Computer-Based Training Module: Erosion In Piping Systems October 2006

Effective December 6, 2006, this report has been made publicly available in accordance with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export Administration Regulations. As a result of this publication, this report is subject to only copyright protection and does not require any license agreement from EPRI. This notice supersedes the export control restrictions and any proprietary licensed material notices embedded in the document prior to publication.

Introduction to Navigation
‡ Module can be navigated in a linear fashion ± Click Page Down or Enter. ‡ By following hyperlinks for more information ± The file must be viewed in ³Slide Show´ mode for the hyperlinks to work ± Click on a hyperlink to go directly to related information in the training, clicking page down or enter will take you back to where you left off. ‡ Click on the camera picture to view a related photograph, page down, or enter will return to the original page.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Introduction
‡ Mechanical damage is commonly found in piping systems. There are various mechanisms possible. They are normally combined under the category of ³erosion´ or ³erosive damage.´

‡ ‡

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Examples of Erosive Damage

Pump impellor damaged by cavitation.

Turbine blades damaged by solid particle erosion.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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All rights reserved. 5 . Inc.Purpose This module will: ‡ ‡ ‡ ‡ Introduce the subject Describe the four common mechanisms that cause damage in piping systems Discuss how these mechanisms cause damage. and Describe where damage is typically found. © 2006 Electric Power Research Institute.

6 .. This module will not treat damage in machinery. A short quiz is provided at the end of this module.Purpose . Inc. materials and countermeasures. All rights reserved. ‡ ‡ © 2006 Electric Power Research Institute. pumps.g. steam turbines. e.Continued ‡ Discuss inspection approaches.

7 .Description ‡ Erosion is the damage of materials caused by physical processes such as high-speed. For more information on corrosion ± go to corrosion. All rights reserved. Inc. This is contrasted to corrosion which involves a chemical or electrochemical process.Erosion . impinging flows or solid impacts on the surface. ‡ ‡ © 2006 Electric Power Research Institute.

Continued ‡ Erosion occurs in a variety of power-plant systems ± see sample photographs. All rights reserved. Inc. © 2006 Electric Power Research Institute.Erosion ± Description . the cause of the damage must be identified as there may be substantial differences between mechanisms. ‡ To successfully manage problems caused by erosion. 8 .

All rights reserved.Erosion Mechanisms ‡ The four most common erosion mechanisms in power plants are: ± Cavitation erosion ± Flashing erosion ± Droplet impingement ± Solid particle erosion ‡ These will be introduced © 2006 Electric Power Research Institute. Inc. 9 .

All rights reserved. Inc.Photographs of Damage Cavitation Erosion Flashing Erosion photo courtesy of Florida Power & Light Droplet Impingement photo courtesy of EDF © 2006 Electric Power Research Institute. Solid Particle Erosion photo courtesy of Bruce Power 10 .

All rights reserved. 11 . Inc.Summary Table Cavitation Erosion Fluid Conditions Surface Noise Vibration Flashing Erosion Water U/S 2phase D/S Smooth ± polished Yes Droplet Impingement Solid Particle Erosion Single or two phase Variable No Water Very rough Yes Two-Phase Very rough No Damage rate Non-linear Non-linear Non-linear Linear D/S = Downstream U/S = Upstream © 2006 Electric Power Research Institute.

© 2006 Electric Power Research Institute.see.see Liquid droplet impingement -. Inc.see Flashing erosion -. All rights reserved.Types of Erosion Damage For more information: ‡ ‡ ‡ ‡ Cavitation erosion -. 12 .see Solid particle erosion -.

Other Related Mechanisms ‡ There are other types of damage that may be experienced: ± Corrosion and erosion may occur simultaneous (see next slide) ± Erosive effects may also be combined ± Other erosion mechanisms. Inc. © 2006 Electric Power Research Institute. 13 . All rights reserved.

Inc. 14 .Photograph of Corrosion and Erosion Damage Elbow Damaged by Erosion and FAC photo courtesy of Public Service Electric & Gas © 2006 Electric Power Research Institute. All rights reserved.

Inc. 15 .Other Erosion Mechanisms ‡ Wire drawing ± high speed liquid flow normally encountered in valve internals. Steam cutting ± high speed steam flow normally occurring in valve seats or when leaks occur in heat exchangers. ‡ © 2006 Electric Power Research Institute. All rights reserved.

16 .Photographs of Damage Caused by Steam Cutting Steam cutting in a flange Steam cutting in a steam trap body © 2006 Electric Power Research Institute. Inc. All rights reserved.

17 . EPRI Report TR-108943-V2. Inc. ‡ ‡ © 2006 Electric Power Research Institute.For More Information ‡ CHUG website ± User experience ± Past presentations on erosion. All rights reserved. EPRI Report 1011231.

True False Question 2 There are materials that are more resistant to cavitation erosion than carbon steel. True False © 2006 Electric Power Research Institute. Inc. All rights reserved.Quiz Question 1 Droplet impingement and solid particle erosion are similar in many ways. 18 .

Quiz - Continued
Question 3 In order for cavitation to occur the downstream pressure must be less than the local vapor pressure. True False Question 4 In order for flashing to occur the downstream pressure must be less than the local vapor pressure. True False

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Quiz - Continued
Question 5 Data sets are available to describe cavitation in: a) Valves b) Orifices c) Valves and orifices d) Elbows e) Nearly every situation Question 6 Models to calculate the rate of droplet impingement are commonly used to determine susceptibility of components in piping systems. True False
© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Quiz - Continued
Question 7 Flashing erosion and droplet impingement often occur in high pressure drop situations. True False Question 8 Solid particle erosion has been found to have a) A damage rate that is linear with time. b) A damage rate that varies linearly with velocity c) A damage rate that is independent of the particle size d) A well understood damage mechanism e) All of the above
© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Quiz - Continued
Question 9 Noise and vibration associated with a valve indicate that cavitation erosion is occurring. True False Question 10 The critical velocity for damage caused by droplet impingement is much greater than the critical velocity for solid particle erosion. True False

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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All rights reserved.Training Complete! © 2006 Electric Power Research Institute. Inc. 23 .

they differ in more ways than they are similar. © 2006 Electric Power Research Institute. Please try again. 24 .1 . All rights reserved. Inc.True While droplet impingement and solid particle erosion are both mechanical damage mechanisms.

All rights reserved. Inc. 25 .1 . © 2006 Electric Power Research Institute. Return to quiz.False Correct! Droplet impingement and solid particle erosion differ in many ways including material response and velocity dependence.

Inc. 26 .True Correct! There are materials more resistant than carbon steel available including Inconel. Return to quiz.2 . All rights reserved. © 2006 Electric Power Research Institute.

False Incorrect! There are materials more resistant to cavitation than carbon steel. 27 . Thus.2 . partial material solutions to cavitation are possible. © 2006 Electric Power Research Institute. All rights reserved. Inc. Please try again.

3 . Inc. Please try again.True Incorrect! It is not the downstream pressure that matters. it is the lowest pressure within the restriction. © 2006 Electric Power Research Institute. The point of lowest pressure is known as the vena contracta. All rights reserved. 28 .

All rights reserved. Inc.3 . the pressure at the vena contracta) within the restriction that dictates whether or not cavitation will occur..e. Return to quiz. © 2006 Electric Power Research Institute. 29 .False Correct! It is the lowest pressure (i.

All rights reserved.4 . Return to quiz. © 2006 Electric Power Research Institute. 30 .True Correct! It is necessary that the downstream pressure be lower than the vapor pressure if flashing is to occur. Inc.

Please try again. 31 .4 . © 2006 Electric Power Research Institute. All rights reserved. flashing will not occur.False If the downstream pressure is above the vapor pressure. Inc.

Please try again. Inc.5-A Incorrect! While cavitation information is available for valves. 32 . © 2006 Electric Power Research Institute. All rights reserved. there are other geometries that have data.

5-B Incorrect! While cavitation information is available for orifices. © 2006 Electric Power Research Institute. 33 . there are other geometries that have data. Inc. All rights reserved. Please try again.

there are other geometries that have data.5-C Incorrect! While cavitation information is available for valves and orifices. Please try again. 34 . Inc. All rights reserved. © 2006 Electric Power Research Institute.

Inc. Please try again. © 2006 Electric Power Research Institute. there are other geometries that have data.5-D Incorrect! While cavitation information is available for elbows. 35 . All rights reserved.

Inc. Return to quiz.5-E Correct! There is information available for most geometries. All rights reserved. 36 . © 2006 Electric Power Research Institute.

True Incorrect. All rights reserved.6 . Inc. 37 . © 2006 Electric Power Research Institute. Models to predict droplet impingement are not normally used. Please try again.

False Correct! There are no commonly used models to predict droplet impingement. All rights reserved. 38 .6 . © 2006 Electric Power Research Institute. Inc. Return to quiz.

True Correct! Flashing and impingement are often associated with high-pressure drops and the resultant high-velocity. Inc.7 . 39 . Return to quiz. All rights reserved. © 2006 Electric Power Research Institute.

Please try again. Inc.7 . 40 .False Incorrect! High pressure drops are often associated with flashing and droplet impingement. © 2006 Electric Power Research Institute. All rights reserved.

Inc. © 2006 Electric Power Research Institute. All rights reserved. Return to quiz. 41 .8-A Correct! The damage rate for solid particle erosion varies linearly with time.

© 2006 Electric Power Research Institute. Please try again. All rights reserved. 42 .8-B Incorrect! The damage rate for solid particle erosion varies with velocity to a power slightly greater than 2. Inc.

8-C Incorrect! The damage rate is independent of particle size above a critical value. Inc. 43 . Please try again. Below this value damage does not occur. All rights reserved. © 2006 Electric Power Research Institute.

Please try again. Inc. 44 . © 2006 Electric Power Research Institute. All rights reserved.8-D Incorrect! The damage mechanism of solid particle erosion is not well understood although there appears to be different mechanisms for ductile and brittle materials.

All rights reserved. Inc. Please try again. © 2006 Electric Power Research Institute. 45 .8-E Incorrect! More than one of the above statements are not true.

46 . Inc. © 2006 Electric Power Research Institute.9 .True While noise and vibration may indicate that cavitation is occurring. All rights reserved. Please try again. cavitation erosion will only occur if the collapsing bubbles impinge upon a surface.

© 2006 Electric Power Research Institute. All rights reserved.False Correct! While noise and vibration may indicate that cavitation is occurring.9 . Return to quiz. cavitation erosion will only occur if the collapsing bubbles impinge upon a surface. 47 . Inc.

Inc. 48 . Return to quiz.True Correct! The critical velocity for droplet impingement on steel is about 300 feet per second (100 meters per second).10 . The critical velocity for damage to ductile materials is about 1% of this value. © 2006 Electric Power Research Institute. All rights reserved.

© 2006 Electric Power Research Institute. 49 .False The critical velocity for damage for solid particle erosion is about 3 feet per second (1 meter per second).10 . Inc. The critical velocity for droplet impingement is much greater than this value. All rights reserved. Please try again.

Corrosion
‡ ‡ ‡ Corrosion may be defined as material attack which is chemical or electrochemical in nature. Coping with corrosion has been a continuing activity for power plant operators. Corrosion damage may be widespread or localized.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Examples of Corrosion Mechanisms
‡ Widespread attack ± General corrosion ± Flow-Accelerated Corrosion (FAC). Localized attack ± Galvanic corrosion (between dissimilar metals) ± Crevice corrosion ± Cracking ± Pitting.

‡

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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FAC vs. Erosion
‡ ‡ FAC is the most important damage mechanism active in steam and feedwater related systems. FAC and erosion may be distinguished by: ± Surface morphology ± Extent of damaged area ± Chemistry dependence ± Material dependence.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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FAC vs. Erosion - Continued
‡ Surface morphology ± FAC damaged surface has distinctive features. ± Single-phase FAC exhibits a scalloped or ³orangepeel´ surface. ± High-quality, two-phase flow exhibits a characteristic pattern known as tiger-striping. These features are not found in surfaces damaged by erosion.

‡

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Photographs of FAC Damage Single-phase FAC showing scalloped surface photo courtesy of Pacific Gas & Electric Two-phase FAC in a crossover line showing µtiger striping´ photo courtesy of EDF © 2006 Electric Power Research Institute. Inc. All rights reserved. 54 .

‡ © 2006 Electric Power Research Institute. Chemistry ± the rate of damage due to FAC may be controlled by the water chemistry.Continued ‡ Damaged area ± damage caused by erosion is often localized while FAC-caused damage is normally widespread. All rights reserved. Inc. Erosion . 55 . Such dependence is not present with erosive mechanisms.FAC vs.

All rights reserved.1% or larger). Thus FAC does not damage stainless or alloy material.. while erosive attack commonly does. Erosion . This is not true of erosive mechanisms.FAC vs. ‡ © 2006 Electric Power Research Institute. Cr ~ 0.e. Inc.Continued ‡ Materials ± FAC is effectively inhibited by small amounts of chromium in the material (i. 56 .

57 . All rights reserved.Information on FAC ‡ Further information on FAC are contained in the Computer-Based Training module for FAC. Inc. ‡ © 2006 Electric Power Research Institute. EPRI 1013249. EPRI report TR-106611-R1 is a complete review of the subject.

‡ © 2006 Electric Power Research Institute.Cavitation . Inc.Introduction ‡ Cavitation is a phenomenon that occurs in a large number of technically important areas including: ± Ship propellers ± Hydraulic turbines ± Centrifugal pumps ± Piping systems. All rights reserved. 58 . Particular areas of concern are downstream of valves and orifices.

If the fluid pressure then increases. The fluid then locally vaporizes forming small bubbles (also known as cavities). these bubbles collapse. Inc. 59 . All rights reserved.Cavitation ± Mechanism ‡ ‡ ‡ Cavitation occurs when a flowing liquid stream encounters an area in which the local static pressure falls below the vapor pressure. © 2006 Electric Power Research Institute.

The damage rate caused by cavitation is non-linear with time (i.Continued ‡ The collapse of the bubbles causes noise and vibration. All rights reserved. 60 . the damage rate varies with time).. Inc.Cavitation ± Mechanism . and if close to a solid surface will cause damage to the surface. ‡ ‡ © 2006 Electric Power Research Institute. Cavitation may occur because of flow curvature ± see.e.

Unsteady Pressure and Vibration © 2006 Electric Power Research Institute. All rights reserved. 61 . Inc.

‡ © 2006 Electric Power Research Institute.Mechanism ‡ The next slides shows a schematic of the cavitation process at a flow restriction. All rights reserved. 62 . Inc.Cavitation . The following slide shows a schematic of the damage rate as a function of time.

All rights reserved.5 2 © 2006 Electric Power Research Institute. 63 .Schematic of Cavitation Process 100 90 Pressure 80 0 apor Pressure 60 50 Bubbles form Bubbles collapse 0 0 0.5 1 istance 1. Inc.

64 . Inc. All rights reserved.Schematic of Cavitation Damage Rate vs. Time Note ± the letters A-E refer to the stages of damage ± see. © 2006 Electric Power Research Institute.

All rights reserved.. and the vibration often causes more problems than the cavitation erosion ± e. Vibration and noise are associated with cavitation. © 2006 Electric Power Research Institute.Cavitation ± Damage ‡ ‡ Cavitation damage to surfaces is called cavitation erosion.g. 65 . Inc. ± Cracked welds ± Broken pipe hangers ± Damaged valve actuators.

Inc.Degrees of Cavitation ‡ ‡ ‡ ‡ For convenience workers have defined several levels or regimes of cavitation. © 2006 Electric Power Research Institute. These divisions are often somewhat arbitrary. All rights reserved. A commonly used set of definitions is shown on the next slide. 66 . Different regimes are used for different purposes. but are often used.

Cavitation Regimes Regime Incipient Description Cavitation is just beginning.e. All rights reserved. 67 . Inc. © 2006 Electric Power Research Institute.. Critical Cavitation is occurring at a steady state value. Supercavitation or Flashing The flow through the obstruction has reached critical (i. choked or sonic velocity) flow. For information about using regimes in design see.

68 . Noise does not necessarily indicate that damage is occurring. bubble and collapse production) is occurring.e. If the bubbles collapse away from solid surfaces no damage will occur. Inc. All rights reserved. © 2006 Electric Power Research Institute.Cavitation ± Noise and Damage ‡ ‡ ‡ Noise does indicate that cavitation (i..

Inc. 82 dba Typical noise levels for a standard trim valve. All rights reserved. Metallic rattling or shot-blasting often likened to the sound of flowing gravel ± known as µcrepitation.Cavitation ± Noise Regime Description of Noise High-pitched hissing or sizzling.¶ Noise Level Incipient 85 dba Critical 120 dba Supercavitation Humming or hissing. Also described as intermittent light popping or as bacon frying. © 2006 Electric Power Research Institute. 69 .

Morphology ‡ ‡ ‡ Surfaces damaged by cavitation are very rough with a texture similar to a new cement block. 70 . See photograph of damage on next slide. Cavitation damage is normally localized. Inc. All rights reserved. © 2006 Electric Power Research Institute.

71 . All rights reserved.Cavitation Damage in a Plug Valve More Photos Cavitation Damage in the Body of a Plug Valve © 2006 Electric Power Research Institute. Inc.

Inc. Cavitation erosion will be accompanied by noise and possibly vibration. butterfly or gate valves used for throttling will cavitate.Where to Look for Damage ‡ Cavitation erosion normally takes place ± In solid liquid flows ± Downstream of large pressure drops such as valves or orifices. ‡ ‡ © 2006 Electric Power Research Institute. Often. All rights reserved. 72 .

73 . All rights reserved. ultrasonic methods should use 100% scans or finer grids than are normally used for FAC inspections.Inspection Considerations ‡ Cavitation damage may be detected using conventional inspection techniques ± usually UT or RT. Inc. ‡ © 2006 Electric Power Research Institute. As the damaged area is likely small.

Design Options to Reduce Cavitation ‡ ‡ ‡ There are various options to reduce the severity of cavitation. 74 . ‡ © 2006 Electric Power Research Institute. There is a tremendous amount of literature available on the subject. Material and repair considerations ± see. Inc. For information on reducing cavitation in: ± Valves ± see ± Orifices ± see ± Other components ± see. All rights reserved.

‡ © 2006 Electric Power Research Institute.g. The approach is normally to compare the local system properties to the cavitation propensity of the component being considered. All rights reserved. Knowledge of both the local conditions (e. 75 .. the inlet pressure) and the component are necessary for accurate calculations. Inc.Calculation Approach ‡ ‡ There are well established methods to calculate the occurrence of cavitation.

All rights reserved. © 2006 Electric Power Research Institute.Calculating Cavitation in Valves ‡ ‡ There is a great deal of information available on this subject. 76 . Inc. Detailed procedures for calculating cavitation in valves may be found in: ± EPRI Reports TR-103198-T1 and TR-103198-T2 ± NUREG/CR-6031 ± Valve manufacturers¶ methodologies ± For details.

.e. All rights reserved.Calculating Cavitation in Orifices ‡ ‡ Methods are available to calculate cavitation in orifices. 77 . For single-holed orifices: ± There are correlations available to predict cavitation. ± These correlations are normally based on the hole/pipe diameter ratio (i. ± There are methodologies available to design orifices in series to eliminate cavitation. Inc. © 2006 Electric Power Research Institute. ).

the manufacturer should be able to supply necessary design information. For proprietary orifice/restrictor designs. All rights reserved. ‡ ‡ © 2006 Electric Power Research Institute. For more details ± see. ± Manufacturers often have design information. Inc. 78 .Continued ‡ For multiple holed single orifices: ± Correlations are available for some geometries.Calculating Cavitation in Orifices .

elbow. © 2006 Electric Power Research Institute. design data are available in these sources. tee). For common geometries (e.g. All rights reserved. 79 .. bend. Inc.Calculating Cavitation in Other Geometries ‡ ‡ There is a great deal of literature available on this subject especially in textbooks on the subject.

Information Sources ‡ Textbooks such as: ± Hammitt. All rights reserved. Paul ³Cavitation Guide for Control Valves...´ NUREG/CR-6031. Report 1011231. Valves. Paul. ± Tullis.g. 1980. Inc. Hydraulics of Pipelines: Pumps. Tullis. Transients. Cavitation and Multiphase Flow Phenomena. 1989. e. 80 . USNRC. 1993. © 2006 Electric Power Research Institute. Frederick G. Cavitation. J. ‡ ‡ EPRI Reports.

All rights reserved. four cavitation regimes can be considered: ± Incipient ± light. 81 . © 2006 Electric Power Research Institute. intermittent noise present ± Critical ± light.Four Regimes ‡ For purposes of design. steady noise ± Incipient Damage ± pitting damage begins ± Choking ± very heavy damage. and drop off in performance ± flow no longer increases with pressure drop ± see next slide. Inc.

All rights reserved. 82 .Non-Ideal Behavior of a Valve 0 2 20 Flow ull cho ed low 0 ho ing egins 0 0 20 0 re 60 re ro 80 00 Ideal ehavior Actual ehavior © 2006 Electric Power Research Institute. Inc.

and ± Cost of the valve. 83 . the maximum degree of cavitation allowable should be established.Using Regime Information ‡ ‡ When designing a control valve. © 2006 Electric Power Research Institute. Some of the factors that should be considered are: ± Operating time. All rights reserved. Inc. ± Maximum acceptable noise level ± Allowable vibration level.

relief valves). © 2006 Electric Power Research Institute. then the valve should not operate beyond ³incipient damage. then the valve should not operate beyond ³incipient.. Inc.Some Design Guidance ‡ ‡ ‡ If noise is not acceptable. All rights reserved.´ Valves that operate in the choking regime should only operate there for short periods of time (e.g. 84 .´ If noise is acceptable.

Inc.e. if at all. All rights reserved.. on the flat portion of the curve presented above). This regime is known as supercavitation and damage to the valve will normally not occur. the bubbles will collapse downstream of the valve.Supercavitation ‡ When a valve operates beyond choking (i. 85 . ‡ © 2006 Electric Power Research Institute.

86 . Inc. ‡ © 2006 Electric Power Research Institute.Supercavitation . the entire pipe section is filled with vapor for several diameters downstream of the restriction.Continued ‡ When supercavitation occurs. All rights reserved. noise and vibration may occur downstream of the valve. flashing is occurring. and flashing erosion. Note in this regime.

© 2006 Electric Power Research Institute. 87 .Flo Curvature Cavitation . and in fittings. This is called ³flow-curvature´ or ³re-circulation cavitation. in regions of flow mixing. All rights reserved. These occur at locations in turbo-machinery.´ It is caused by the generation of bubbles in areas of low pressure in secondary or recirculating flows.Introduction ‡ ‡ ‡ ‡ Cavitation may occur in elbows and tees. Inc.

Cavitation in an Elbo ‡ ‡ Secondary flows occur when streamlines have to adjust to curve around a bend. © 2006 Electric Power Research Institute. 88 . Inc. As the fluid at the extrados has to travel further than the fluid at the intrados. a transverse pressure gradient is established with the higher pressure at the intrados of the elbow. All rights reserved.

‡ © 2006 Electric Power Research Institute. This reduced pressure caused by the higher flow may induce cavitation bubbles to form. the elbow will choke. If the process continues. Inc. At this point.Cavitation in an Elbo ‡ ‡ ± Continued This pressure gradient induces a flow from the inside to the outside of the elbow. the acoustic velocity is reached and the flow rate is a maximum. 89 . eventually. All rights reserved.

All rights reserved. Inc.Void Formation in an Elbo Schematic of vapor pocket formed by cavitation in an elbow. © 2006 Electric Power Research Institute. 90 .

Thus this type of damage should be expected only in low-pressure lines. 91 . © 2006 Electric Power Research Institute. The next slide shows examples of this type damage. All rights reserved. Inc.Recirculation Cavitation ‡ ‡ ‡ This type of cavitation occurs only when the static pressure is relatively near the vapor pressure.

Inc. 92 . All rights reserved.Examples of Recirculation Cavitation Elbow and tee damaged by recirculation cavitation © 2006 Electric Power Research Institute.

© 2006 Electric Power Research Institute.Damage To Valve Internals Valve trim damaged by cavitation erosion. 93 . All rights reserved. Inc.

Damage to a Reducer Chrome-moly (P-22) reducer. All rights reserved. Cavitation downstream of an orifice photos courtesy of Dominion Virginia Power © 2006 Electric Power Research Institute. 94 . Inc.

95 . All rights reserved. Inc.Damage Do nstream of an Orifice photo courtesy of Southern Nuclear © 2006 Electric Power Research Institute.

All rights reserved. Inc.Damaged Surface Do nstream of an Orifice photo courtesy of Dominion Virginia Power © 2006 Electric Power Research Institute. 96 .

. This is normally the lowest cost option.Valve Countermeasures ‡ ‡ ‡ Increase cavitation resistance within valve type (i. 97 . Inc. All rights reserved. © 2006 Electric Power Research Institute. globe valve). In all cases except butterfly valves.e. there is a more cavitation-resistant style within the same valve type.

.e. go from butterfly to globe). ball) valves will cavitate before low-pressure recovery valves (e.. These terms are defined in the section ³Calculating Cavitation in Valves. globe) under the same conditions.Continued ‡ ‡ Improved valve types (i.g.´ ‡ © 2006 Electric Power Research Institute. butterfly..g.Valve Countermeasures . Inc. All rights reserved. In general high-pressure recovery valves (e. 98 .

99 .Valve Countermeasures ± Continued ‡ ‡ Install anti-cavitation valves see. © 2006 Electric Power Research Institute. ± However. the use of this technique is only effective if the range of flows expected is limited to 1:3. Inc. Add orifice or valve in series .the use of a valve and orifice combination can be as effective in reducing cavitation to acceptable levels. All rights reserved.

100 . © 2006 Electric Power Research Institute. Similarly.Continued ‡ ‡ Add sudden expansion downstream of the valve to keep the collapsing bubbles away from solid surfaces.Valve Countermeasures . a target tee-type arrangement may be used to control the surfaces damaged by cavitation erosion. Inc. All rights reserved.

Various designs are available ± see photographs.Orifice Countermeasures ‡ Three methods to reduce cavitation damage downstream of orifices are: ± Use a multiple-holed orifice in place of a singleholed orifice ± see photographs. © 2006 Electric Power Research Institute. 101 . ± Use several single-holed orifices in series. ± Use a proprietary flow restrictor. Inc. All rights reserved.

Inc.Multiple-Holed Orifices ‡ ‡ The use of orifices with multiple holes may reduce or eliminate cavitation. 102 . ‡ © 2006 Electric Power Research Institute. All rights reserved. The disadvantages include the greater likelihood of plugging and different choking cavitation characteristics. This approach has some advantages over single-holed orifices including better noise and vibration characteristics and requiring less space than using orifices in series.

All rights reserved. 103 . At each step (or stage). Methods exist to allow calculation of an orifice string to avoid cavitation.Orifices in Series ‡ Multistage orifices eliminate cavitation by breaking down the total pressure drop into a number of smaller steps. Inc. ‡ ‡ © 2006 Electric Power Research Institute. the pressure drop is controlled by the orifice diameter to prevent cavitation.

Proprietary Restrictors ‡ ‡ ‡ Various vendors supply proprietary restrictors to reduce cavitation.g. All rights reserved. letdown lines).. Inc. Normally these restrictors are used in high-pressure drop lines (e. © 2006 Electric Power Research Institute. 104 . Vendors will normally supply design information.

All rights reserved. 105 . Inc.Multiple-Holed Orifices Photos courtesy of CU Services LLC © 2006 Electric Power Research Institute.

All rights reserved. 106 .Proprietary Restrictor Drawings courtesy of CU Services LLC Proprietary restrictor design and installation © 2006 Electric Power Research Institute. Inc.

107 . Photos courtesy of Pratt © 2006 Electric Power Research Institute. Inc.Another Proprietary Restrictor Upstream end Mockup of downstream end showing impinging jets. All rights reserved.

. ± Local design changes to eliminate bubbles collapsing near solid surfaces ± e.Countermeasures ± Other Components ‡ Options available include: ± Changing the material. abrupt expansions. target tees. 108 .. moving the pressure drop downstream). ± Changing the location of the major pressure drop (i. All rights reserved.e.g. © 2006 Electric Power Research Institute. Inc.

There are two basic types. although there are many variants to these designs. 109 .Anti-Cavitation Valve Types ‡ ‡ ‡ There are valves designed to reduce or eliminate cavitation even under extreme conditions.¶ © 2006 Electric Power Research Institute. All rights reserved. Inc. These types are: ± µcolliding jet¶ and ± µstack arrangement.

All rights reserved. Inc. 110 .Anti-Cavitation Valve ± Colliding Jet Arrangement ‡ ‡ The flow is split and is made to pass through a number of orifices that expand into a sudden enlargement. Usually. the trim is cylindrical in shape and the flow passes through a large number of small holes. © 2006 Electric Power Research Institute.

Continued ‡ ‡ Some of these designs have the flows inward where the jets collide with each other in the center. the flows are outward toward the valve boundary. In other designs. All rights reserved. © 2006 Electric Power Research Institute. Inc. 111 .Anti-Cavitation Valve ± Colliding Jet Arrangement .

All rights reserved. labyrinth passages). ‡ © 2006 Electric Power Research Institute. 112 . Inc.Anti-Cavitation Valve ± Stack Arrangement ‡ The flow passes through a large number of parallel paths containing designed obstructions (i.e. Typically.. there are stacks of discs containing these obstructions.

These valves can be designed to operate at. ‡ © 2006 Electric Power Research Institute.Anti-Cavitation Valve ± Stack Arrangement Continued ‡ The resistance of the obstructions in the discs can be tailored to control the valve characteristics as different disks may have different flow passages. the choking limit with little noise and vibration. or near. 113 . All rights reserved. Inc.

Anti-Cavitation Valves ± General ‡ In either of the above designs. Inc. found in conventional valve styles. All rights reserved. to many jets reduces the amount of noise and vibration. 114 . The following slides present some anti-cavitation valves with a brief commentary. the change from one jet. ‡ © 2006 Electric Power Research Institute.

etc. Note that there are other designs available designed for different size. Inc. pressure level. pressure drop.Continued ‡ Some of the designs shown allow a conventional globe valve to be back-fitted to become an anti-cavitation type. ‡ © 2006 Electric Power Research Institute. 115 . control requirements. All rights reserved.Anti-Cavitation Valves ± General .

Inc. All rights reserved. 116 . Colliding Jets Drawings courtesy of Emerson Cross Section and Operation of a Cavitrol® III One-Stage Trim Control Valve © 2006 Electric Power Research Institute.Cavitrol® III ± Anti-Cavitation Valve Example of a Valve Using Inward.

Inc. © 2006 Electric Power Research Institute. 117 .Valtek Anti-Cavitation Stack Valve Drawings Courtesy of Flowserve Valtek Valtek Anti-Cavitation Stack Valve with ³tiger-teeth¶ flow passages. Note the flow is radially outward. All rights reserved.

118 . All rights reserved.Valtek Anti-Cavitation Sleeve Valve Drawings Courtesy of Flowserve Valtek Valtek Anti-Cavitation Sleeve Valve with ChannelStream trim. © 2006 Electric Power Research Institute. Inc.

Calculating Cavitation in Valves ± Basic Definitions ‡ In order to introduce the calculation of cavitation in valves. some terms must be defined. These terms are: ± Vena Contracta ± High-Pressure Recovery Valve ± Low-Pressure Recovery Valve ± Cavitation index and cavitation number. Inc. see. 119 . All rights reserved. ‡ If you are not familiar with these terms. © 2006 Electric Power Research Institute.

Using Cavitation Parameters
‡ The fluid conditions are related to the valve characteristics through either the cavitation number or the cavitation index. A determination is then made as to: ± If the valve is not cavitating ± If the valve is cavitating, how severe the cavitation is.

‡

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Using Cavitation Parameters - Continued

‡ ‡

There are variants to this process, although they differ mainly in the details. Methodologies and correlations are available from: ± EPRI & NUREG reports cited at the end of the cavitation section ± Valve manufacturers¶ data.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Outline of Calculation
‡ ‡ ‡ ‡ ‡ Define problem. Determine local conditions. Calculate the cavitation parameter (index or number). Determine valve performance by comparing the cavitation parameter with the appropriate correlation. State result.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

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Calculating Cavitation in Orifices ± Basic Definitions

‡ ‡

As orifices have a constant geometry, they are easier to analyze than valves. If you are not familiar with the following terms: ± Vena Contracta ± Cavitation index and cavitation number ± See.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

123

These correlations are available in various references including NUREG/CR-6031.Single-Hole Orifices ‡ ‡ ‡ Empirical correlations have been published relating the onset of the various regimes of cavitation. USNRC. Inc. © 2006 Electric Power Research Institute. All rights reserved. 124 . Corrections may be required to account for the diameter and pressure level. 1993.

500 2. Inc. All rights reserved. Corrections may be required for other diameters and pressures.62 2.39 Note: These values are for one diameter and pressure.Sample Single-Hole Data Sample line from a table of orifice cavitation parameters vs.20 1. 125 . © 2006 Electric Power Research Institute. ratio Do/D ( ) incipience critical choking 0.

Inc. from the geometry. All rights reserved. 126 . Thus. These data seem to show that the cavitation response is related to the ratio of the total hole area to the pipe area. an equivalent beta ratio should be determined.Multi-Holed Single Orifices ‡ ‡ There is less cavitation data than on single-holed orifices. ‡ © 2006 Electric Power Research Institute.

See NUREG/CR-6031 for more information. ‡ ‡ © 2006 Electric Power Research Institute.Multi-Holed Single Orifices ‡ Using this value of beta. Inc. All rights reserved. single-holed orifice correlations should be applied with corrections for pressure and diameter as recommended. Manufacturers¶ data may also be available for some designs. 127 .

Series Orifices ‡ ‡ ‡ ‡ Series orifices are an effective way of dealing with a cavitating orifice. © 2006 Electric Power Research Institute. All rights reserved. Methodology for calculating a series arrangement will now be presented. See NUREG/CR-6031 and EPRI 1011231. 128 . Single-holed or multiple-holed orifices may be used in series. Inc.

If this design is satisfactory. the process is over. 129 . All rights reserved. © 2006 Electric Power Research Institute.Series Orifices ± Methodology ‡ ‡ ‡ The first step is to size a single orifice and see if it cavitates. Inc. If not. an iterative process must be used to design the orifices.

Inc. assume a beta ratio. All rights reserved.Continued ‡ ‡ ‡ ‡ Beginning at the downstream end. © 2006 Electric Power Research Institute. proceed upstream until the desired pressure drop is obtained. assume a larger beta and recalculate. 130 .Series Orifices ± Methodology . If the orifice is not cavitating. If the orifice is cavitating. Calculate the allowable cavitation index.

the point of lowest pressure and highest velocity is found just downstream of the restriction. All rights reserved. Inc.Vena Contracta ‡ When a flow passes through a restriction. © 2006 Electric Power Research Institute. 131 . ‡ This point is known as the vena contracta.

For a given pressure drop across a valve. © 2006 Electric Power Research Institute. 132 .High-Pressure Recovery Valves ‡ ‡ Valves types may be classified as high or low-pressure recovery (see later slide). a highpressure recovery valve will have a lower pressure at the vena contracta than a low-pressure recovery valve. All rights reserved. Inc.

Inc. See next slide for a schematic diagram.Continued ‡ The lower pressure at the vena contracta means that they are more susceptible to cavitation than lowpressure recovery valves.High-Pressure Recovery Valves . Examples of high-pressure recovery valves are ball. All rights reserved. butterfly and gate valves. ‡ ‡ © 2006 Electric Power Research Institute. 133 .

Loca ion 1 1. All rights reserved. Inc.2 1.6 0. 134 .4 igh Pressure Recover ow Pressure Recover Vapor pressure Cavitation likel © 2006 Electric Power Research Institute.4 0.2 0.and Lo -Pressure Recovery Valves 110 100 Pressure 0 0 0 60 0 0 0.High.

Lo -Pressure Recovery Valves ‡ Similarly for a low-pressure recovery valve.g. e. All rights reserved. Most types of control valves. This means that they are less susceptible to cavitation than high-pressure recovery valves. are lowpressure recovery valves. there will be a higher pressure at the vena contracta than for a high-pressure recovery valve.. 135 . Inc. globe. ‡ ‡ © 2006 Electric Power Research Institute.

‡ © 2006 Electric Power Research Institute. Inc. 136 .Cavitation Coefficient ‡ Cavitation coefficient is defined as: P d . This coefficient is commonly used in the United States.P d where: = Cavitation coefficient Pd = Mean pressure 10 diameters downstream Pv = Liquid vapor pressure Pu = Mean pressure one diameter upstream. All rights reserved.Pv W= Pu .

Pv velocity head Pu .P v VV 2 2 where: = Cavitation index = Mass density of the liquid v = Mean pipe velocity upstream.Cavitation Index ‡ Cavitation index is defined as: / Pu . Inc. © 2006 Electric Power Research Institute. 137 . ‡ This index is commonly used in Europe. All rights reserved.

Stage B ± Acceleration ± the fatigue limit of the material is reached and the material is losing pieces of the surface. © 2006 Electric Power Research Institute. but the subsurface is being fatigued by repeated impacts. 138 . Stage C ± Maximum rate ± the maximum rate of erosion damage is reached as the surface becomes very rough. Inc.Stages of Damage Stage A ± Incubation ± no damage is apparent visually. All rights reserved.

Stages of Damage -- Continued

Stage D ± Deceleration ± the surface has been roughened, and the rate of damage remains relatively constant. Stage E ± Terminal or Final Steady State Stage ± this stage may not be reached.

© 2006 Electric Power Research Institute, Inc. All rights reserved.

139

Flashing Erosion - Introduction
‡ ‡ Flashing erosion is related to cavitation erosion. Flashing erosion occurs when a liquid flow passes through a restriction and the local pressure drops below the vapor pressure forming bubbles (or cavities). In contrast to cavitation, these bubbles do not collapse but travel downstream.

‡

© 2006 Electric Power Research Institute, Inc. All rights reserved.

140

Flashing Schematic

100 0
e

0 0 60 0 40 0 0. 1
siti n

a

ess

e

ess

1.

2

© 2006 Electric Power Research Institute, Inc. All rights reserved.

141

Flashing Erosion ± Mechanism
‡ Since the bubbles formed by flashing have a much lower density than the liquid they were formed from, the average liquid velocity must increase. Flashing erosion causes damage, not from the collapse of bubbles, as with cavitation, but from the high liquid velocities.

‡

© 2006 Electric Power Research Institute, Inc. All rights reserved.

142

‡ ‡ © 2006 Electric Power Research Institute. The term flashing erosion is here to distinguish it from flashing which describes the flow conditions. 143 . For more information on flashing ± see.Continued ‡ Note that while cavitation may be prevented. Inc. All rights reserved.Flashing Erosion ± Mechanism . flashing will occur if the downstream pressure is below the vapor pressure.

Flashing Erosion ± Critical Flo ‡ ‡ ‡ When flashing occurs. the flow is critical or choked. All rights reserved. Inc. For more information ± see. 144 . That is the restriction is passing as much flow as possible for the upstream conditions. © 2006 Electric Power Research Institute.

´ Note again the difference between cavitation erosion and flashing erosion ± very rough vs. 145 . smooth.Flashing Erosion ± Morphology ‡ ‡ Surfaces damaged by flashing erosion are usually described as being ³smooth´ or ³polished. All rights reserved. Inc. © 2006 Electric Power Research Institute.

146 . Inc. All rights reserved.Damage Caused by Flashing Erosion Flashing damage downstream of a multi-hole orifice Photo courtesy of Southern Nuclear © 2006 Electric Power Research Institute.

Flashing Erosion Damage in a feedwater minimum flow recirculation line. Inc. photo courtesy of Florida Power & Light © 2006 Electric Power Research Institute. 147 . All rights reserved.

Where to Look for Damage ‡ Flashing erosion occurs: ± In single-phased systems ± Downstream of large-pressure drops caused by letdown valves or orifices Usually the downstream pressure is low. All rights reserved. 148 . Inc. Flashing erosion will be accompanied by noise and possibly vibration. ‡ ‡ © 2006 Electric Power Research Institute. perhaps as low as the condenser pressure.

Where to Look for Damage ± Continued ‡ It is important to note that cavitation and cavitation erosion may be prevented through design measures. but« ± Flashing will always occur whenever the pressure downstream of the restriction is less than the vapor pressure. All rights reserved. © 2006 Electric Power Research Institute. Inc. 149 . ± Vibration and or noise may be present and cause damage.

As the damaged area is likely small. All rights reserved. 150 . © 2006 Electric Power Research Institute.Inspection Considerations ‡ ‡ Flashing damage may be detected using conventional inspection techniques ± usually UT or RT. Inc. ultrasonic methods should use 100% scans or finer grids than are normally used for FAC inspections.

Countermeasures ‡ Design methods to reduce flashing erosion include: ± Use a sudden expansion or a target tee to keep the fluid away from the wall ± Use a larger diameter downstream to reduce the fluid velocity ± Move the restriction closer to the sink ± The use of a proprietary restrictor may help. 151 . Inc. All rights reserved. © 2006 Electric Power Research Institute.

Inc. 152 . All rights reserved. Materials consideration ± see.Countermeasures ± Continued ‡ ‡ These methods are described in more detail in EPRI Report 1011231. © 2006 Electric Power Research Institute.

All rights reserved.Calculation Approaches ‡ ‡ Little work has been done in this area. ‡ © 2006 Electric Power Research Institute. 153 . Valve manufacturers often recommend a maximum discharge velocity. See also EPRI Report 1011231. Inc. A suggested approach would be to calculate the downstream velocity and compare with a maximum allowable downstream velocity.

Flashing ‡ ‡ Flashing occurs when a liquid encounters a pressure below the vapor pressure.. Flashing has been extensively studied to predict the rate of depressurization following a loss of coolant accident ± e. LOFT series of tests.g. Inc. 154 . All rights reserved. This work was designed to predict the critical flow rate. ‡ © 2006 Electric Power Research Institute.

RELAP5.g.Flashing . These models are used in Nuclear Safety Codes (e. RETRAN).g.. All rights reserved. Inc. © 2006 Electric Power Research Institute.. TRAC) and system analysis codes (e. 155 .Continued ‡ ‡ Various models have been developed to predict the flow rates in these situations.

critical flow will occur. this will occur when the downstream pressure falls below the vapor pressure of the water. All rights reserved. Inc. At this point. ‡ © 2006 Electric Power Research Institute.Critical Velocity ‡ ‡ If the pressure downstream of a restriction is low enough. 156 . If the fluid involved is water. the flow rate is independent of the downstream conditions.

´ At this time. the flow is said to be ³choked.´ ‡ ‡ © 2006 Electric Power Research Institute. At this point. Inc. All rights reserved. This condition is also known as ³supercavitation. 157 . the flow rate through the restriction is a maximum for the upstream conditions. the speed of the fluid is the acoustic velocity.Critical Velocity ± Continued ‡ When critical velocity occurs.

As the flow is two-phase (i. the acoustic velocity is much less than the acoustic velocity for either the liquid-only phase or the steam-only phase. the flow is traveling at the local acoustic velocity. Inc. 158 .. All rights reserved. © 2006 Electric Power Research Institute. steam and water) at this point.e.Acoustic Velocity ‡ ‡ When flashing occurs.

All rights reserved. 159 . Inc.Acoustic Velocity of a Water-Steam Mixture © 2006 Electric Power Research Institute.

damage to the surface will result. If the droplets are big enough and if the velocity is high enough. All rights reserved. 160 .Droplet Impingement .Introduction ‡ Droplet impingement erosion occurs when a highvelocity stream of a liquid jet or a two-phase stream containing liquid droplets impacts a surface. Inc. ‡ © 2006 Electric Power Research Institute.

161 . © 2006 Electric Power Research Institute. Inc.Droplet Impingement ± Introduction . All rights reserved.Continued ‡ ‡ ‡ Damage to steam turbine blades is a common example of damage caused by droplet impingement. Droplet impingement is also known as liquid droplet impingement and liquid impingement erosion. Rain damage to aircraft canopies is another common example.

droplet impingement is a continuing problem in steam turbines. All rights reserved. 162 . ‡ ‡ © 2006 Electric Power Research Institute. Consequently much is known about the details of the processes involved. Aside from piping systems. Inc.Description of Mechanism ‡ Droplet impingement is an important mechanism in a number of technical areas. These details are beyond the scope of this module. Note this mechanism is not similar to solid particle erosion.

Inc. © 2006 Electric Power Research Institute. below which damage does not occur ± For steels.Description of Mechanism ± Continued Tests and experience have demonstrated that: ‡ The damage increases with velocity to a power between 3 and 6 ‡ There is a Critical Velocity. All rights reserved. 163 . this value is approximately 300 feet per second (~100 m/s).

164 . Inc. © 2006 Electric Power Research Institute. As with cavitation. damage decreases with decreasing size. damage is not a function of drop size.Continued ‡ ‡ ‡ Above drop sizes of about 1 mm.Description of Mechanism . All rights reserved. the damage is non-linear with time. Below this value.

© 2006 Electric Power Research Institute. All rights reserved. Time for Droplet Impingement Note ± the letters A-E refer to the stages of damage ± see.Damage vs. Inc. 165 .

Through-wall leaks are commonly experienced. Damage is normally localized to the impact region. All rights reserved. 166 . ‡ ‡ © 2006 Electric Power Research Institute.Morphology ‡ Surface damage caused by droplet impingement exhibit a very rough irregular surface with a cratered aspect. Inc.

Inc.Droplet Impingement Damage Copper alloy condenser tube damage by droplet impingement Overall View Cross Section photos courtesy of EDF © 2006 Electric Power Research Institute. 167 . All rights reserved.

Droplet Impingement Damage Comparison of an Eroded Turbine Blade with a Test Sample © 2006 Electric Power Research Institute. Inc. All rights reserved. 168 .

Inc. 169 . photo courtesy of Electrabel/Tractebel © 2006 Electric Power Research Institute. All rights reserved.Droplet Impingement Damage Damage downstream of a leaking valve in an extraction steam line.

All rights reserved. 170 ..Where to Look for Damage ‡ Damage caused by droplet impingement is often found in two-phase lines that experience a large pressure drop accelerating the flow to high velocities. ‡ Other locations include at the backside of spargers opposite incoming flows. e. Inc. © 2006 Electric Power Research Institute. ± Downstream of valves or steam traps that have failed open.g. ± In extraction lines where the relief valves have failed to shut.

Inc. photo and sketch courtesy of Constellation Energy © 2006 Electric Power Research Institute. 171 .Droplet Impingement Damage in a Sparger Leak in sparger with sketch showing location. All rights reserved.

Inspection Considerations ‡ ‡ Radiographic or ultrasonic techniques may be used to locate damaged areas. As degradation caused by droplet impingement is normally quite localized. Inc. © 2006 Electric Power Research Institute. ultrasonic methods should use 100% scans or finer grids than are used for FAC inspections. All rights reserved. 172 .

Improve the material ± see. © 2006 Electric Power Research Institute. 173 .. Use separators to eliminate some of the moisture and hence the damaging drops Repair leaking valves and traps. Inc.g. Improve the local geometry. All rights reserved.Countermeasures ± General Approaches ‡ ‡ ‡ ‡ ‡ Use larger pipe sizes to reduce velocity ± remember damage ~ v3±6. e. target tee.

As key parameters are unlikely to be known (e.Calculation Models for Droplet Impingement ‡ ‡ There are no known correlations suitable for predicting droplet impingement in power piping.g. © 2006 Electric Power Research Institute. droplet size distribution).. All rights reserved. 174 . Inc. it is doubtful that useful models yielding detailed results are possible.

All rights reserved.Calculation Models for Droplet Impingement ± Continued ‡ ‡ Approximate models for droplet impingement do exist ± see. velocities at various points of the system may be calculated and compared to the threshold velocity to produce a susceptibility ranking. © 2006 Electric Power Research Institute. As an alternative to a model. Inc. 175 .

All rights reserved. Inc. Two will be mentioned here: ± ASTM Model developed by Technical Committee G-2 ± Model of Frank Heymann¶s of Westinghouse Steam Turbine division. 176 . © 2006 Electric Power Research Institute.Droplet Impingement Models ‡ ‡ There are several models designed to predict the rate of droplet impingement.

ASTM Model ‡ ASTM has developed a purely empirical model for predicting the maximum erosion rate and the incubation period. ‡ ‡ © 2006 Electric Power Research Institute. This model is described in the annual ASTM Book of Standards. This model is felt to be accurate to about a factor of 3 for laboratory data. Inc. All rights reserved. with less accuracy expected for field predictions. 177 .

All rights reserved.6 mm. 178 . ‡ © 2006 Electric Power Research Institute. The erosion rate is a function only of the material resistance. the velocity.Heymann¶s Model ‡ ‡ Heymann developed a very simplified model designed to predict the rate of erosion. and the flux of droplets. provided the droplets are greater than 0. Inc. This equation may is described on the next slide.

All rights reserved. Inc.41 ™ 10 ‡ 18 v 5. 179 .Heymann¶s Model ± Continued ‡ The model is written as: N e Re ! 6.047 Where: ± Ne = rationalized erosion rate = ratio of the volume lost per second to the volume of impinging liquid per second ± Re = normalized erosion resistance ± v = velocity in meters per second. © 2006 Electric Power Research Institute.

© 2006 Electric Power Research Institute. As no accuracy limits are stated.6025 ™10 19 ‡ ‡ v 5. this correlation should be used with caution. this model reduces to: N e ! 1. Inc.Heymann¶s Model for Carbon Steel ‡ For carbon steel. All rights reserved.047 This correlation is based on steam velocity between 50 and 500 meters per second. 180 .

Material response is completely different for solid particle erosion. materials are usually considered to behave identically. All rights reserved. Inc. © 2006 Electric Power Research Institute. 181 . Flashing erosion is probably similar but little.Materials Considerations ‡ ‡ ‡ ‡ It has been found that materials respond similarly to cavitation erosion and droplet impingement. In fact. if any. work has been done in this area.

© 2006 Electric Power Research Institute. 182 . this work has met with limited success. A different approach was taken by Heymann who plotted relative resistance to erosion versus material. See more. Inc. All rights reserved. This approach is a good screening method.Correlating Damage ‡ ‡ ‡ ‡ Many investigators have attempted to correlate the degree of damage with material properties. In general.

1 10 1 ali e ro sio n R esista ic hr o e 30 0 er ie s ta er ie s ta ne lw el d ov er la ss in le ss In co in le l ee 00 st st ca ol te el on ar el © 2006 Electric Power Research Institute. All rights reserved.or 100 0 .1 oo E P l te R I or e el 2 co In ss . Resistance of Materials 183 u le r u le ta te l li te 6. Inc. ne l in le 6 .

Recommendations ‡ ‡ Based on information from the literature and from anecdotal sources. 184 . 300 Series stainless steel will provide more resistance than carbon steel.. the following materials should provide improved resistance to erosion: ± Inconel ± Duplex stainless steel ± Hard facing ± e.g. © 2006 Electric Power Research Institute. Norem. Inc. All rights reserved. Stellite. but less resistance than those on the above list.

g. 185 . Inc.. target tee. heavier wall fittings. © 2006 Electric Power Research Institute. All rights reserved.Repair Considerations ‡ Some repair options include: ± Replacement in kind ± Replacement with a more resistant material ± Local repair with an overlay or a patch of resistant material ± Local redesign ± e.

Some of the properties that have been used include: ± Hardness ± Tensile strength ± Ultimate strength © 2006 Electric Power Research Institute.Correlating Damage ‡ ‡ Many workers have attempted to correlate the erosion resistance of material with physical properties. 186 . All rights reserved. Inc.

Inc. Recently.Correlating Damage -.. e.Continued ‡ ‡ These attempts have only succeeded in correlating damage within a narrow class. EPRI has sponsored work which has been more successful by correlating damage with the fatigue related parameters: ± Fatigue strength coefficient ± Cyclic strain-hardening exponent © 2006 Electric Power Research Institute.g. All rights reserved. 187 . carbon steels.

All rights reserved. ‡ © 2006 Electric Power Research Institute. Details are available in EPRI Reports ± ± EPRI Report TR-108943-V2 ± EPRI Report 1011231 Details are also available in technical papers cited in these references. 188 . Inc.Continued ‡ ‡ Good agreement has been demonstrated for a wide range of materials.Correlating Damage -.

As SPE has been extensively studied..Solid Particle Erosion ± Introduction ‡ Solid particle erosion (SPE) occurs when a fluid stream containing particles impacts a surface causing damage. Inc. SPE is commonly encountered and is even used commercially (e. ‡ ‡ © 2006 Electric Power Research Institute. there is a large body of literature available.g. 189 . sand blasting to clean surfaces). All rights reserved.

‡ SPE is also called Particle Erosion. Apparently. the exact damage mechanism depends on the material and the particles involved ± For example. ductile target materials behave differently than brittle materials. and Particle Impact Erosion © 2006 Electric Power Research Institute. Solid Impact Erosion. Inc. 190 .Description of Mechanism ‡ ‡ Despite its inherent simplicity. the detailed mechanism of damage by SPE has not been determined. All rights reserved.

© 2006 Electric Power Research Institute. 191 . Inc. non-linear. All rights reserved.Important Note ‡ It is very important to note that SPE and droplet impingement are not at all similar in terms of parametric effects including: ± Materials effects ± Velocity dependence ± power dependence and critical velocity ± Damage rate behavior ± linear vs.

Impact of Velocity ‡ ‡ ‡ Velocity is a key parameter in SPE. 192 . Inc. There is a critical velocity below which SPE does not cause damage to surfaces. All rights reserved. This velocity is quite low. normally about 3 feet per second (~ 1 m/s) for ductile materials. © 2006 Electric Power Research Institute.

Investigators have found that the damage rate for ductile materials increase with the velocity to the power of between 2. ‡ © 2006 Electric Power Research Institute. 193 . Inc.Impact of Velocity .004´ (100 microns).Continued ‡ Damage to ductile materials from SPE will occur if the velocity is above the threshold velocity and the particles are greater than about 0.4. All rights reserved.3 and 2.

Surfaces may be rough or polished. 194 .Morphology ‡ Surface damages by SPE exhibit a variable morphology depending on the material. ‡ © 2006 Electric Power Research Institute. All rights reserved. Inc. ± Rippled surfaces are possible at small angles of attack on a ductile material. and grooving may occur. the properties of the particles and the fluid velocity.

195 .Damage Caused by Solid Particle Erosion Valve Internals Damaged by Solid Particle Erosion photos courtesy of Dominion Virginia Power © 2006 Electric Power Research Institute. All rights reserved. Inc.

Damage Caused by Solid Particle Erosion Turbine Blades Damaged by Solid Particle Erosion © 2006 Electric Power Research Institute. Inc. 196 . All rights reserved.

197 . All rights reserved. Inc.Solid Particle Erosion in a Steam Generator Blo do n Line Note the rippled surface. photo courtesy of Constellation Energy © 2006 Electric Power Research Institute.

All rights reserved. ± Service water systems ± the particles are silt and/or sand contained in the water. © 2006 Electric Power Research Institute. 198 .Where to Look for Damage ‡ Damage caused by SPE is often found in: ± Steam generator blowdown ± the particles are corrosion products from the steam generator. Note the critical velocity is small enough that damage occurs even in service water and related systems. Inc.

ultrasonic or visual techniques may be used to locate damaged areas.Inspection Considerations ‡ ‡ Radiographic. As degradation caused by SPE is normally quite localized. All rights reserved. 199 . Inc. © 2006 Electric Power Research Institute. ultrasonic methods should use 100% scans or finer grids than are used for FAC inspections.

for commonly used piping materials there is a much smaller difference in resistance than compared to the other mechanisms. Depending on conditions. 200 . ‡ ‡ © 2006 Electric Power Research Institute. See figure on next slide. Inc. All rights reserved.Materials Considerations ‡ It is important to note that the material resistance characteristics of SPE are completely different than other erosive mechanisms discussed in this module.

.20 0.Material Resistance to Solid Particle Erosion tellite 6 tellite 0 16 0 tainles s tainles s tainles s Inc onel 600 Inc olo 800 Inc onel 6 1 ild teel 0.00 1.80 1.00 0.20 Re la ti e Erosion Re sista nce a re d to S te llite For conditions of severe erosion (i. 201 . high velocit ) © 2006 Electric Power Research Institute. Inc. All rights reserved.60 o 0. 0 0.e.

Redesign may be necessary in particularly bad situations. All rights reserved. there is no material solution to problem. © 2006 Electric Power Research Institute. Probably 300 series stainless is the best replacement material available for piping systems.Continued ‡ ‡ ‡ Based on these data for severe conditions. 202 .Materials Considerations . Inc.

© 2006 Electric Power Research Institute. All rights reserved. Inc.Countermeasures The methods to reduce damage due to SPE include: ‡ Reducing velocity by increasing the pipe size or redesign ‡ Using target tees or similar approaches ‡ Reduce particle loading by ± Cleaning upstream ± Filtering/separation ‡ Using more resistant material. 203 .

Inc. These models may be useful under certain circumstances. particle size. particle material. © 2006 Electric Power Research Institute. geometry. 204 . material are some of the input requirements. More about models.Calculation Models and Parametric Trends ‡ ‡ ‡ ‡ There are empirical models available to predict the rate of SPE. Fluid velocity. All rights reserved.

For More Information ‡ EPRI Report 1011231 for a treatment of SPE in piping systems. Inc. All rights reserved. ± This report also contains a number of relevant references. © 2006 Electric Power Research Institute. 205 . ‡ EPRI Report TR-108943-V2 has a treatment of SPE in steam turbines.

206 . and friability (i.Parameters The parameters influencing SPE may be conveniently divided into three categories. particle size distribution. and microstructure. hardness. work hardening behavior. Target Material Variables ± all material properties including. the ease of fracture). ‡ Impingement Variables including ± particle velocity. angle of incidence. ‡ ‡ © 2006 Electric Power Research Institute. Particle Variables including ± particle shape. particle concentration. melting point.e.Solid Particle Erosion .. particle rotational speed. All rights reserved. hardness. Inc.

Parametric Effects ‡ ‡ Velocity ± the erosion rate for ductile materials varies as the velocity raised to a power between 2. ± Note that this is a much lower critical velocity than for droplet impingement © 2006 Electric Power Research Institute.3 and 2.4. Inc. All rights reserved. 207 . Critical velocity ± the critical velocity (above which damages occurs) is normally taken to be 3 feet/second (1 meter per second) for ductile materials.

208 . Note that intermediate behavior (not shown on the graph) is possible for materials that are not easily characterized.Continued ‡ Impact angle ± the amount of damage is a function of impacting angle. See chart on next slide. The damage profile depends on whether the material is ductile or brittle. All rights reserved. ‡ ‡ © 2006 Electric Power Research Institute. Inc.Parametric Effects .

Inc. 209 .Influence of Impact Angle on SPE © 2006 Electric Power Research Institute. All rights reserved.

210 . Experiments have shown that the damage for ductile materials is essentially linear with time. the erosion rate decreases rapidly with decreasing particle size below 100 microns. Inc. All rights reserved.Continued ‡ Particle Size ± the size of the erodent particle has little effect on the erosion rate of ductile materials as long as the particle size is above about 100 microns [i. ‡ © 2006 Electric Power Research Institute.e. 0.Parametric Effects ..004´].

© 2006 Electric Power Research Institute.e. All rights reserved.Most Commonly Used Models ‡ Two commonly cited models to predict the rate of solid particle erosion are: ± Finnie ± erosive wear as a consequence of the cutting (i. micro-machining) of the surface by impacting particles.. Inc. 211 . ± Hutchings ± erosive wear occurs as a result of material being plowed out by the impacting particles.

All rights reserved. Inc. e. Further.g. ‡ © 2006 Electric Power Research Institute. e. elbows. particle loading.g.Practical Limitations of SPE Models ‡ In power plant environments.. the available models are not applicable to piping geometries. the information needed to model the impacting particles is normally unknown. 212 . particle size distribution..

All rights reserved. 213 . Inc.Cavitation Erosion Damage to Pump Impellors © 2006 Electric Power Research Institute.

214 . All rights reserved.Control Valve Trim Damaged by Cavitation © 2006 Electric Power Research Institute. Inc.

Cavitation Damage in a Globe Valve © 2006 Electric Power Research Institute. All rights reserved. Inc. 215 .

Inc.Pipe Sho ing Extensive Cavitation Damage © 2006 Electric Power Research Institute. All rights reserved. 216 .

photos courtesy of Southern Nuclear © 2006 Electric Power Research Institute. All rights reserved.Erosion Damage in a Dump Valve Note the damage was caused by leakage. 217 . Inc.

Inc.Droplet Impingement Damage in a MSR Pocket Drain photo courtesy of Constellation Energy © 2006 Electric Power Research Institute. All rights reserved. 218 .

photo courtesy of Bruce Power © 2006 Electric Power Research Institute. Inc.SPE in a Valve Body Valve was located in the steam generator blowdown system. All rights reserved. 219 .

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CA 94304 Principal Investigator J. Taylor This report describes research sponsored by the Electric Power Research Institute (EPRI). CA: 2006. 1013570. . Horowitz T.CITATIONS This report was prepared by EPRI Solutions 1661 Page Mill Rd Palo Alto. The report is a corporate document that should be cited in the literature in the following manner: Computer-Based Training Module on Erosion in Piping Systems. EPRI. Palo Alto.

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