FAC PRESENTATION

PIPE THINNING
Corrosion Erosion Erosion corrosion Flow assisted corrosion Cavitations

Factors necessary for corrosion

Requirements for corrosion Anode & cathode Electrolyte & electron flow
Anodic dissolution: Fe+2 + 2eCathodic reduction 2 e- + 1/2O2 + H2O Fe

Electrolyte H2O ,4 OH2Fe

+2

O2 Cathode

Anode 2Fe 2OH4e-

OH

OH or oxide Corrosion products Metal ions dissolves Cathod + e Anode e

Typical anodic reactions: + + Fe ( Metal) = Fe + 2e + 2 Fe + 2OH = Fe(OH)2 4Fe(OH)2 + O2 +2H2O = 4Fe(OH)3 Typical cathodic reactions: 1/2 O2 + H2O + 2e= 2OH + 3 Fe + e= Fe+2 + 2H + 2e= H2

Erosion-Corrosion : EPRI defines this as:

Degradation of material caused by both mechanical and chemical processes.

Flow Accelerated (or Assisted) Corrosion: EPRI defines this as:

A process whereby the normally protective oxide layer on carbon or low ally steel dissolves into a stream of flowing water or a water steam mixture. It can occur in single phase and in two phase regions. EPRI has stated that the cause of FAC is water chemistry. Identified by TIGER STRIP or CHEVRONS

FAC DEFINITION :
FLOW ASSISTED CORROSION IS A DEGRADATION PHENOMENA THAT ATTACKS PIPING AND VESSELS EXPOSED TO MOVING WATER OR STEAM RESULTING IN THE LOSS OF MATERIAL AND WALL THINNING.

Factors affecting Flow Assisted Corrosion

Sl.No. 01 02 03 04 05 06 07 08 Parameters Low velocity Low pH Low dissolved oxygen Low temperature Geometry Low chromium Low molybdenum Low copper Lower Higher Higher Higher 150oC) (80-230oC),Maximum (130FAC rate

Turbulence Higher Higher Higher

Flow Assisted Corrosion (FAC):

FAC is the chemical dissolution of surface oxide and metal, accelerated by flow and flow impingement.

Diagram of the interaction of key controllable factors that jointly lead to flow-assisted corrosion

Factors Affecting FAC

Environment Water Coolant (Single phase or Two Phase) Temperature pH Oxygen Content

Hydrodynamics

Velocity Turbulence Flow impingement such as at bends Flow discontinuities such as at bends and tees Turbulence promoters such as irregular weld or changes in pipe diameter

Material

Carbon Steels containing some amount of Cr, Cu and Mo reduce FAC rate

Corrosion as a function of velocity

Mechanism of flow assisted corrosion of steel

Schematic representation of the mechanism of flowassisted corrosion of steel.

Flow

1
Start with water at surface of base metal

2
Reaction between dissolved oxygen and metal surface forms a protective oxide layer

5
Continual removal and reforming of oxide results in wall thinning

New oxide High flow layer forms on velocity exposed removes oxide and carries it patches of bare metal downstream

Simplified mechanism for FAC Simplified mechanism for FAC

FAC induced Scallops

How Scalloped Surface is Formed ?

FAC induces Scalloped or Orange Peel surface appearance. It is formed due to surface irregularity:

Fluid motion in the vicinity of a Scallop At point 1 the main flow separates in the form of a jet above the recirculating flow At point 2 the jet flow becomes irregular and turbulent At point 3 it causes mixing between the jet fluid and and the fluid in the lee eddy At point 4 the jet flow impinges most directly on the surface where the rate of dissolution is the highest.

Effect of temperature on Flow Assisted Corrosion

Single phase FAC damage: within 80230oC. Maximum: ~130-150oC (within O2 free environment.
38 65 93 122 150 178 205 232 260 288

Temperature (oC)

Effect of temperature on FAC

With increasing temperature Fe+2 concentration at the water -oxide interface decreases linearly. Fe+2 diffusivity into the coolant increase,resulting in a mass transfer coefficient that increase almost linearly. The resulting FAC rate variation with temperature is a bell shaped curve.

Effect of temperature on Flow Assisted Corrosion

Both the pH at temperature and the level of dissolved oxygen in the stream influence the stability and solubility of the magnetite oxide layer. The solubility increases increasing temperature decreasing pH. with and

The solubility of Fe(OH)2 rises with increasing temperature to a maximum at around 150oC, then decreases with a steep drop to the solubility of magnetite between 200250oC.

Effect of pH on Flow Assisted Corrosion

US NRC Information Notice No. 86-106 FAC wear rate:High between pH 7.0 and 9.0 or below pH 5.0. FAC rates: Drop sharply at pH > 9.2. At Surry-2: pH levels were between pH 8.8 and 9.2.
Effect of pH on FAC

Korean literature, Corrosion rate decreases In the pH range from 8.0 to 9.5. Corrosion rate increases in the pH range from 9.5 to 10.0.

Effect of oxygen on Flow Assisted Corrosion

Oxidising conditions (10-50 g/l O2) Makes the OPR positive, Favours formation of FeOOH, and Restricts diffusion of oxidant (O2/H2O) Overall effect: Reduction in FAC rate.
Effect of dissolved O2 on FAC

Haematite more stable than magnetite. Haematite is less soluble than magnetite. FAC rates come down when dissolved oxygen is increased over this threshold values. Concept is called as Oxygenated Water Chemistry (OWC).

Effect of flow on Flow Assisted Corrosion

Increase in flow velocity: Increases the FAC rate. Local flow velocities: Can be 2-3 times higher than bulk velocities. Areas prone to FAC: Down stream of restricting orifices, flow control valves, reducers, and in elbow and tees. FAC can occur in both low and high velocity area where there is a change in flow pattern (laminar to turbulence).

Effect of flow on Flow Assisted Corrosion

Laminar flow regime

Turbulent flow regime

Effect of velocity on FAC

Erosion corrosion rate

Vc Flow Velocity

At low velocity: FAC rate controlled by the rate of mass transfer. At higher velocity: FAC rate controlled by chemical reactions at the metal-oxide and oxide-water interfaces. Above critical velocity: Metal will be removed by mechanical processes.

Effect of alloy on Flow Assisted Corrosion

As per US NRC Information Notice No. 86-106 Carbon steel: More vulnerable to erosion/corrosion under certain unfavorable conditions. Resistance to erosion corrosion can be increased significantly by increasing the alloy element. 2 Cr-1 Mo steel improves piping resistance to erosion corrosion by a factor of four. Surry 2 failed pipe elbow: Unusually low amounts of these elements, particularly chromium (less than 0.02%).
Chemical composition (% by weight) (ASTM) A106 Gr.B A336 P11 A335 P22 C 0.30 0.15 0.15 Mn P S 0.058 0.03 0.03 Si 0.1 0.5~1.0 0.5 1.0~1.5 1.9~2.6 0.44~0.65 0.87~1.13 Cr Mo Fe Balance Balance Balance 0.29~1.06 0.048 0.3~0.6 0.3~0.6 0.03 0.03

2.25% Cr & 1% Mo Material

Properties similar to Carbon Steel. No significant Design Change required. No separate design analysis required. Solubility of FeCr2O4 is less compared to Fe3O4. Disadvantage Require special welding, preheat & post weld heat Treatment.