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primary concern as over 60% of all utilities have reported condensate/feedwater system contains copper alloys, oxygen
finding it in their facilities. Defined as localized rapid metal scavenger feed is not recommended, but rather programs that
loss resulting in tube wall thinning of carbon and low alloy make use of deliberate oxygen feed are now the preferred
piping, FAC is known to occur in the mid-temperature regions choice.
of the cycle, between 120 deg. C and 205 deg. C. In high
pressure boiler cycles, these temperatures exist in boiler
feedwater or “LP” (low pressure) and “IP” (intermediate
pressure) sections.
FAC induces metal dissolution at flow disturbances
(Figure 1), i.e., elbows, reducing fittings, in carbon steel, and
is most pronounced at temperatures near 150 deg. C. FAC is
also greatly influenced by pH, and becomes increasingly
severe if the pH is allowed to drop towards 9.0 or below.
While FAC has become a recognized problem, many people in FAC Mechanism
the power industry are still unaware of the issue, and continue
to specify oxygen scavenger feed for new units. Unless the
FAC metal loss is best described as the absence of the • Turbine exhaust diffuser (T)
protective iron oxide layer that, when present, limits corrosion • Air-cooled condenser (T)
in boiler systems. Without this protection, the surface is free • Downstream of control valves (most often T).
to react with the passing water (or steam-air mixture called
two-phase FAC) and metal loss is rapid. Classic FAC attack
is bare (shiny) metal with a scalloped appearance in the
direction of flow (figure 6 pictured below).
Fig. 6
Factors that affect FAC are: flow velocity, geometry, Fig. 7
metallurgy, temperature, dissolved oxygen concentration, and FAC is a process whereby the normally protective
pH. Piping geometry and flow velocity go hand in hand, as magnetite (Fe3O4) layer on carbon steel dissolves in a stream
failures typically occur in areas of higher velocity relative to of flowing water (single phase FAC) or wet steam (two phase
adjacent areas like the outside of tube bends or where a tube FAC). Historically, the terms “Flow assisted corrosion, and
intersects a header, so periodic inspection of these areas in Flow induced corrosion have been used to define FAC. This
your boiler cycle is highly recommended. To understand why process reduces or eliminates the oxide layer and leads to a
iron oxides would not develop in these areas, researchers rapid removal of the base material until the pipeline bursts.
focused on the sometimes complex physics and chemistry of The FAC process can be as high as 3 mm/year.
iron oxides. Iron exists in two oxidation states (Fe+2 and Fe+3)
and a variety of structures, so there are sixteen known iron Fig. 8 to 13.below are some cases of failure due to FAC.
oxides and oxy-hydroxides, each with different properties.
Magnetite (Fe3O4) is formed in a boiler circuit under anaerobic
conditions and is very stable, dense and uniform at high
temperatures (>205 deg C). Between 120 deg C and 205 deg
C, magnetite forms less rapidly and is pourous and irregular;
and below 120 Deg C, magnetite forms very slowly.
Therefore, in the temperature range that FAC is of concern,
magnetite is of less help when it comes to corrosion protection
than at the higher temperatures as shown in figure 7 below.
Commonly recognized locations of FAC damage and
Fig. 8
failure in conventional fossil plants (S: Single Phase, T: Two
phase) included the following:
• Feedwater heater normal drains (S, T). Most Prevalent
area, where about 60% of organizations record
problems.
• Piping around boiler feed pump (S). Includes steam
attemperation supply piping and downstream spray
control valve (S, T).
• Piping to economizer inlet headers (S). Especially
associated / near valves to header and supply tees.
• Economizer inlet header tubes (S). Most frequent are
usually those nearest to supply header. Fig. 9
• High pressure (HP) feedwater heater tubes and tube
sheets fabricated in carbon steel (S).
• Low pressure (LP) feedwater heater shells (T),
especially near cascading drain entries.
• Deaerator shells (T) near to fluid entry (HP cascading
drains) piping.
• Expanders and reducers on either side of valves (most
often T).
• Locations near thermo-wells in piping (S).
Fig. 10
Fig. 13
Prevention of FAC through All Volatile Treatment
Oxidizing (AVT (O)) or Oxygenated Treatment (OT)
There are two possible choices for feed water treatment
viz. AVT (O), and OT. The treatment chosen should match the
unit, unit metallurgy particularly feed water, cooling water and
possible contaminant ingress, but the aim of all the treatments
should be to prevent boiler tube failures and provide
protection to the steam turbine.
Fig. 14: SEM Photomicrograph inside Boiler Tubes
Research has shown that alpha structured ferric oxide,
known as hematite (α-Fe2O3) can strengthen the porous
magnetite layer and result in a more stable protective layer.
Hematite is formed in oxidizing environments, so having some
dissolved oxygen present in feedwater circuits (<10 ppb) is
now seen as beneficial. This has led many plants to abandon
the use of chemical oxygen scavengers in all ferrous systems
where continuously well operated mechanical deaeration and
minimal air in-leakage is the norm. Iron oxide solubility is
also very dependent upon pH especially in the typical FAC
temperature range as pictured above.
Over 40 years, researchers in Germany and then Russia
Fig.15: Behaviors of ECP and FAC Rate as a Function of DO
began using a programme known as oxygenated treatment
Concentration
(OT) to minimize carbon steel corrosion and iron dissolution
in steam generators. The key component of the program is OT was developed in Germany some 40 years ago for
deliberate injection of pure oxygen into the replacement of AVT(R). The program was adopted by other
condensate/feedwater network to establish oxygen residuals of European utilities and has gained large acceptance at utilities
in the U.S. The treatment requires the controlled injection of
oxygen into the condensate/feedwater system. Common teen ppb concentration should be investigated and corrected as
injection points are just after the condensate polisher and again quickly as possible.
at the deaerator outlet. In CWT programs, which are most
For mixed-metallurgy systems, OT and AVT (O) are not
common in the U.S., oxygen is dosed to maintain a 30 to 150
acceptable, as they would initiate excessive copper corrosion.
ppb residual. Ammonia is added to raise the pH within a range
However, operation with complete absence of oxygen leads to
of 8.0 to 8.5. Typically, in pure DM water 50 to 70 ppb of
FAC. So, the correct program is to feed an oxygen scavenger,
ammonia will produce this pH.
but at reduced concentrations to minimize FAC. This can be
The chemistry of oxygenated treatment is interesting and quite difficult when relying upon standard dissolved oxygen
explains why the program has become popular. In and oxygen scavenger analyses. The technique of oxidation-
conventional AVT(R) programs, it may be difficult to keep reduction potential (ORP) monitoring is becoming popular for
dissolved/suspended iron concentrations in the feedwater mixed-metallurgy condensate/feedwater chemistry. In short,
below 2 ppb and excursions above 10 ppb are not uncommon. on-line ORP monitors measure the electrochemical potential
Iron particulates are the primary product that carries over to of the solution versus a standard electrode, most commonly
the boiler. With oxygen injection however, the base layer of silver/silver chloride.
magnetite becomes covered and interspersed with an even
A general rule-of-thumb is that the oxygen scavenger
tighter film of ferric oxide hydrate (FeOOH). This compact
should be fed to maintain an ORP within a range of -350 to -
layer is more stable than magnetite and releases very little
300 millivolts (mV). This corresponds to a range of -150 to -
dissolved iron or suspended iron-oxide particles to the fluid. A
100 mV for a standard hydrogen electrode (SHE). However,
properly orchestrated OT program should lower feedwater
chemists have found that this guideline should not be
iron concentrations to less than 1 ppb.
considered an absolute. A better plan is to set up
The keys to an OT program are controlled oxygen feed and comprehensive tests that include dissolved iron and copper
high-purity condensate, where cation conductivity can be analyses, and coordinate the optimum ORP range with
maintained ≤0.15 μS/cm. Such steam generating systems are minimized copper and iron concentrations. In figure 16, we
always equipped with condensate polishers. OT has also been can see the increase of benefits with increase of controls in
applied to a number of drum units throughout the world, as it steam water cycle.
is a condensate/feedwater treatment and thus can function
regardless of boiler design. OT cannot be used in systems that
contain copper-alloy feedwater heater tubes, as copper
corrosion would be much too severe.
An issue that has come to light regarding OT programs is
that of two-phase FAC. At points in the steam generating
system, particularly deaerators and feedwater heater drains,
zones of physical separation between water and steam will
develop. Chemicals in the feed solution that prevent FAC may
settle in one phase leaving the other without protection. Thus,
FAC can occur when all chemistry parameters are seemingly
in acceptable ranges. Two-phase FAC is virtually impossible
to control chemically. The issue can be addressed Fig. 16: Hierarchy of Controls and Benefits for Employment
mechanically by utilizing 1.25-chrome steel in affected areas, of AVT (O) or OT, AVT (O) [Oxidizing All Volatile
as was mentioned earlier for HRSG elbows. Treatment]
An offshoot of OT is a program developed by EPRI known In oxidizing all volatile treatment the use of reducing agent
as all-volatile treatment (oxidizing), or AVT (O). The idea is eliminated. The ORP will be around 0 mV which could be
continues to be establishing a FeOOH layer on the feedwater slightly +ve or –ve. For units operating with AVT (O), the
piping, but by a less intensive mechanism. What the achievable iron levels can be around 1ppb or less. The
researchers found is that in condensate/feedwater networks requirements for AVT (O) are:
where condenser air in-leakage is minor and where condensate • Elevated pH of 9.2 – 9.6.
dissolved oxygen levels stay at or below 10 ppb, discontinued • Cation conductivity of less than 0.20 μS/cm.
feed of the oxygen scavenger allows the FeOOH protective • Minimum air in-leakage to ensure less than 10 ppb
layer to form naturally. As with OT, this program is only for dissolved oxygen at CPD.
systems with all-ferrous metallurgy. One difference from OT,
• No addition of reducing agent (N2H4) to the feed water
however, is that the pH should be maintained within a range of
to ensure oxidizing ORP.
9.2 to 9.6. An operating guideline is cation conductivity ≤0.2
With AVT (O) or OT, the protective cover layer pores
μS/cm. Excursions in dissolved oxygen concentration and
become plugged with ferric oxide hydrate (FeOOH) or ferric
cation conductivity-particularly the former-indicate excess air
oxide (Fe2O3). The Fe2+ ion diffusion from steel surface
in-leakage within the condenser. Increased air in-leakage also
through the pores in the protective cover layer to the
introduces excess carbon dioxide, which influences corrosion.
oxide/water phase boundary is strongly inhibited. The few
Thus, for a unit on AVT (O) any air in-leakage difficulties that
raise condensate dissolved oxygen levels much above a mid-
ferrous ions leaving the steel are oxidized either in the layer Fig. 18: Major Difference between AVT(R) and OT
pores or right at the protective layer/water boundary.
2Fe (OH)2 + ½ O2 + 2H+ = 2Fe(OH)2+ + H2O
2Fe (OH)2 + ½ O2 = 2FeOOH + H2O • Advantages of OT:
2Fe (OH)2 + ½ O2 = Fe2O3 + 2H2O
• Reduction in Boiler Chemical Cleaning frequency
• The very low level of corrosion product transport into
the boiler results in less deposition on waterwalls thus
considerably reducing the boiler chemical cleaning
frequency. In addition, fouling of BFPs, feedwater
control valves, boiler orifices and of valves may be
overcome.
• Reduction in Boiler Tube failures
• For boiler tube failures there are three under deposit
corrosion mechanisms: Hydrogen damage, caustic
Fig. 17: Growth of a Cover Layer of FEOOH on the magnetite gouging, and Acid phosphate corrosion. The under
under oxidizing conditions of AVT (O) or OT deposit corrosion is likely to initiate in areas where the
excessive amounts of deposits have formed. Any
In AVT (O) the lower levels of oxygen maintained by air measure e.g., OT resulting in reduced corrosion
in-leakage control are not high enough to passivate 100% of product transport into the boiler is the most important
the feed water particularly the deaerator surfaces. For this corrective action w.r.t. possible boiler tube failures.
reason, the achievable ferrous ion concentration in the • Reduction in Pressure drop in once through units
feedwater is around 1 ppb under AVT (O) conditions and • Due to the formation of rippled magnetite deposits in
below 1 ppb for OT conditions. For HRSG plants with all supercritical once through units operating on AVT(R),
ferrous feedwater systems the feedwater chemistry should be the pressure drop increase is a typical problem. This
AVT (O) to avoid single-phase FAC in feedwater and LP problem can be overcome by use of AVT (O) or OT.
evaporator circuit. • Control of single phase FAC
OT (Oxygenated Treatment) • Single phase FAC in the condensate and feedwater
In Oxygenated treatment, oxygen and ammonia are added system typical of units operated on AVT(R) can be
to feedwater. The ORP is kept around +100 to +150 mV. stopped.
• Reduction in Polisher regeneration Frequency
The requirements for OT are:
• In once through boilers the lower pH i.e., low
• Cation conductivity of less than 0.15 μS/cm. ammonia content in the condensate to be polished
• Minimum air in-leakage to ensure less than 10 ppb results in less no. of regenerations. This leads to huge
dissolved oxygen at CPD. savings in chemicals and manpower. The service runs
• Addition of oxygen to the feed water to ensure in OT are much longer in comparison to AVT.
oxidizing ORP. There is one important pre-condition for getting benefit
OT uses oxygenated high purity water to minimize from all above advantages that is the purity of whole cycle has
corrosion and FAC in the feed water train. Oxygen, hydrogen to be excellent i.e., cation conductivity less than 0.15 μS/cm.
peroxide, and air can be used as oxidants. OT can be applied If this purity level cannot be maintained then AVT (O) should
only in plant cycles with all ferrous metallurgy downstream of be used instead of OT.
condenser. The Chemistry Controls required in Table 1 below:
Fig. 19: Decision Tree for Optimization of All-Ferrous Feed Water Chemistry in Conventional and HRSG Units
Cation conductivity- CPD, CP O/L or ECO I/L, MS (or RH), III. CONCLUSION
Blowdown (or down comer) (each drum) Feedwater treatment optimization by adopting the right
Specific conductivity- Make up, Blowdown (or downcomer) feed water treatment i.e. OT or AVT (O) depending on system
(each drum) metallurgy can significantly reduce the flow accelerated
pH- Blowdown (or downcomer) (each drum) corrosion (FAC) both in conventional and HRSG plants.
Dissolved oxygen- CPD, ECO I/L Besides reduction/elimination of FAC, the transportation of
Sodium- MS (or RH) corrosion products from pre-boiler system to the boiler are
Phosphate- Blowdown (or downcomer) (each drum using a minimized resulting in reduced deposits, cleaner heat transfer
phosphate treatment) surfaces, delayed or no need for boiler chemical cleaning,
Silica- Makeup minimum under deposit corrosion, and reduction in boiler tube
In India a 500MW unit station having all ferrous feed failures.
water system were converted to AVT(O). The first 500MW
unit was converted to AVT(O) w.e.f. June-2004. The iron and As compared to AVT (O), Oxygenated treatment (OT)
crud values in feedwater were reduced significantly. which uses addition of oxygen in feedwater can further reduce
the FAC because in AVT (O) the lower levels of oxygen
• The optimization of feedwater chemistry was carried maintained by air in-leakage control are not high enough to
out by the following four steps: passivate 100% of the feed water surfaces. Hence OT should
• Step 1: Monitoring and controlling the Dissolved be considered as the next step for implementation on the units
oxygen in the condensate to around <10-15ppb. presently operating on AVT (O) feedwater chemistry.
• Step 2: Reviewing the AVT (R) that was in practice Operation of boiler feedwater systems in an oxidizing
prior to June 2004 and FAC was monitored by environment produces an oxide layer on the ferrous metals
recording the total iron in the feed water sample. The that is more tenacious than the normal ferric oxide found in
crud values were in the range of 10 ppb in the AVT boiler feedwater systems operated in a reducing environment
(R) regime. as is the common practice in most steam cycles. With the
• Step 3: Reduction of reducing agent i.e. Hydrazine oxide layer being more tenacious, it is significantly less likely
from 20 ppb to 10 ppb, and monitoring the iron in to be removed in the process known as flow accelerated
feedwater, crud levels, and all other base parameters. corrosion (FAC).
• Step 4: Total elimination of reducing agent by July
2004 and conversion to AVT (O) regime. The crud ACKNOWLEDGEMENT
values in feed water decreased to <4.0 ppb after
stopping hydrazine and the total iron in feedwater Authors is thankful to the management of JIPT, Jindal
dropped from 2- 5 ppb to <2.0 ppb. Power Limited for giving permission to study, present and
publish this paper. Thanks are also due to operational staff of
Commissioning Chemistry Department of Jindal Power
Limited, Tamnar, Raigarh.
REFERENCES
[1] Cornell, RM; Schwertmann, U. (2003). The iron oxides: structure,
properties, reactions, occurrences and uses. Wiley VCH.
[2] Dooley, Barry (2005). EPRI Presentation to HRSG User’s Group.
[3] FAC in conventional fossil fuel units, PPChem, R. Barry Dooley, Kevin
J. Shields, and Steve J Shulder
[4] Japan Society of Maintenology (E-JAM)
[5] Design Factors and Water Chemistry Practices Frank Gabrielli and Horst
Schwevers
[6] Evaluation of Oxygenated Water Treatment, Mitsuhiro Yamagishi,
Masamichi Miyajima, 14th International Conference on the Properties of
Water and Steam in Kyoto
[7] Power Plant Main Cycle Oxygenated Treatment: Victor Marcu, Orot
Rabin Power Station, The Israel Electric Corporation Ltd.Flow-
Accelerated Corrosion: A Critical Issue Revisited By Brad Buecker