QHSE Manual -- Chemical Tanker Operation Manual – Section 9

Date: 1 - 1 - 2024
Rev: 3

6CT.9 STAINLESS STEEL

6CT.9.1 INTRODUCTION

Stainless steel depends for their corrosion resistance on the formation of a passive surface
film, which is composed, mainly of chromium oxide. Although this film forms

y
spontaneously when the metal is exposed to air or to water, it is possible to damage or
contaminate the surface during fabrication or by service operation so that the ability to

nl
form a satisfactory film is impaired. It is necessary to avoid or correct such damage if the
optimum corrosion resistance of the stainless is to be obtained. The thickness of oxide
film is about one millionth of a millimeter on the surface of stainless steel. Despite the
thinness of this film provided, it will provide good corrosion resistance.

O
After completion of tank cleaning, it is essential to steam stainless steel cargo tanks and
ventilate thoroughly. Empty tanks are to be further ventilated on a weekly basis.

e
6CT.9.2 CORROSION RESISTANCE OF AUSTENITIC STAINLESS STEELS
nc
6CT.9.2.1 PITTING

Certain specific agents such as halides cause a local breakdown of the passive film on the
steel surface. This highly localized breakdown followed by electrochemical action results in
re

pitting which rapidly propagates into steel. Chlorides are particularly conducive towards
this form of attack even when present in minute quantity.

Collection of solid sludge’s on the surface of stainless steel may also result in pitting.
e

When sludge is known to be present in certain type of cargoes, means of circulating the
cargo should be provided e.g. phosphoric acid.
ef

6CT.9.2.2 CREVICE CORROSION

Rapid corrosion will occur in narrow crevices / geometric irregularities in the metal
R

surface where oxygen cannot gain access. It is essential to design tanks with this in mind.
All welds are smooth finish and all spatter is removed.

6CT.9.2.3 STRESS CORROSION CRACKING

r
Fo

This may be defined as the fracture of a component by the conjoint action of a tensile
stress in a corrosive environment. The failure of this is confined to environments
containing sodium hydroxide, sulphides, halides and mainly chlorides.

Chlorides are particularly conducive to this form of attack and cracking, which is trans-
granular and found most frequently in the Ph range of 3 to 8. Cracking associated with
caustic solutions may be either trans or granular and is usually confined to solutions of
high concentrations and with temperatures in excess of 55C.

1
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

6CT.9.2.4 INTERGRANULAR ATTACK (WELD DECAY)

If the steel is heated in the temperature range of 500 to 850C the carbon may precipitates
as chromium carbide at the grain boundaries. These areas become denuded of chromium
and the protective oxide film is prevented from forming.

y
6CT.9.3 APPLICATION OF STAINLESS STEEL ON BOARD THE VESSEL

nl
6CT.9.3.1 SOLID STAINLESS STEEL

The tanks are built of full stainless steel plates. The problem with using solid stainless steel
is that the space outboard of the tanks contains mild steel, which is used for water ballast

O
tanks.

This causes bimetallic corrosion causing the mild steel to corrode preferentially and the
corrosion is generally overall. There may also be pitting of stainless steel due to the

e
deposition of the mild steel. nc
This corrosion could be avoided by coating both the steels, but the corrosion would start
with the breakdown of coating.

6CT.9.3.1 CLAD STEEL

re

The term clad steel refers to a mild steel base plate to which a thinner layer of a stainless
steel is continuously and integrally bonded. In this way cost of vessel could be reduced the
mild steel side is used in water ballast tanks and the difficulties of bimetallic corrosion in
e

connection with the use of solid stainless steel are avoided.

ef

6CT.9.4 WELDING

A correct procedure and correct consumables shall be used for welding of stainless steel
to prevent weld joints to crack (for eg. Welding rod MOL916L).
R

It is important that the heat input during welding is kept low to ensure a small heat
affected zone and exposure to the sensitizing temperature range for the shortest possible
time. After carrying out the welding repairs, localized pickling shall be done by applying
r

pickling paste.
Fo

6CT.9.4.1 WELDING OF SOLID STAINLESS STEELS

For butt welds the V preparation has been used successfully in the construction of ships
tanks for both flat and vertical positions. Some times for welding of thick plates copper
backing bars are used. The copper backing bars extracts heat during welding and also
gives profile to the root bead.
In order to avoid distortions for thicker plate’s double V preparation with separate runs
deposited alternately one on each side of the joint is used.

2
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

6CT.9.4.2 WELDING OF CLAD STEEL

Welding of clad steel plates generally involves separate treatment procedures for steel
base and cladding material. The weld deposit for the backing plate must at least match
the strength of the carbon steel parent material , the usual practice is to choose an
electrode, which would be used, if the cladding was not present. If this carbon steel weld

y
metal comes in contact with the corrosion resistant cladding, the weld material will be
diluted by the alloy and the deposit is likely to hard and brittle. This problem is offset by

nl
using of filler materials having alloy contents greater than those of the parent stainless
steel.

Generally the first weld made from carbon steel backing side should penetrate to the

O
stainless cladding but not into this layer. The backing side should be completed before
chipping back to clean metal on the clad side. Sufficient metal should be removed to
allow at least two runs of alloy weld metal to be deposited. The first two runs are made
by using filler materials having alloy contents greater than those of the parent stainless

e
steel. For subsequent runs should be made with a view to ensuring that the deposited
metal matches the composition of the clad material and that the properties are not
impaired.
nc
6CT.9.5 CORROSION OF STAINLESS STEEL IN SEA WATER
re

Stainless-steel tanks left in prolonged contact with static sea water will develop pitting.
This is due to the local breakdown of the passive film when chloride ions are present. Such
pitting is likely to occur at crevices or under deposits where access to oxygen to the
surface is restricted.
e

The possibility of stainless-steel pitting is increased if the Ph of the seawater is reduced

from normal level of about 8. Therefore,
ef

- Ensure cargo tanks are well fresh-water rinsed after sea water wash.
- Steam stainless steel cargo tanks after completion of tank washing to minimize
exposure to chloride ions.
- When tank washing of cargoes in acidic nature, the quantity of seawater used
R

must be the maximum possible to minimize the drop in Ph.

- As far as possible, do not stow seawater wash water or ballast in stainless steel
cargo tanks. According to steel makers, stowing ballast or sea water slops for more
r

than three days in stainless-steel tanks will expose the tanks to severe
pitting/corrosion, and is to be avoided.
Fo

3
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

6CT.9.5.1 MATERIALS

Chemical Composition of Stainless Steel:

Stainless Chemical composition

Steel
C Si Mn P S Ni Cr Mo Others

y
standards
0.08 1.00 2.00 0.045 0.030 8.00– 18.00–
SUS304

nl
max. max. max. max. max. 10.50 20.00
0.08 1.00 2.00 0.045 0.030 10.00– 16.00– 2.00–
SUS316
max. max. max. max. max. 14.00 18.00 3.00

O
0.030 1.00 2.00 0.045 0.030 12.00– 16.00– 2.00–
SUS316L
max. max. max. max. max. 15.00 18.00 3.00
0.030 1.00 2.00 0.045 0.030 10.50– 16.50– 2.00– N
SUS316LN
max. max. max. max. max. 14.50 18.50 3.00 0.12–0.22

e
6CT.9.6 REPAIR AND MAINTENANCE OF CARGO TANKS AND COATINGS
nc
6CT.9.6.1 INSPECTION OF TANKS

Whenever possible, cargo tanks are to be inspected internally prior to every loading. This
re

is subject to the tanks being gas free and fit for entry. Enclosed space entry procedures
documented in QHSE Manual Section 9.14.3 shall be complied with.

6CT.9.6.2 ITEMS TO BE CHECKED

e

1. Condition of tank coating for coated tanks, and condition of surface of the steel in case
ef

of SUS tanks, and tank cleanliness.

2. Condition of structural members and plating, confirming no structural distortion.
3. Any cracks in the structure or in the welding.
4. Condition of heating coils, check tightness of nut / bolt.
R

5. Condition of ladders and other fittings, such as gauging and temperature monitoring.
6. Condition of pipelines and supports.
7. Condition of tank openings, seals and securing arrangements.
8. Condition of the deep-well pumps, and pump stacks if fitted.
r
Fo

Presence of cracks can be detected by looking for rust weepings / discolouration of the
coating / surface

6CT.9.6.3 REPAIR OF CRACKS/DAMAGE

As far as possible, permanent repairs are to be carried out for the repair of
cracks/damage.

Cracks are to be gouged out, arrested and then re-welded. After completing repairs,
localized passivation should be carried out using pickling paste.

4
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

6CT.9.6.4 REPAIR OF TANK COATINGS

The importance of maintaining the tank coatings in top condition cannot be overstated.
Maintenance shall be carried at every opportunity. In coated tanks coating manufacturer’s
instructions shall be followed with regard to surface preparation, application of coatings
and curing time. Some general precautions:

y
• Surface shall be thoroughly de-rusted.
•

nl
Edges shall be feathered (smoothened) by using disc grinder.
• Wipe the bare metal with methanol / thinner prior application of the first coat.
• Coating should be applied by brush and not by roller. Overlap of the surrounding area
should be kept to bare minimum.

O
• Humidity in the tank shall be controlled in accordance with manufacturer’s
requirements.
• Epoxy coatings require low relative humidity (dry air) - Running ventilation fans in

e
conjunction with steam to heating coils crack open is a good way to raise the air
temperature and reduce relative humidity.
• Zinc Silicate coatings require high humidity at the time of application and during curing
nc
- A steam hose lowered into the tank with the valve crack open raises the relative
humidity in the tank.
• Ensure sufficient coats are given to obtain the necessary manufacturer’s required dry
film thickness.
re

• Over coating interval should be in accordance with the manufacturer’s instructions.

• Sufficient curing time is to be allowed. While the temperature of the air in the tank
may be high, the substrate temperature may be quite low in the case of tanks exposed
to seawater on the outboard side. In this case, the sea water temperature should be
e

used when referring to the curing time table.

ef

6CT.9.6.5 PRECAUTIONS PRIOR CARRYING OUT REPAIR AND MAINTENANCE

Prior carrying out repair and maintenance of cargo tanks, pipings, pumps, valves, heating
coils and any associated cargo or ballast handling systems, the following precautions must
R

be complied with.

1. The area/equipment is free and clean of cargo.

r

2. There is adequate ventilation.

3. The equipment has been isolated from the power supply.
Fo

4. All cargo lines / valves have been sealed/lashed and the lines positively blanked to
isolate the compartment.
5. Staff are provided with adequate PPE as per Company PPE requirements.
6. ‘Entry into enclosed space’ and ‘Hot work’ is to be carried out in accordance with
relevant section of the ‘QHSE Manual Section 9.14.3’.

5
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

6CT.9.7 PICKLING AND PASSIVATION

After carriage of aggressive cargoes, stainless steel may require complete pickling or
passivation. The decision for pickling or passivation should be taken only after obtaining
test results of stainless steel ‘Palladium/Passivation meter test’.

y
Passivation of stainless steel tanks should be checked:
- At an interval not exceeding 12 months,

nl
- Prior loading cargoes aggressive to stainless steel (e.g. Phos Acid, Sulphuric Acid, EDC).
- Post tank cleaning of aggressive cargoes.
6CT.9.7.1 TESTS

O
To determine if stainless steel is active or passive, one of the tests shall be carried out. At
least three sections of each single bulkhead / tank-top shall be tested.

e
1. Palladium Test Procedure: Palladium Chloride bottle has to be stored in dark/dry/cool
place. Its shelf life is at least one year. The effectiveness of Palladium Chloride solution
nc
can be tried out by lightly scoring small stainless-steel object and carry out the test as
follows:
• Make the test area free from oil and grease.
• Add one drop of Palladium Chloride on the test area of the stainless steel.
• After 3 to 5 minutes, the Palladium Chloride can be wiped of by the use of clear
re

tissue. Do not touch surface with hand.

• Investigate the colour of the treated area.
Colour Result
e

No Change in Colour PASSIVE

Discolouration to black ACTIVE
ef

Discolouration (Grey) Doubtful, needs to be monitored

2. Passivation Meter (KUSLOW) Test: The Passivation meter is similar to a thickness

gauging instrument.
R

• Connect black probe to the tank surface.

• Put a drop of ‘Acetic Acid’ on cotton swab and put it on the tank surface.
• The red probe tip should be placed on cotton swab and measure the meter
reading.
r

• Assessment of readings:
Fo

Reading Result
Zero to -400 Passivated
-400 to -500 Indeterminate
-500 to -1100 Active

3. Passivation Meter (STEINCHECKER) Test: The Passivation meter uses Sulphuric Acid
for measuring.
• Connect black probe to the tank surface.
• Clean the tip by fine emery paper.

6
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

• A drop of Sulphuric Acid is put on the paper and the tip is pressed over it to the
surface being measured.
• The difference in voltage will indicate the tank status.
• Assessment of readings: (Please refer to the maker’s instructions).
Reading Result
0.6V (for 60 seconds) Passivated

y
0.6V to 0.2V (less than 60 seconds) Active

nl
6CT.9.7.2 PICKLING

Picking method is used for the removal of any rust, oxides and discolouration from the

O
welding or from cargoes. Pickling solution containing nitric acid and hydrofluoric acid shall
be applied.

Precautions for picking (and passivation)

e
- Ensure correct PPE level (corrosive cargoes) is utilized.
- For pickling and passivation with Nitric acid, ensure nitic acid resistant tank
cleaning hoses are utilized and tank cleaning machines seals are resistant to acids
(Kalrez or similar material).
nc
- No personnel is to stand in the vicinity of the tank cleaning machines to avoid
accidental exposure to acidic contents.
re

PROCEDURE FOR PICKLING:

1. Tank surface must be free from oil. Tanks shall be washed with a non caustic alkaline
detergent.
e

2. The surface must be thoroughly flushed with fresh water.

3. Pickling is carried out with a mixture of Hydrofluoric acid (2-3%) and Nitric Acid (12-
ef

13%).
4. The duration of the pickling is approximately 3 to 4 hours in each cargo tank, by
recirculation method at various heights, depending on the local atmospheric
temperature.
R

5. In general, 2-3 tanks can be applied for pickling one after another in turn by the same
pickling liquid. If pickling liquid’s iron content exceeds 5000PPM, the pickling solution
has to be renewed.
r

6. After completion of the pickling, the tank surface has to be flushed with cold fresh
water until the pH of the flushing water has a pH of 7.0.
Fo

7. As Hydrofluoric acid contained in pickling liquid destroys the layer of Chromium oxide,
ventilation for minimum of 12 hours per tank has to follow immediately after final
wash.

6CT.9.7.3 PASSIVATION

1. Passivation shall be carried out after surface repair by grinding, pickling and after
carriage of aggressive cargoes such as Sulphuric Acid or Phosphoric Acid.
2. Stainless Steel tanks are usually passivated by application of 15% Nitric Acid. This acid
is strongly oxidizing and assists in building up the passive chromium layer on the

7
 QHSE Manual -- Chemical Tanker Operation Manual – Section 9
Date: 1 - 1 - 2024
Rev: 3

surface of stainless steel. A higher concentration is required for removing very

persistent discolouration.
3. The duration of the passivation is approximately 3.0 to 4.0 hours, by recirculation
method at various heights, depending upon ambient temperature.
4. Same solution can be used for 2-3 tanks. But top up of additional Nitric acid may be
required to maintain effectiveness.

y
5. Concurrent to passivation, pass passivation liquid through cofferdam, followed by
thorough flushing.

nl
6. Post freshwater rinse, additional rinsing of cargo pump pump-stack (shadow area)
may be necessary.

VENTILATION:

O
After passivation, it is essential to carry out forced ventilation. The formation of passive
layer of Chromium oxide is by ventilation. At least 24-36 hours ventilation is required for
cargo tank to become truly passive. This has to be confirmed by checking the passivation

e
readings. nc
6CT.9.7.3.1 CITRIC ACID PASSIVATION

Citric Acid is less corrosive than Nitric Acid, thus reduces hazards associated with handling
corrosive chemicals. Some Charterers may request passivation of cargo tanks to amend
re

last cargo history and Citric Acid passivation remains preferred alternative over Nitric
Acid.

Procedure of Citric Acid passivation is detailed below;

e

1. Recirculation using Citric Acid is carried out with 4~5% concentrated solution.
ef

2. Make as solution of 4m3 FW and 200kg Citric Acid flakes in the first tank.
3. Recirculate this solution in the first tank for 2 hours. Maintain PH level between 1.8 -
2.2.
4. This solution can be further recirculated upto 3 tanks by adding 0.5m3 FW and 25KG
R

Citric Acid in each tank.

5. After recirculation, Butterworth the tank using FW for one hour and more, until the PH
value is observed near 7.
6. During the recirculation, ensure that all drop/drain/manifold/stripping lines are
r

thoroughly flushed with passivation solution for atleast 15-20 minutes.

Fo

7. Each tank shall be ventilated for minimum 24 hours to 48 hours.

8. After gas-freeing, check the passivation reading using passivation meter and maintain
records onboard.