Thermal expansion stress at direction changes 25 API RP 570 CMLs on extrados of susceptible elbows 10,890 elbows in the plant register (derived from piping length at class-typical density) SA-234 WPB / alloy / SS by class Extrados thinning Weld-end cracking Matching filler Weld defects SA-234 WPB / alloy / stainless matching line class Crotch and impingement zones Mixing tees with temperature differential (thermal striping) 25 API RP 570 CMLs; mixing tees get temperature monitoring class 2,722 tees in the plant register SA-234 by class Crotch cracking Impingement thinning Matching filler Weld defects SA-234 WPB / alloy / stainless matching line class Turbulence downstream of concentric reductions in liquid service At pump suction reducers under vibration 25 API RP 570 with parent circuit 1,331 reducers in the plant register SA-234 by class Turbulence thinning Matching filler Weld defects SA-105 forged carbon steel; SA-182 F11 / F22 / F316 alloy and stainless facings; B7/2H or B8M bolting The dominant flange failure: assembly procedure, not material, is the control Bolt and flange-face corrosion, crevice at hub Cyclic pressure / temperature joints 25 Joint integrity program: torque / tension records, leak survey (LDAR ties in), face inspection at every break 12,672 flanged joints in the plant register (LDAR-relevant count from v1) SA-105 / SA-182 by class Face damage Crevice corrosion Counted as one joint assembly Spiral-wound 316L/graphite; RTJ ring in HP service Gasket blowout Relaxation leakage Sacrificial: replaced at every joint break B7/2H or B8M, coated Bolt corrosion Yielding on over-torque Galling (stainless) Counted as one set (typically 8-16 studs) Phenolic sleeves and washers Kit failure defeating cathodic isolation Body: SA-216 WCB cast steel (gate / globe / check), SA-105 / A105N forged small-bore, ball valves SA-216 / CF8M; trim 13% Cr / Stellite hardfacing; Monel trim in acid service Globe and throttled gate valves High-DP liquid service LDAR-monitored; low-E packing is the control Safety and isolation integrity item Body / bonnet bolting and stagnant services 20 LDAR Method 21 class monitoring; seat leak test at turnaround for critical isolation; packing adjustment route Block valves: gate 2,016 + globe 864 + ball 1,440 + check 576 from the v1 valve split (control valves and PSVs templated separately) SA-216 WCB / CF8M / WC9 by service Body corrosion Bonnet joint leakage 13% Cr / Stellite-faced; PTFE seats on soft ball valves Wire drawing Seat scoring Flapper pin wear (check) Stellite hardfaced / PTFE Seat leakage 410 / 17-4PH stainless Stem scoring Thread wear Die-formed graphite low-E packing Fugitive leakage (LDAR) B7/2H; spiral gasket Joint leakage Cast iron gearbox; bevel gears Gearbox seizure Lost motion Ductile iron / bronze nut Thread wear Body per block valve class; trim Stellite / tungsten carbide in severe service; cage-guided globe as plant default Severe service letdown The dominant control-loop performance failure plant-wide LDAR Control, not process, failure mode 20 Online valve diagnostics (travel deviation, friction) via smart positioners; bench test at turnaround 576 control valves from the v1 valve split SA-216 WCB / CF8M by service Body corrosion Stellite / WC trim Cavitation damage Erosion Cage plugging Stellite / metal seat Seat leakage 17-4PH / 316 Scoring Graphite low-E with live loading Fugitive leakage Excess friction (stiction) Steel case, elastomer diaphragm Diaphragm rupture Spring fatigue Stainless / coated aluminum housing, HART / FF class Positioner failure Air supply contamination 316 tubing, brass / SS fittings Water in instrument air (the plant-wide classic) Sealed switches Feedback failure Wetted parts 316L default; diaphragm seals with exotic fill in corrosive service; enclosures 316 / polycarbonate by area Plugging and thinning of small-bore impulse tubing Small-bore instrument connections Analyzer availability is sample-system availability 15 Proof testing by SIL class (IEC 61511) for SIS loops; calibration / loop checks for BPCS; analyzer availability tracking 2,620 field instruments in the plant register; DCS / SIS points about 2.2x this count (v1) 316L; thermowells per ASME PTC 19.3 TW class Thermowell vibration failure (wake frequency) Orifice edge wear 316L tubing Plugging Freezing (winterization is the control) Corrosion 316 / coated housing, HART / FF class Drift Electronics failure Lightning / surge (SPD at marshalling) Cu / XLPE armored; fiber on long command runs Water ingress Insulation damage Redundant controller class for SIS I/O card failure Common-cause (independence is the design control) 316 Bourdon / diaphragm Gauge failure / overrange Frame: cast iron / fabricated steel; windings: copper with Class F/H insulation system; bearings rolling element Life halves per ~10 C over class; cooling cleanliness is the control Shaft grounding / insulated bearing is the modeled control Space heaters and breather condition 20 Vibration route + motor current signature / thermography class; insulation resistance trend 341 motors in the plant register Cast iron frame; laminated silicon steel core Core damage Frame corrosion Copper, resin-rich / VPI insulation system Insulation aging Turn faults Contamination Copper / aluminum cage rotor; alloy shaft Cage bar cracking Shaft fatigue Rolling element; insulated NDE on VFD service Fluting (VFD) Fatigue Lubrication failure Steel / composite fan Fan damage Cowl blockage (overheating) Cast iron / steel Water ingress Loose terminations (hot spots) Resistance element Heater failure (moisture risk) Tank: carbon steel; core CRGO; windings copper; oil mineral / ester Degree of polymerization decline; furans in oil are the modeled indicator Breather and conservator condition Fan / pump auxiliary failure raises hot-spot temperature 35 Dissolved gas analysis (DGA) oil sampling annual class; thermography; bushing power factor tests at outages 18 transformers from the v1 electrical note (6 substations) Carbon steel, painted / galvanized Tank corrosion Radiator leaks Gasket aging Grain-oriented silicon steel Core insulation failure (rare, catastrophic) Copper with paper insulation system Paper aging Short-circuit forces Mineral oil ASTM D3487 / ester Oxidation Moisture Sludge Condition-replaced / reclaimed on DGA and quality trend Porcelain / composite polymer with oil or dry insulation Bushing failure (a leading transformer loss cause) Moisture ingress Bushings counted per transformer, plant average Steel / cast auxiliaries Auxiliary failure (overheat follows) Oil / vacuum interrupter class Contact wear Mechanism failure Steel tank; silica gel breather; gas relay Breather saturation Relay failure Per instrument class Relay failure Enclosures: painted / galvanized steel; busbar copper (tinned / silver-plated joints); breakers with vacuum interrupters Thermography is the control Humidity and contamination driven Protection settings and arc-resistant design are the controls 30 Thermographic survey annual class; breaker timing / contact tests at outages; partial discharge survey on MV gear 24 switchgear lineups + 32 MCCs from the v1 electrical note Copper bus, insulated / bare by class Joint overheating Bus insulation damage Vacuum interrupters, spring mechanisms Mechanism wear Interrupter wear Failure to trip Breakers / starters counted per lineup, plant average Numerical relays Relay failure / mis-setting Cast resin / oil class Insulation failure VRLA / NiCd battery bank Battery capacity fade (the hidden dependency of every trip) Resistance heaters, fans Condensation (insulation tracking) Structural steel ASTM A36 / A992, galvanized or coated; reinforced concrete foundations (4,000 psi class); anchor bolts F1554 Coating breakdown is the control point At fireproofed members Vibrating equipment supports and flare structures Tanks and heavy equipment; survey monuments are the modeled control 40 Structural survey cycle (coating condition grading); settlement survey on tanks and heavy equipment Structural assemblies: equipment foundations tied to equipment count + pipe rack bents over ~9 km of rack + building frames (reference derivation) Reinforced concrete Settlement Concrete degradation (sulfate / ASR class) Anchor corrosion ASTM F1554 Gr.55 / 105 Corrosion Loosening A992 wide-flange, coated / galvanized Coating failure and section loss Connection corrosion A36, galvanized grating Grating corrosion Bracing damage Concrete / cementitious / intumescent per zone Fireproofing damage hiding steel corrosion Masonry / metal panel; blast-resistant class for control building per API RP 752 Envelope leakage Blast door seal failure Body: SA-216 WCB / WC6 by temperature; trim stainless / Stellite seat; spring per API RP 520 sizing class Flaring and emissions consequence Proof test interval is the control Polymer and coke services; the dangerous failure is failure to open 20 API RP 576: pop / bench test and inspection at interval by service class (1-5 yr); in-situ testing where fitted 288 PSVs from the v1 valve split SA-216 WCB / WC6 Corrosion Erosion at outlet Stellite / stainless seat pair Seat leakage Galling Alloy spring steel, coated Relaxation / setpoint drift Corrosion Stainless Sticking (failure to open) 316L / Inconel bellows Bellows fatigue cracking Carbon / stainless steel Tamper / misadjustment (sealed after test) Per valve / disc class Disc fatigue Isolation left closed (administrative control) Header: carbon steel; flare stack carbon steel with stainless / Inconel tip; KO drum SA-516 Flare tip life is event-count driven Low points and KO drum Pilot and purge integrity is the control 25 Tip inspection by drone / outage class; pilot and thermocouple monitoring continuous; header UT survey 1 flare system plant-wide (FLR-2000); components counted per system Carbon steel large-bore Low-point corrosion Liquid accumulation SA-516 Gr.70 Corrosion Level failure Carbon steel Seal loss (flashback protection) Carbon steel Guy / derrick corrosion 310 SS / Inconel class Tip burnout Cracking Stainless pilots, dual TC class Pilot outage (the reportable failure) Panel + spark class Ignition failure Carbon steel / stainless internals Purge loss (air ingress) Carbon steel Assist failure (smoking flare) Ring main: carbon steel (buried sections cement-lined / coated); pumps per pump template with diesel drivers; branches galvanized Flow testing and internal survey are the controls Stagnant raw water legs Weekly churn / auto-start testing is the modeled control 30 NFPA 25 class: weekly pump churn, annual flow test, 5-yr internal / obstruction investigation 1 firewater system plant-wide (FWS-2100, 12,000 GPM design); components counted per system Per pump template; diesel driver with fuel day tank Failure to start Diesel fuel / battery failure CS buried / above-ground Buried corrosion Valve seizure (exercised on test cycle) Hydrant / monitor branches counted with the main at plant-average density Cast iron / bronze trim Damage Freezing Obstruction Galvanized branches, open nozzles Nozzle plugging Per storage tank template Per tank template Per detection template Panel failure Detector housings 316L / GRP; foam concentrate AFFF / fluorine-free class by policy; foam pourers stainless Catalytic bead poisoning and IR window fouling drive calibration intervals Annual concentrate testing is the control Detector placement study (ISA TR84.00.07 class) is the modeled control 15 Calibration / bump test cycle by detector type; foam concentrate annual test; coverage revalidation at modifications ~420 detectors + 18 foam systems from the v1 safety note 316L housing, sintered flame arrestor Poisoning Fouling Drift Rollup driven by detector count (420) 316L housing, heated window Window fouling False trip from hot work (managed by voting) Armored Cu / XLPE Water ingress Redundant panel class Panel failure GRP / SS tank; bronze proportioner Concentrate aging Proportioner fouling Applies to the 18 foam systems Stainless / coated steel Pourer damage Seal rupture disc aging API 650 carbon steel plate (A36 / SA-516); internal floating roof aluminum Atmospheric Corrosion Soil-side bottom corrosion MIC at water bottom 40 API 653 external / floor scan class API 650 plate, A36 / SA-516 Shell thinning Buckling (wind / vacuum) API 650 plate with corrosion allowance Soil-side corrosion Product-side pitting Carbon steel; aluminum for internal floaters Roof corrosion Pontoon leakage Steel shoe / foam dam with fabric seals Seal gap (emissions) Seal hang-up Carbon steel / stainless Drain plugging Carbon steel impeller, geared drive Gearbox wear Seal leakage SA-105; B7/2H Flange leakage Anode beds, rectifier, reference electrodes CP failure accelerating floor corrosion Radar gauge; SIL-rated high-high switch class Gauge failure Overfill Reinforced concrete; lined earthen bund Settlement Bund cracking / drainage blockage SA-216 WCB casing; 12% Cr impeller; SiC/carbon mechanical seal, Plan 53B class Erosion-Corrosion Cavitation Seal face wear 20 Vibration route + seal reservoir level trend SA-216 WCB cast steel Erosion-corrosion Casing thinning Cavitation damage Spiral wound / elastomer by service Joint leakage 12% Cr / 316L / duplex by service Erosion Cavitation pitting Balance loss from wear 4140 / 4145 alloy steel Fatigue at keyway Corrosion under sleeve 316L / hard-coated Scoring under packing / seal SiC vs carbon faces; FFKM / FKM elastomers Face wear Dry running Elastomer attack Hang-up 316L reservoir and tubing Barrier fluid loss Cooler fouling Rolling element, babbitt in large machines Bearing fatigue Lubrication failure Brinelling Cast iron / steel housing Oil contamination Water ingress Steel spacer coupling; steel guard Element fatigue Misalignment wear Fabricated steel, epoxy grout Grout voids (soft foot) Anchor corrosion Per motor template Per motor template SA-216 WCB casing; 12% Cr impeller; SiC/carbon mechanical seal, Plan 53B class Erosion-Corrosion Cavitation Seal face wear 20 Vibration route + seal reservoir level trend SA-216 WCB cast steel Erosion-corrosion Casing thinning Cavitation damage Spiral wound / elastomer by service Joint leakage 12% Cr / 316L / duplex by service Erosion Cavitation pitting Balance loss from wear 4140 / 4145 alloy steel Fatigue at keyway Corrosion under sleeve 316L / hard-coated Scoring under packing / seal SiC vs carbon faces; FFKM / FKM elastomers Face wear Dry running Elastomer attack Hang-up 316L reservoir and tubing Barrier fluid loss Cooler fouling Rolling element, babbitt in large machines Bearing fatigue Lubrication failure Brinelling Cast iron / steel housing Oil contamination Water ingress Steel spacer coupling; steel guard Element fatigue Misalignment wear Fabricated steel, epoxy grout Grout voids (soft foot) Anchor corrosion Per motor template Per motor template SA-516 shell; SA-179 carbon steel tubes (hot gas oil side) Fouling (process-side) Sulfidation 25 Fouling trend from feed (approach + DP); bundle survey at turnaround SA-516 Gr.70 / Cr-Mo by service Sulfidation Thinning SA-516 Gr.70 / clad by service Pass-partition leakage SA-179 CS / SA-213 SS / duplex / Ti by service Fouling Tube wall thinning Vibration wear at baffles Pitting Carbon steel / stainless by service Baffle corrosion Tube vibration damage SA-266 / clad forgings Tube joint leakage Crevice corrosion Carbon steel / stainless Internal leakage Spiral-wound 316L / graphite; RTJ in HP service Gasket leakage at joint break B7/2H; B8M on stainless Bolt corrosion Relaxation Carbon steel; mineral wool + jacket CUI at saddles SA-516 shell; SA-179 carbon steel tubes (hot diesel side) Fouling (process-side) Sulfidation 25 Fouling trend from feed (approach + DP); bundle survey at turnaround SA-516 Gr.70 / Cr-Mo by service Sulfidation Thinning SA-516 Gr.70 / clad by service Pass-partition leakage SA-179 CS / SA-213 SS / duplex / Ti by service Fouling Tube wall thinning Vibration wear at baffles Pitting Carbon steel / stainless by service Baffle corrosion Tube vibration damage SA-266 / clad forgings Tube joint leakage Crevice corrosion Carbon steel / stainless Internal leakage Spiral-wound 316L / graphite; RTJ in HP service Gasket leakage at joint break B7/2H; B8M on stainless Bolt corrosion Relaxation Carbon steel; mineral wool + jacket CUI at saddles SA-516 shell; SA-179 carbon steel tubes (atmospheric residue side, hottest crude-side fouling duty in the train) Fouling (process-side) Sulfidation Asphaltene deposition 25 Fouling trend from feed; this asset carries the twin's live flag at bundle level SA-516 Gr.70 / Cr-Mo by service Sulfidation Thinning SA-516 Gr.70 / clad by service Pass-partition leakage SA-179 CS / SA-213 SS / duplex / Ti by service Fouling Tube wall thinning Vibration wear at baffles Pitting FOULING WATCH — expressed here, at the tube-bundle component, matching the asset-level flag: crude outlet running about 9 C cool for train position and pressure drop climbing (see live values: Pressure drop). Condition hook: feed values index 0 (Crude outlet) vs index 1 (Expected outlet) and index 2 (Pressure drop). Carbon steel / stainless by service Baffle corrosion Tube vibration damage SA-266 / clad forgings Tube joint leakage Crevice corrosion Carbon steel / stainless Internal leakage Spiral-wound 316L / graphite; RTJ in HP service Gasket leakage at joint break B7/2H; B8M on stainless Bolt corrosion Relaxation Carbon steel; mineral wool + jacket CUI at saddles SA-516 shell; SA-179 carbon steel tubes (kerosene pumparound side) Fouling (process-side) 25 Fouling trend from feed; bundle survey at turnaround SA-516 Gr.70 / Cr-Mo by service Sulfidation Thinning SA-516 Gr.70 / clad by service Pass-partition leakage SA-179 CS / SA-213 SS / duplex / Ti by service Fouling Tube wall thinning Vibration wear at baffles Pitting Carbon steel / stainless by service Baffle corrosion Tube vibration damage SA-266 / clad forgings Tube joint leakage Crevice corrosion Carbon steel / stainless Internal leakage Spiral-wound 316L / graphite; RTJ in HP service Gasket leakage at joint break B7/2H; B8M on stainless Bolt corrosion Relaxation Carbon steel; mineral wool + jacket CUI at saddles SA-516 Gr.70; internal electric grid and coalescer plates stainless-clad class Corrosion under emulsion band CO2 / brine corrosion Grid insulation degradation 30 API 510; grid transformer and interface instrumentation proof checks SA-516 Gr.70 / clad by service Thinning HIC blistering (sour) SA-516 Gr.70 Thinning Carbon steel Support corrosion Fireproofing damage 316L stainless Erosion Fouling 316L mesh / PP in light service Fouling Carryover SA-105; B7/2H Flange leakage CS / 316L with armored glass Glass breakage Bridle plugging Mineral wool, aluminum jacket Jacket damage driving CUI Insulated electrodes, oil-filled transformer class Grid shorting / fouling Transformer failure Stainless plate pack Fouling Plate corrosion Tubes: 5Cr-0.5Mo (P5) radiant class; refractory IFB + ceramic fiber Creep / Stress Rupture Sulfidation Carburization at tube inlets Flue Gas Dew Point Corrosion (convection cold end) 25 Tube skin thermocouple trend + API RP 573 remaining-life class CS / 5Cr / 9Cr / HP-Nb by service Creep Sulfidation Carburization Coking inside tubes CS / low alloy, cast fins Dew point corrosion Fin corrosion High-alloy cast supports (25Cr-20Ni class) Support creep / distortion IFB 2600 + ceramic fiber modules Hot spots Brick failure Fiber shrinkage Stainless / cast alloy burner tiles and tips Tip plugging Flame impingement Tile cracking Carbon / stainless steel linkages Linkage seizure Damper warping Carbon steel; SIL-rated shutoff class Regulator failure Filter plugging Carbon steel, refractory lined lower section Dew point corrosion Damper seizure Alloy lance, steam driven Lance erosion Drive failure Inconel-sheathed TCs TC drift / failure masking hot tubes Refractory / cast alloy frames Refractory damage SA-516 Gr.70 shell; 316L clad lower / hot sections; 304L trays Naphthenic Acid Corrosion Sulfidation (bottom) Ammonium Bisulfide Corrosion (overhead circuit) CUI at skirt 30 API 510 internal at turnaround; tray survey; overhead corrosion probe trend SA-516 Gr.70 / Cr-Mo by section Sulfidation Naphthenic acid corrosion CUI SA-516 Gr.70 Corrosion thinning Fatigue at nozzle junctions Carbon steel skirt; B7 anchor bolts Atmospheric corrosion Anchor bolt corrosion 304L / 316L stainless trays, valves and downcomers Tray fouling Weir corrosion Tray uplift / damage 316L / ceramic packing and liquid distributors Packing fouling Distributor plugging 316L stainless Plugging Corrosion SA-105 forgings; B7/2H bolting Flange leakage Nozzle neck cracking Galvanized carbon steel Atmospheric corrosion Mineral wool / calcium silicate, aluminum jacket Jacket damage driving CUI SA-516 shell; duplex 2205 tubes on cooling-water side service class Cooling Water Corrosion / MIC (tube side) Ammonium Bisulfide Corrosion (process side) Fouling 25 Tube eddy-current survey class; CW chemistry trend SA-516 Gr.70 / Cr-Mo by service Sulfidation Thinning SA-516 Gr.70 / clad by service Pass-partition leakage Duplex 2205 (SA-789) tubes — cooling-water duty upgrade from the CS default Fouling Tube wall thinning Vibration wear at baffles Pitting Carbon steel / stainless by service Baffle corrosion Tube vibration damage SA-266 / clad forgings Tube joint leakage Crevice corrosion Carbon steel / stainless Internal leakage Spiral-wound 316L / graphite; RTJ in HP service Gasket leakage at joint break B7/2H; B8M on stainless Bolt corrosion Relaxation Carbon steel; mineral wool + jacket CUI at saddles SA-516 Gr.70; overhead-system corrosion class (inlet elbow and gas outlet in 316L) Ammonium Bisulfide Corrosion Ammonium Chloride Corrosion (upstream condenser outlet) Wet H2S Damage (mild) 30 API 510; overhead corrosion monitoring (iron counts / probe) SA-516 Gr.70 / clad by service Thinning HIC blistering (sour) SA-516 Gr.70 Thinning Carbon steel Support corrosion Fireproofing damage 316L stainless Erosion Fouling 316L mesh / PP in light service Fouling Carryover SA-105; B7/2H Flange leakage CS / 316L with armored glass Glass breakage Bridle plugging Mineral wool, aluminum jacket Jacket damage driving CUI SA-216 WCB casing; 316L wetted trim (wet overhead liquid); SiC/carbon seal, Plan 52 class Corrosion (wet sour condensate) Cavitation at low drum level Seal face wear 20 Vibration route + seal pot level trend SA-216 WCB cast steel Erosion-corrosion Casing thinning Cavitation damage Spiral wound / elastomer by service Joint leakage 12% Cr / 316L / duplex by service Erosion Cavitation pitting Balance loss from wear 4140 / 4145 alloy steel Fatigue at keyway Corrosion under sleeve 316L / hard-coated Scoring under packing / seal SiC vs carbon faces; FFKM / FKM elastomers Face wear Dry running Elastomer attack Hang-up 316L reservoir and tubing Barrier fluid loss Cooler fouling Rolling element, babbitt in large machines Bearing fatigue Lubrication failure Brinelling Cast iron / steel housing Oil contamination Water ingress Steel spacer coupling; steel guard Element fatigue Misalignment wear Fabricated steel, epoxy grout Grout voids (soft foot) Anchor corrosion Per motor template Per motor template SA-516 Gr.70 shell; 304L trays; reboiler thermosyphon circuit carbon steel Corrosion (wet H2S traces in feed) Tray fouling CUI 30 API 510 internal at turnaround SA-516 Gr.70 / Cr-Mo by section Sulfidation Naphthenic acid corrosion CUI SA-516 Gr.70 Corrosion thinning Fatigue at nozzle junctions Carbon steel skirt; B7 anchor bolts Atmospheric corrosion Anchor bolt corrosion 304L / 316L stainless trays, valves and downcomers Tray fouling Weir corrosion Tray uplift / damage 316L / ceramic packing and liquid distributors Packing fouling Distributor plugging 316L stainless Plugging Corrosion SA-105 forgings; B7/2H bolting Flange leakage Nozzle neck cracking Galvanized carbon steel Atmospheric corrosion Mineral wool / calcium silicate, aluminum jacket Jacket damage driving CUI SA-179 tubes, SA-516 shell Fouling Sulfidation (mild) Carbon steel stack and header; flare tip 310 stainless class High-temperature oxidation / thermal fatigue (tip) Header low-point corrosion 25 Continuous pilot monitoring; tip survey by outage / drone class Carbon steel large-bore Low-point corrosion Liquid accumulation SA-516 Gr.70 Corrosion Level failure Carbon steel Seal loss (flashback protection) Carbon steel Guy / derrick corrosion 310 SS / Inconel class Tip burnout Cracking Stainless pilots, dual TC class Pilot outage (the reportable failure) Panel + spark class Ignition failure Carbon steel / stainless internals Purge loss (air ingress) Carbon steel Assist failure (smoking flare) Structure: treated timber / FRP class with galvanized steel; fill PVC; basin concrete; fan blades composite Fill fouling / scaling Timber / FRP degradation Basin corrosion and leakage Fan drivetrain wear 25 CTI class inspection; fan vibration route; fill condition survey at outages Treated timber / FRP, galvanized hardware Structural degradation Fastener corrosion PVC film fill Fouling Scaling Biological growth PVC Fouling UV degradation PVC / FRP piping, PP nozzles Nozzle plugging Pipe cracking Composite blades, steel hub Blade erosion Imbalance Cast iron gearbox, composite shaft Gear wear Bearing failure Oil degradation TEFC motor, moisture-resistant class Per motor template Reinforced concrete Concrete attack Leakage Silt accumulation Stainless screens; level transmitter Screen blockage Each component template lists its components with a per-item count. The rollup multiplies per-item counts by the item count for that class (equipment counts from the plant register; pipe spools derived from piping length; tubes and trays counted individually at plant-average counts stated in the templates). All totals are reference estimates derived by this stated method, not a real plant count. FCC equilibrium catalyst inventory Reactor / regenerator circulating inventory 220 Reference estimate, not a real plant value Bulk volume about 260 m3 at settled density class. Metals (Ni/V) passivation is part of the makeup strategy class. Hydrocracker catalyst inventory 3 reactors, pretreat + cracking beds 180 Reference estimate, not a real plant value About 150 t. NiMo pretreat plus NiMo/zeolite cracking classes; qualitative composition only. Diesel hydrotreater catalyst inventory 2 reactors 140 Reference estimate, not a real plant value About 110 t, CoMo / NiMo on alumina classes. Naphtha hydrotreater catalyst inventory 2 reactors 60 Reference estimate, not a real plant value About 48 t. Guard bed for metals / silicon is part of the loading class. Reformer catalyst inventory 4 reactors, continuous regeneration (CCR) class 90 Reference estimate, not a real plant value About 70 t, Pt on chlorided alumina class. Chloride management is part of the operating model. Isomerization catalyst inventory 2 reactors 45 Reference estimate, not a real plant value Pt on chlorided alumina plus zeolite classes; water / sulfur are poisons, feed guard is modeled. Claus catalyst inventory 3 converter beds 75 Reference estimate, not a real plant value About 60 t activated alumina; titania class in converter 1. Tail-gas hydrogenation catalyst (CoMo class) about 20 m3 additional. SMR catalyst and adsorbent inventory Reformer tubes, shift beds, PSA vessels 28 Reference estimate, not a real plant value Plus HT shift about 15 m3 (Fe-Cr class), LT shift about 10 m3 (Cu-Zn class), PSA adsorbent about 120 m3 (carbon / molecular sieve classes). Amine inventory (MDEA class) Absorber / regenerator loop 120 Reference estimate, not a real plant value Heat-stable salts and reclaiming are part of the inventory model; amine corrosion is the linked damage mechanism. Sulfuric acid inventory (93% H2SO4) Acid contactor loop + storage 450 Reference estimate, not a real plant value Dedicated tank inside its own containment: bund sized at 110% of largest tank class. Acid-resistant lining in the contactor; Monel trim on acid valves (see materials). Caustic inventory (NaOH, 20-50%) Product treating and water treatment 60 Reference estimate, not a real plant value Shared plant chemical: caustic washing, neutralization and boiler water treatment. Emulsion breaker (demulsifier) Crude charge injection at desalter 8 Reference estimate, not a real plant value Day-tank plus bulk tote storage class; injection point modeled with the desalter. Corrosion inhibitor + neutralizing amine Overhead and product treating injection 10 Reference estimate, not a real plant value Filming inhibitor and neutralizer stocked as separate classes. Cooling water treatment chemicals Cooling water system 15 Reference estimate, not a real plant value Legionella control program is a modeled procedure class on the cooling towers. Organic chloride agent (isomerization) Reactor feed injection 4 Reference estimate, not a real plant value Small inventory, high consequence: dedicated contained storage class. Oxygen scavenger + boiler water chemicals Boiler feedwater system 6 Reference estimate, not a real plant value Sulfite / carbohydrazide class scavenger plus phosphate / polymer program. Steam, high pressure (about 42 barg header) Boilers + cogeneration + waste-heat recovery 272 Reference estimate, not a real plant value 600,000 lb/h matches UTL-1500 design capacity in v1. Distribution: HP to turbines and SMR, MP process, LP heating; unit-level steam figures live in each unit's energy layer. Fuel gas + natural gas import Refinery fuel system 1832 Reference estimate, not a real plant value Refinery fuel gas from process units first, natural gas import as balance. Matches plantEnergy.fuelConsumptionMMBtuPerH in v1. Hydrogen balance HGN-1400 + REF-400 production; HCU / DHT / NHT / ISO consumption 138 Reference estimate, not a real plant value Supply: SMR 120 MMSCFD design (115 simulated) + reformer byproduct about 18 MMSCFD. Consumption class: hydrocracker about 70, diesel HT about 30, naphtha HT about 10, isomerization about 2, losses and fuel balance the remainder. Reference balance, labeled. Cooling water circulation Cooling towers CT-1001 class + cells 120000 Reference estimate, not a real plant value Makeup about 1,800 GPM class (evaporation, drift, blowdown) from raw water; blowdown to WWT-1600. Raw / process water makeup Water treatment and distribution 1800 Reference estimate, not a real plant value Feeds cooling makeup, boiler feedwater demineralizers, process wash water (desalter) and firewater replenishment. Nitrogen Onsite generation / liquid backup 15000 Reference estimate, not a real plant value Blanketing, purging, catalyst work and instrument backup; liquid N2 storage backup class. Instrument air Compressors + dryers 12000 Reference estimate, not a real plant value Oil-free, dried to -40 C dew point class; receiver capacity sized for ride-through class. Wet air is a named plant-wide failure mode in the valve templates. Lubricating oil inventory Rotating equipment lubrication 45 Reference estimate, not a real plant value ISO VG 46 / 68 classes in a central lube room plus machine sumps; oil analysis program is the modeled condition attribute (see materials library, lube-oils). Seal support fluids (Plan 53 barrier fluid) are an additional modeled class at pump level. Mechanical seal sets and dry-gas seal cartridges Pump classes by frame and seal plan; compressor cartridges per machine 1 spare set per critical pump class; 1 cartridge set per compressor (reference class) Spare exchanger tube bundle Critical preheat train and reactor effluent services 1 bundle per critical train class (reference) PSV spare pool Tested, sealed spares by set pressure / orifice class About 5% of installed PSVs (reference class) Control valve trim sets and positioners Severe-service and critical loops 1 trim set per severe-service valve class (reference class) Spare motors by frame size Critical services without installed spares 1 per frame / rating class on critical list (reference class) Mobile / spare transformer Unit substation backup 1 mobile unit substation class (reference) Hardened electronics spares (DCS / SIS cards, positioners, transmitters) Command and control spares, stored in the shielded spares enclosure (see protection layer) Critical-card coverage per system (reference class) Protection is modeled here as design requirements on a reference plant. A status of 'Modeled' in the matrix means the design requirement is written into this twin's register for that unit. It does not mean any real plant is protected: this is a reference model, no operator data, and no protection claim is made for any real facility. Statuses: Modeled = design requirement modeled in the register. Partial = the layer applies in reduced form at that unit. Roadmap = requirement identified, design not yet modeled at that unit. Cyber and command integrity A command that reaches iron must be authorized, signed, and arbitrated. Control authority lives at the asset; remote command is a delegation, never a seizure. The aggregation layer is the one door, and it checks every key. IEC 62443-3-2 (zones and conduits, risk assessment) IEC 62443-3-3 (system security requirements, security levels) IEC 61511 (SIS independence) NIST SP 800-82 (OT cybersecurity guidance class) IEC 62443 zones and conduits modeled for the whole plant: field (L0/L1), control (L2), operations (L3), industrial DMZ (L3.5), enterprise (L4/L5). Every cross-zone path is a named conduit in the register. Security level targets by zone: SL-T 2 for basic process control zones; SL-T 3 target for the SIS zone and for the command / aggregation zone. SIS independence per IEC 61511: safety sensors, logic solvers and final elements separate from the BPCS, on their own network; SIS status leaves the zone one-way only (data-diode class export). Hybrid command authority: the asset holds authority by default. Remote command operates as a delegation through the aggregation layer with deterministic arbitration (local wins on conflict) and a logged, reversible handoff between local and remote control. Protocol-mediation aggregation layer as the single policy enforcement point: heterogeneous device protocols (Modbus, OPC UA, HART and vendor classes) are mediated into policy-checked command objects before anything reaches a controller. Signed commands: every command object carries a digital signature and a nonce; controllers and aggregation nodes reject unsigned or replayed commands. Signature algorithms per the quantum-safe layer. Hardware-anchored trust: keys for command signing and node identity live in TPM / secure-element class hardware on aggregation nodes and engineering workstations; measured-boot attestation before a node may mediate commands. Purdue level is a register attribute on every modeled control system, so the command path of any asset can be drawn from the register alone. Main control building; the policy enforcement point for all remote command One-way SIS status out of the safety zone TPM-anchored keys, application allow-listing class L3 / L3.5 class; no direct enterprise-to-control path exists in the model Emanations security (Van Eck / TEMPEST class) Computers and control electronics radiate. What radiates can be read. Command spaces are therefore built so that what they radiate stays inside them: separation, shielding, and fiber where copper would carry a signal out of the room. TEMPEST-class installation practice NATO SDIP-27 equipment emanation levels (reference targets only) Red / black separation guidance class Red / black separation inside the main control building and satellite instrument houses: red (command-bearing) equipment, cable and power physically separated from black (general plant) systems, with separate power feeds and grounding paths per class. Fiber preference on command links: every command link that leaves a building is fiber-optic. Copper command links do not cross building boundaries. Shielded construction for critical command paths: shielded tray and conduit inside zones; aggregation cabinets are shielded enclosures with filtered power and signal entries (shielding targets shared with the directed-energy layer). Emanation control zones modeled around the main control building and each aggregation cabinet. Equipment inside a zone carries an emanation class attribute in the register: SDIP-27 Level B style target for command equipment, Level C style for general control equipment. Stated as design targets, never as test results. No wireless command paths inside emanation control zones. Wireless instrumentation, where present, is monitoring-only and physically outside the command path. Emanation class is a modeled attribute per instrument / controller class in the register, so a scan of the register lists every emitter class inside each zone. Red/black build-out, shielded aggregation cabinets, filtered entries No copper command path crosses a building boundary Shared with the directed-energy layer penetration treatment Directed energy, EMP and HPEM hardening A pulse or a beam does not care about your firewall. Hardening is physical: shield the rooms that command, protect every wire that enters them, bond everything to one grid, bury what matters, and keep spares that survive the event they recover you from. MIL-STD-188-125-1 concepts (HEMP protection of fixed facilities), used as design targets IEC 61000-4-23 / 61000-4-24 class test concepts IEEE C62 surge protective practice NFPA 70 / IEEE 80 grounding class Shielding effectiveness targets (design targets, labeled as targets, not test results): main control building 80 dB across 10 kHz to 10 GHz; critical cabinets and satellite instrument houses 60 dB. Every penetration of a shielded boundary is treated: filtered power entries, fiber signal entries, waveguide-below-cutoff ventilation, shielded doors with conductive gasket class seals. An untreated hole voids the target and is modeled as a defect. Surge protective devices: Type 1 SPDs at service entries, Type 2 at distribution panels, and signal-line protectors on every copper line entering a shielded zone. About 380 devices plant-wide (reference estimate). Bonding and grounding modeled as an asset: plant ground grid under all unit plots, about 450 ground rods (reference estimate), welded (exothermic class) connections, two-point bonding for critical cabinets. The grid is in the register like any other asset, with condition inspection. Critical cable runs (command backbone, SIS runs between buildings) buried or in shielded conduit. Hardened spares storage: critical electronics spares (DCS / SIS cards, positioners, transmitters) stored in a shielded (Faraday class) enclosure. Exposed optical and flame sensors (flare pilots, flame detectors) get redundant sensing classes rather than shielding claims; sensor blinding is answered with redundancy and voting, stated plainly. Modeled as an asset with its own components and inspection Power entries, distribution, and signal lines into shielded zones Holds the critical electronics spares in the resources layer 80 dB / 60 dB targets as above Storm and weather resilience On the Gulf Coast the design storm is not a scenario, it is a schedule. Structures, tanks and the control building are rated for it in the register, lightning is treated as a system with countable parts, and the hurricane itself is a modeled procedure with named steps. ASCE 7-22 (loads; Risk Category IV for critical facilities) NFPA 780 (lightning protection systems) API RP 752 / 753 (building siting and blast class for occupied buildings) Design wind: ultimate design wind speed 170 mph class, Exposure D (coastal), Risk Category IV for the control building, substations, flare and structures whose failure escalates an event; Risk Category III minimum elsewhere. Wind rating is a register attribute per structure class. Flood: design flood elevation = base flood elevation + 2 ft freeboard (reference target). Critical electrical and control equipment is set above the design flood elevation. Site drainage is sized to the 25-year storm class with surge routing to WWT-1600; tank bunds hold 110% of the largest tank plus a rainfall allowance class. Lightning protection per NFPA 780, modeled as components: air terminals (about 140, reference estimate) on buildings and non-self-protecting structures, down conductors (about 280), and bonding to the plant ground grid. Steel tanks and spheres of qualifying wall thickness are self-protecting class per NFPA 780 and are bonded, not terminal-fitted; the rolling-sphere method is applied to columns and the flare. Hurricane securing actions modeled as procedures in the register: tank level management ahead of landfall, crane and loose-material securing, flare pilot redundancy verification, control building readiness, and a safe-shutdown decision tree class with named decision points. Temperature design envelope: ambient -18 C to 49 C class (Gulf Coast reference), minimum design metal temperature per ASME class, and freeze protection (tracing class) on water, amine and caustic lines. Components modeled in the structures and tank templates; bonded to the ground grid asset Surge routing to WWT-1600 Modeled procedures with named steps, not equipment Quantum-safe locking of command and evidence Quantum locking, in xGRIDx usage, is the locking of command authority and of the evidence record with cryptography that survives a quantum adversary: post-quantum signatures on commands, post-quantum key establishment on command links, and a hash-chained, anchored evidence trail for the twin itself. It is a cryptography requirement, not quantum hardware in the plant, and this register says so wherever the term appears. NIST FIPS 203 (ML-KEM key establishment) NIST FIPS 204 (ML-DSA signatures) NIST FIPS 205 (SLH-DSA, hash-based signatures) NIST post-quantum migration guidance class Post-quantum key establishment: ML-KEM (FIPS 203), 1024 class, for command-link session keys, run hybrid with classical ECDH during the transition period. Design requirement; deployment is roadmap at unit level. Post-quantum signatures: ML-DSA (FIPS 204), 87 class, on signed command objects (the cyber layer's signed commands) and on twin register releases, so the register itself is signed evidence. Crypto-agility: a maintained algorithm inventory for every command and evidence path in the register; negotiated algorithm suites; no hard-coded single-algorithm dependency is accepted in the design. Tamper-evident evidence anchoring: every change to the twin register is hash-chained and anchored (the platform's existing anchored-evidence pattern), so the twin's state history can be verified independently of any single server or operator. Quantum key distribution (QKD) is an evaluation track only, for the control-building to aggregation backbone (the highest-value, shortest links). Status: emerging option. It is not deployed technology, it is not part of the protection claim, and no unit in the matrix is credited with it. Terminology rule: wherever 'quantum locking' appears in xGRIDx material it means this layer exactly: quantum-safe locking of command and evidence as defined here. Algorithm-agile; ML-KEM / ML-DSA as the design requirement Hash-chained and anchored; register releases signed Every command and evidence path, with its suite and migration state