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Flow Flow- -Accelerated Accelerated
Corrosion Solutions Corrosion Solutions Corrosion Solutions Corrosion Solutions 2010, Lucius Pitkin, Inc. Flow Flow--Accelerated Accelerated Corrosion? Corrosion? Flow-Accelerated Corrosion (FAC) is a chemical corrosion process that causes wall loss in piping Flow Flow Accelerated Accelerated Corrosion? Corrosion? process that causes wall loss in piping. FAC is caused by the dissolution of the oxide layer on the inside surface of piping in flowing water or wet the inside surface of piping in flowing water or wet steam. This affects carbon or low allow steel. The pipe wall p p thickness can progressively be reduced to the point of rupture. FAC i ll l t d t t b l i ll FAC is normally related to turbulence especially near fittings, e.g., elbows, orifices, valves 22 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Mihama Mihama Unit Unit 33 -- -- 2004 2004 Mihama Mihama Unit Unit 3 3 2004 2004 A 22 inch condensate line downstream of an orifice ruptured catastrophically catastrophically Five fatalities and several injuries l d resulted Failure was downstream of an downstream of an orifice 33 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Millstone Millstone 33 1990 1990 Millstone Millstone 3 3 1990 1990 Simultaneous failure of t 6 i h d i li two 6-inch drain lines downstream of the moisture separator p drain tank Failures were downstream of level downstream of level control valves Two parallel trains p failed. 44 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Fort Fort Calhoun Calhoun -- -- 1997 1997 Fort Fort Calhoun Calhoun 1997 1997 Failure in a hi h high pressure extraction line. Failure Failure occurred in bend. 55 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Pleasant Prairie Power Pleasant Prairie Power Plant Plant -- -- 1995 1995 Failure in a f d t t t feedwater system to a fossil fueled boiler. Failure occurred downstream of a tee tee. Two workers killed. 66 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Single and Two Phase Systems Single and Two Phase Systems Single and Two Phase Systems Single and Two Phase Systems FAC occurs in both single and two phase systems. g p y These systems include: Feedwater d Condensate Extraction/Bleed Steam Heater Drains and Vents Boiler Blowdown Others 77 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved What Factors Influence What Factors Influence FAC FAC?? Material Chemistry Chromium Copper Molybdenum Water Chemistry Water Chemistry pH O 2 Concentration O 2 Concentration Temperature Geometry and Steam Quality 88 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Geometry and Steam Quality Material Chemistry Material Chemistry yy Affects Carbon Steel and Low Alloy Steel As Chromium increases, FAC rate , decreases. This is the primary element that affects FAC As Copper increases, FAC rate decreases. decreases. As Molybdenum increases, FAC rate increases 99 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved increases. FAC Wear Rates FAC Wear Rates Decreases as Decreases as Chromium Content Increases Chromium Content Increases 10 10 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Water Chemistry Water Chemistry yy pH pH influences the solubility of the oxide film. H l i f h b d i i lif pH control is one of the best ways to extend piping systems life pH should be as high as possible to provide the best FAC protection. O C t ti O 2 Concentration Oxygen affects the composition of the surface oxide layer Higher oxygen levels increase the stability of the surface oxide hi h d th t f FAC which reduces the rate of FAC. Temperature Temperature affects the formation and solubility of the oxide layer. At moderate temperatures (> 250F - 400 F) the magnetite layer is porous and irregular. FAC rate is the highest. 11 11 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved FAC Wear Rates as pH Increases FAC Wear Rates as pH Increases 12 12 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved FAC Wear Rates as Oxygen Level FAC Wear Rates as Oxygen Level Increases Increases Increases Increases 13 13 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved FAC Wear Rates FAC Wear Rates as Temperature as Temperature Increases Increases Increases Increases 14 14 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Geometry and Steam Quality Geometry and Steam Quality y Q y y Q y Higher velocity gives higher FAC rates Transitions in geometry, like at elbows, orifices, tees, valves, and other changes , , , g in flow direction creates turbulence and increases FAC susceptibility. p y Both single phase and two phase flows can cause FAC. can cause FAC. 15 15 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved FAC Wear Rates as Velocity FAC Wear Rates as Velocity IIIncreases Increases 16 16 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved FAC Thinning FAC Thinning FAC Thinning FAC Thinning Single phase FAC damage looks like small scallops or g p g p has an orange peel appearance. The edges of the scallops are usually fairly smooth. Two phase flow damage may have a tiger striped appearance. There may be plateaus on the pipe surface over a fairly wide area. surface over a fairly wide area. 17 17 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved FAC Damage FAC Damage FAC Damage FAC Damage Single phase Single phase FAC damage looks like small scallops. 18 18 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved 18 18 FAC Damage FAC Damage FAC Damage FAC Damage Tiger Striping Tiger Striping. 19 19 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved 19 19 An Effective FAC Program An Effective FAC Program gg System Susceptibility Screening y p y g Input on Operations, Maintenance, Water Chemistry Computer Modeling (EPRI Codes commonly used) Selection of Inspection Locations Inspections l l f Structural Evaluation of Inspection Data Component Life Determination Mitigating Actions to Slow the FAC rate if necessary Mitigating Actions to Slow the FAC rate, if necessary 20 20 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved Methods to Mitigate FAC Damage Methods to Mitigate FAC Damage Methods to Mitigate FAC Damage Methods to Mitigate FAC Damage Improve Water Chemistry Improve Water Chemistry Use Improved Materials System Design Changes System Design Changes 21 21 Lucius Learning Series: FAC 2010, Lucius Pitkin, Inc. All Rights Reserved
42 - Extensive Feedwater Quality Control and Monitoring Concept For Preventing Chemistry-Related Failures of Boiler Tubes in A Subcritical Thermal Power Plant