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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
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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
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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.
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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.
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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.
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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
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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
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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
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increases.
FAC Wear Rates FAC Wear Rates Decreases as Decreases as
Chromium Content Increases Chromium Content Increases
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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.
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FAC Wear Rates as pH Increases FAC Wear Rates as pH Increases
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FAC Wear Rates as Oxygen Level FAC Wear Rates as Oxygen Level
Increases Increases Increases Increases
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FAC Wear Rates FAC Wear Rates as Temperature as Temperature
Increases Increases Increases Increases
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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.
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FAC Wear Rates as Velocity FAC Wear Rates as Velocity
IIIncreases Increases
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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.
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FAC Damage FAC Damage FAC Damage FAC Damage
Single phase Single phase
FAC damage
looks like small
scallops.
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FAC Damage FAC Damage FAC Damage FAC Damage
Tiger Striping Tiger Striping.
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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
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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
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