Effective Flow Accelerated Corrosion

Maintenance Program for Reliable Power

Generating Stations

Wael H. Ahmed, PhD

Mechanical Engineering Department
King Fahd University of Petroleum & Minerals

April 20, 2009

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
Outline

1 Flow Accelerated Corrosion Background

Factors Affecting FAC
Failures Due to FAC
Significant Experience with FAC Failures

2 Effective FAC Program

Customer Requirements
Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

3 Role of Basic and Applied Research

Analysis
Inspections
References

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Flow Accelerated Corrosion Background

Part I

Flow Accelerated Corrosion (FAC) Overview

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Flow Accelerated Corrosion Background

Flow Accelerated Corrosion (FAC) is the degradation of

material by means of a chemical reaction and flowing
water/wet steam.
FAC is of primary concern in the carbon steel portion of high
temperature piping and equipment found in power plants.
FAC results in thinning of piping, vessels, and equipment from
the inside out, therefore can not be detected except by
specialized inspection techniques.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Flow Accelerated Corrosion Background

Flow Accelerated Corrosion (FAC) is the degradation of

material by means of a chemical reaction and flowing
water/wet steam.
FAC is of primary concern in the carbon steel portion of high
temperature piping and equipment found in power plants.
FAC results in thinning of piping, vessels, and equipment from
the inside out, therefore can not be detected except by
specialized inspection techniques.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Flow Accelerated Corrosion Background

Flow Accelerated Corrosion (FAC) is the degradation of

material by means of a chemical reaction and flowing
water/wet steam.
FAC is of primary concern in the carbon steel portion of high
temperature piping and equipment found in power plants.
FAC results in thinning of piping, vessels, and equipment from
the inside out, therefore can not be detected except by
specialized inspection techniques.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

FAC Wear Patterns

“scalloped” or
“orange-peel”
surface

“Tiger
stripping”

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Description of FAC

FAC occurs when the normally protective iron-oxides dissolve

into the flowing stream.
FAC This results in a global attack (i.e., widespread thinning)
rather than local attack (i.e., pitting or cracking).
FAC caused failures are often sudden and catastrophic.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Description of FAC

FAC occurs when the normally protective iron-oxides dissolve

into the flowing stream.
FAC This results in a global attack (i.e., widespread thinning)
rather than local attack (i.e., pitting or cracking).
FAC caused failures are often sudden and catastrophic.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Description of FAC

FAC occurs when the normally protective iron-oxides dissolve

into the flowing stream.
FAC This results in a global attack (i.e., widespread thinning)
rather than local attack (i.e., pitting or cracking).
FAC caused failures are often sudden and catastrophic.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Factors Affecting FAC

Hydrodynamics Parameters
Flow Velocity
Component Geometry
Steam Quality
Water Chemistry
pH Level
Oxygen Content
Temperature
Pipe Material Composition
Chromium
Copper
Molybdenum

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Factors Affecting FAC

Hydrodynamics Parameters
Flow Velocity
Component Geometry
Steam Quality
Water Chemistry
pH Level
Oxygen Content
Temperature
Pipe Material Composition
Chromium
Copper
Molybdenum

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Factors Affecting FAC

Hydrodynamics Parameters
Flow Velocity
Component Geometry
Steam Quality
Water Chemistry
pH Level
Oxygen Content
Temperature
Pipe Material Composition
Chromium
Copper
Molybdenum

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Failures Due to FAC

Plant Event date Consequences Ruptured Area

(Year Commercial) Pipe O.D./Thickness

Iatan 1 May 2007 Pipe rupture Downstream orifice

(1995) 80mm/7.6mm

South Ukraine 2 August 2005 Pipe rupture Elbow

(1985) 219mm/8mm
South Ukraine 2 July 2005 Pipe rupture Downstream of elbow
(1985) 530mm/8mm
Piping

Clinton February 2005 Pipe through-wall Extract steam line inside

(1987) holes/Bellows condenser
failure 305mm (diameter)
Smolensk 2 February 2005 Pipe rupture Downstream of valve
(1985) 108mm/4.5mm
Zaporozhye 4 September 2004 Pipe rupture Downstream of elbow
(19896) 159mm/7mm
Pipe rupture/11 Downstream of flow
Mihama 3 August 2004 causalities/steam restricted orifice
(1976) ingress main 560mm/10mm
Control room

Plant Event date Consequences Ruptured Area

Equipment

(Year Commercial) Shell or plate Thickness

Smolensk 2 February 2006 Low pressure Heater Shell
(1990) Heater rupture 16mm
Bruce 8 October 2003 SG tube support SG tube support plate
(1987) plate ligament loss 25.4mm

December 2001 Shell side damage Feed-water heater shells

Maanshan 1& 2 Unit 1 (1984) of HP and LP feed- and nozzles
Unit 2 (1985) water heater 11.1mm

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Significant Experience with FAC Failures

(Surry Unit 2 (USA)) An 18 inch elbow in a condensate line

ruptured catastrophically in 1986. Four fatalities and several
injuries resulted
Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Significant Experience with FAC Failures Cont.

(Mihama (Japan)) A 22 inch condensate line downstream of an

orifice ruptured Catastrophically in 2004. Five fatalities and several
injuries resulted
Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Significant Experience with FAC Failures Cont.

Failure in extraction line at Dukovany (Czech Republic)

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Significant Experience with FAC Failures Cont.

Failure in a high pressure extraction line at Fort Calhoun (USA) in

1997

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Factors Affecting FAC
Flow Accelerated Corrosion Background Failures Due to FAC
Significant Experience with FAC Failures

Significant Experience with FAC Failures Cont.

FAC also occurs in equipment, particularly feedwater heater shells

at Point Beach 1 (USA)

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
Effective FAC Program

Part II

Effective FAC Program

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Customer Requirements

1 Safe work environment

2 Protect the asset
3 Improve plant capacity factor and system performance
The goal is to help meet the customer requirements by
supporting the implementation and maintenance of an
effective FAC Program

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Elements of an Effective FAC Program

Corporate
Commitment
Should include:
• Adequate financial resources
• Clearly defined responsibilities
and authority Effective
• Personnel qualifications FAC
• Communications between Program
departments
• Minimizing personnel turnover
• Long-term strategy
• QA procedures

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Elements of an Effective FAC Program

Corporate
Commitment
Important ingredient in each step
• Should be applied at all steps Engineering
• Personnel should be trained in Judgment
ƒFAC Effective
ƒAppropriate engineering FAC
discipline Program

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Elements of an Effective FAC Program

Corporate
Commitment
Objectives
• Predicts FAC wear rate Engineering Analysis
• Determine the remaining service Judgment
life for components Effective
•FAC models FAC
TM
• CHECWORKS Program

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Elements of an Effective FAC Program

Corporate
Commitment
Helps to:
• Identify problem areas for Engineering Analysis
additional inspections Judgment
• Understand not typical situations, Effective
e.g., running bypass lines full time FAC
• Know cost, materials, qualified Program Industrial
suppliers, new equipment, Experience
inspection techniques

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Elements of an Effective FAC Program

Corporate
Commitment
Foundation of a program
Will establish the extent of Engineering Analysis
wear in lines, components and Judgment
within a component Effective
provides data to FAC
•Help evaluate FAC trends Program Industrial
•Refine the predictive model Inspection Experience

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Elements of an Effective FAC Program

Corporate
Commitment
Should focus on:
• Reducing the number of inspections Engineering Analysis
• Reducing FAC wear rate Judgment
Reducing FAC: Effective
• Improving materials FAC
• Improving chemistry
Program Industrial
Inspection Experience
• Improving local design

Long Term
Strategy

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Customer Requirements
Effective FAC Program Elements of an Effective FAC Program
Applicability to Other Maintenance Programs

Applicability to Other Maintenance Programs

Corporate
Commitment

Engineering Analysis
Judgment
Effective
Maintenance
Program
Industrial
Inspection Experience

Long Term
Strategy

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Role of Basic and Applied Research

Part III

Role of Basic and Applied Research at KFUPM

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Role of Basic and Applied Research

Corporate
Commitment

Engineering Analysis
Judgment
Effective
Maintenance
Program
Industrial
Inspection Experience

Long Term
Strategy

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Analysis for the Degradation Mechanisms

Analytical models to predict the most susceptible components

to specific degradation.

Analysis should utilize the results of plant-specific inspection

data to develop plant-specific correction factors.

The analytical models can also be used to develop an

inspection and/or repair/replacement plan.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Analysis for the Degradation Mechanisms

Analytical models to predict the most susceptible components

to specific degradation.

Analysis should utilize the results of plant-specific inspection

data to develop plant-specific correction factors.

The analytical models can also be used to develop an

inspection and/or repair/replacement plan.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Analysis for the Degradation Mechanisms

Analytical models to predict the most susceptible components

to specific degradation.

Analysis should utilize the results of plant-specific inspection

data to develop plant-specific correction factors.

The analytical models can also be used to develop an

inspection and/or repair/replacement plan.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Inspections

Develop measurements strategy that identify the extent of

component degradation.

Provide evaluation methods of degradation trends in order to

refine the predictive models.

Help industry to focus inspection resources based on models

predicted trends.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Inspections

Develop measurements strategy that identify the extent of

component degradation.

Provide evaluation methods of degradation trends in order to

refine the predictive models.

Help industry to focus inspection resources based on models

predicted trends.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

Inspections

Develop measurements strategy that identify the extent of

component degradation.

Provide evaluation methods of degradation trends in order to

refine the predictive models.

Help industry to focus inspection resources based on models

predicted trends.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Analysis
Role of Basic and Applied Research Inspections
References

References

1 B. Chexal, ”Flow-Accelerated Corrosion in Power Plants”,

TR-106611-R1, EPRI, 1998
2 J.S. Horowitz and D Munson, ”Recommendations for an
Effective Flow Accelerated Corrosion Program”,
NSAC-202L-R3, 1011838, EPRI Report, May 2006.
3 Wael Ahmed, ” TRENDING FAC IN CANDU REACTORS”
COG-Report 07-4065, June 2007.

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for
 Questions

Questions

Wael H. Ahmed, PhD Effective Flow Accelerated Corrosion Maintenance Program for