Proceedings of the ASME 2011 Power Conference
Proceedings of the ASME 2011 PowerPOWER2011
Flow Accelerated Corrosion in Steam Condensate Piping & Valves.
Problems faced and actions taken.
K. C. Upreti,
Senior Vice President
(Engineering & Maintenance - Mechanical),
Reliance Industries Limited,
Nagothane Manufacturing Division,
Raigad, Maharashtra, India - 402125.
Tel:+91 7709010867, Email:Kailash.upreti@ril.com.
ABSTRACT
Flow accelerated corrosion (FAC) is a combined form of
erosion, corrosion and Cavitation. This is prominent in steam
condensate lines which results in fast reduction of thickness in
piping, piping components and valves. It is estimated that this
problem is faced by majority of plants. There has been an
increased emphasis on correcting these problems due to fatal
accidents that occurred in 1986, 1995, 1996 and 2004 at
various locations around the world. [3] After commissioning
of the plant, Steam condensate system erosion/corrosion
problem started appearing within one year of operation. To
ensure uninterrupted plant running on line sealing was done
and monitoring was done by proper thickness checking. These
on line sealing points were replaced during available
opportunity.
In some cases plant shutdown was taken to replace leaking
piping components & these incidents resulted into revenue
loss to company. Aggressive inspection programs were taken
up for thickness measurement on condensate lines and as a
proactive measure, elbows were encapsulated with higher size
elbows, reducers by on line welding/furmaniting with special
clamps. Similarly gate and globe valves in condensate service
also started failing as a result of erosion of body seat rings.
Globe valves installed on bypass lines of control valves were
found passing. Once these valves were operated for
maintenance of control valves they could not be closed. In
some cases valve body developed leak due to high velocity
erosion.
Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use
Conference
July 12-14, 2011, Denver, Colorado,
POWER USA2011
July 12-14, 2011, Denver, Colorado, USA
POWER2011-55222
POWER2011-55222
Sai Vamsidhar Bontha,
Senior Manager
(Engineering & Maintenance - Mechanical)
Reliance Industries Limited,
Jamnagar Manufacturing Division,
Jamnagar, Gujarat, India – 361142.
Tel:+91 9998215667, Email:sai.bontha@ril.com.
Various studies conducted for replacing these components by
higher schedule fittings & pipes but it did not improve the
situation except for slight increase in life of these components.
Velocities were calculated at various locations and higher
velocity, condensate impingement/cavitation was found as root
cause of problems. This problem was solved by various
methods like using higher metallurgy P11, P22 material, line
size increase with increase in control valve sizing, lay out
changes etc. This helped in improving reliability of condensate
system and reducing risk associated with failure of piping.
This paper presents a variety of cases where single-phase and
two-phase steam flows, caused erosion-corrosion damage
mainly at turn points of elbows and valves. It was observed that
the presence, even of a small amount of the vapor phase can
significantly increase the velocity of the condensate. This paper
describes the mechanism of failures by study of the failed
components, operating conditions & piping lay out.
In this study velocity of steam /condensate at reducing section
was found to be very high. Other various contributing factors
like control valve / piping sizing, metallurgical requirements,
effectiveness of steam traps, flow velocity and valve design
(globe & gate) were also studied. The main causes of the
failures are discussed and recommendations are provided to
rectify the root cause of the problems & avoid similar problems
in the future.
.
1 Copyright © 2011 by ASME
 I. IINTRODUCT TION TO FLOW AC CCELERATED D occurss in pure wateer at 100-150°°C in the preseence of even 1
COR RROSION & EROSION IN N STEAM CONDENSAT
C E ppm oof oxygen. Steeam generally ppasses throughh piping system
m
PIPIN NG & SYSTE EMS. at verry high velociities. The flow w velocity is another majo
or
Flow acceleratted corrosion (FAC) also called erosio
F on acceleerating factor inn a steam conddensate system.
corrosion (E-C) is a significant & common dam mage mechanism m
for mmost of the faiilures in steam m and condensate systems in i
indusstries [3]. FAC results in thinnning of carbonn and low-allo oy
steel pipe & piping g components, mostly of carb bon steel pipinng
and tuubing. It is a mass
m transfer process in whicch the protectiv ve
oxidee (mostly magn netite) is remov
ved from the stteel surface intto
the flowing water / condensate. The material weear rate depend ds
on thhe steel com mposition, temp perature, flow
w velocity an nd
turbuulence—and on n water and water
w droplet pH
p and oxygeen
and ooxygen scaveng ger concentration. [3]

FAC occurs when thet normally protective

p iron--oxides dissolv
ve
into tthe flowing sttream. Two th
hings are neceessary to creatte
erosioon with steam and condensatee:

• High velocity.
• Two-phasee flow conditions with primarrily steam and
additional few small partticles of conden
nsate.
Fig. 2 – Formation oof pits on outer rradius due to losss of protective
W
When steam condenses,
c liqu
uid formation results and th he layer
systemm becomes acctually a two--phase (vapor--liquid) system m.
Normmally, the wetteer the steam (ii.e., the greaterr the amount of
o Actuaal operating eexperience sh
hows that eroosion in steam
m
condeensation), the more
m corrosivee it becomes. It
I is well knowwn condeensate piping is due to coombined effecct of FAC andd
that the steam is acidic because of the decomposition of o cavitaation.
bicarbbonates resultiing in carbonicc acid formatiion. At elevateed
tempeeratures and prressures pH off water also fallls to 6.0. Acidiic Cavitaation Erosion is the name ggiven to the reepeated growth h
condiitions make thee steel surface extremely suscceptible to locaal and coollapse of bubbbles (or cavitiees) in a liquid bbecause of locaal
attackk at such highh temperatures.. Oxygen, even at very smaall static pressure fluctuuations, usuallly caused by cchanges in flow w
conceentration as low as 50 ppb willw significan ntly increase thhe velociity. If the presssure in a flowiing liquid decrreases to beloww
corrosion rate at eleevated temperatures. [3]. its vappor pressure beecause of, for eexample, significant increases
to the local flow veloocity, then vappor bubbles aree nucleated.

Thesee bubbles are transported ddownstream ffrom this flow w

disturbbance. When tthey reach a reegion of higherr pressure, they
y
collappse suddenly aand may erodee any solid m material in theiir
vicinitty.

Fig. 1 – Daamage to protectiive oxide layer by

b FAC

The m mode of dam mage is generaally characterizzed by pattern ns

such as grooves, waaves, rounded holes, valleys and horseshoee-
shapeed depressions. All these forrms of damagee exhibit stron ng
Fig. 3 – Dam
mage due to bubbble collapse (cavvitation)
directtional pattern consistent
c with
h liquid flow. Pitting
P corrosio
on

2 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 Wheree,
F(R) =
=> Steel compoosition factor
F(C) =
=> Water treatmment factor
F(T)=
=> Temperaturee dependence ffactor
=> Geometry faactor
F(G)=
F(X)=
=> Mass transfefer dependence function
TL =>> Thickness looss rate

Most oof the above faactors have a vvery strong, expponential effecct
on thee material wearr rate.

Temp perature has a pronounced eeffect on the F FAC wear ratee.

Whenn a system is iinspected, com mponents in thhe 250˚F-400˚FF
(i.e Appprox. 100 0C – 220 0C ) raange should bee of the highesst
prioritty as it has beeen experimenntally found ouut that FAC is
greateest in the menntioned temperrature range [11].The figure 5
beloww indicates thhat the erosiion-corrosion rate becomes
Fig. 4 – Dam
mage due to impin
ngement at high
h velocity maxim mum at 121 0C to 204 0C temmperature rangee. [1].

Any liquid water handling

h systeem that can operate near th he
saturaation conditionns is susceptib
ble to cavitation damage. This
proximity to saturaation can be lo ocally increaseed by increaseed
flow velocity aroun nd obstacles anda in regionss of turbulencce
wheree the static pressure of thee water is red duced or by an a
increaase in water teemperature. Caavitation is mo ost often causeed
by thhe collapse of steam
s bubbles,, but it can alsso be caused byb
gasess (nitrogen andd oxygen) and volatile
v chemiccals coming ou ut
of thee solution in water
w and subssequently redisssolving. Unlik ke
FAC, all materialss used in steaam cycle watter systems arre
susceeptible to caviitation damagee. The materiaal property thaat
correllates best with the susceptibility to cavitatio
on is the fatigu
ue
limit. However, it is not clear whether,
w for various
v aqueouus
enviroonments, the cavitation co orrelates with air fatigue or o
corrosion fatigue prroperties. [3]

Liquiid Droplet Imp pingement corrrosion is caused by the impacct

of thee liquid droplets on the waall material. Th his paper treatts
these similar type ofo failure mecchanisms causeed by effects ofo
fluid flow in the samme field as Flo
ow Accelerated d Corrosion [1]. Fig. 5 - E-C R
Rate Vs. Temperaature –Source – Ref - [1]
The slow FAC daamage can leaad to a catasttrophic “break k-
beforre-leak” situatiion with steam m expanding and hot wateer Tempeerature, velociity and oxygenn content are tthe factors thaat
flashiing into steam.. Carbon steel pipe thinning typically
t occurrs will m most aggravaate the corrossion reactions. It has been n
in thee return conden
nsate piping establiished that an iincrease of tem
mperature up too 180°C resultts
in moore than fourfoold increase off the corrosionn rate of carbonn
SSENTIAL RE
II. ES EQUIREMEN NTS OF FAC. steel inn neutral soluttions.
TThe major facttors that affect the erosion-co
orrosion rate on
o The ffigure also inndicates that tthe erosion- ccorrosion value
FAC include the folllowing: decreaases for alloy steels containiing Cr & Mo aas compared to
((a) Temperatu
ure carbonn steels. As thhe Cr & Mo coontent increasees the E-C rate
((b) Flow Veloccity decreaases. This will be discussed aagain in refereence to MOC &
((c) pH Metalllurgy effects on E-C rate. [1]]
((d) Oxygen Co oncentration
((e) MOC / Meetallurgy (Cr, MoM Content) Flow velocity has a strong effeect, which maakes wet steam m
((f) Geometry / Shape ms very suscepptible to FAC
system C because the velocity of the
((g) Flow Cond dition ( Singlee Phase / 2 Phaase (Dryness or
o steam flow is usuallly much higheer than the watter flow. It haas
Wetness off Steam)) been derived that the Erosion – Corrosion rate increases
Thesee can be formuulated mathemaatically as: exponnentially with tthe velocity. Exxperiments of various studiees
have iindicated that erosion starts above 35 metter/second flow w
TL = F(X). F(G). F (T).F(C).F(R
R)….. [3] velociity. [3]

3 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 In 2 pphase flows thee FAC also is governed by thhe mechanism ms
of drooplet impingem ment erosion annd also the cavvitation erosion
n.
The raate of erosion in a 2 phase flow depends on the dryness
fractioon (dry ration or wet ratio of the flowing fluid). The rate
of walll thinning deppends / increasses with increaase in wet ratio
in casee of 2 phase floow.[1]

Metalllurgy of the ppipes and the ppiping materiall also increases

the ressistance to FAC
C. The FAC prroblem is mostt pronounced in n
carbonn steels. In thhese steels, evven small conncentrations ofo
chrommium, molybdeenum and coppper can impprove the FAC C
resistaance.

A survvey of 38 heatts of carbon stteel found thaat depending on n

Fig. 6 - E-C Raate V/s. Fluid Vellocity [1] –Sourcce –Ref-[3] the scrrap compositioon, there couldd be up to 0.3%% Cr, which can n
improove the FAC resistance up to 100 timess. Where FAC C
The pH & Dissolv ved O2 Conceentration also effect the E-C probleems cannot bee resolved byy changing water chemistry y,
rate tto a large exteent. The Erosio
on – Corrosion n rate decreasees carbonn steels are oftten replaced byy low-alloy steeels, such as P11
graduually over a pH H range of 8 to
o 9. The pH off feed water annd and PP22, or a weldd deposited ovverlay is used. [3]. The FAC C
steam
m droplets need ds to be kept above
a the 9.5 th
hreshold, whicch value decreases foor alloy steelss containing Cr & Mo as a
depennds on the pH agent used an nd on temperatture [1]. Similaar compaared to carbon steels.
to thee effect on E-CC because of teemperature, prresence of Cr &
Mo ddecreases the effect
e of pH onn the E-C rate.. [1]. Oxygen is As thee Cr & Mo conntent increases the E-C rate ddecreases. Also o,
good at preventing g FAC. It hass been shown that 5 ppb of o Similaar to the effectt on FAC becaause of temperrature, presence
oxygeen in feed wateer can practicaally stop FAC, while excessiv ve of Cr & Mo also deccreases the effeect of pH on thhe E-C rate. [1]
conceentration of ox xygen scavengers acceleratess it. It has beeen
shown that in most cycles that do not have copp per alloy tubing
g, Geommetry is an impportant factor affecting the F FAC. Generallyy
oxygeen concentratiions can be as high as 20 2 ppb withou ut turbullent flows are ggenerated at orrifices, valves, bends, Tees &
causinng any problem ms. Elbowws. Further errosion is advvances by im mpingement by y
dropleets or due to caavitation at thesse areas.
Flow Condition (S Single phase orr dual phase) has
h a bearing on o
the loocations wheree the erosion – corrosion takees place. In casse For bbends /elbows for example as shown inn the figure 6. 
of sinngle phase thee FAC progressses due to thee turbulent flow w Maximmum FAC / erosion and thereby thickkness reduction n
that ooccurs near the connection off the bend area and the straighht occurss at the intraddos portion off the elbow foor single phase
pipe on the anterio or side of the bend referred d to as intradoos flows and the extraddos portion of tthe elbow for 2 phase flows.
portioon of the bendd as indicated in the figure 5. On the otheer
hand,, in case of 2 phase flow (condensate & steam), FAC The fi
fig. 8 & 9 givven indicate thhe mechanismss and thickness
advannces when the flow impingess on the pipe wallw surface an nd reducttion locations for single & 2 phase flowws for bends &
causees the erosion particularly on n the exterior part
p of the ben nt elbow
ws.
portioon referred ass the extrados portion of th he Elbow. Waall
thinniing action in particular
p is go
overned by ero osion mainly ini
the 2 phase flow. [1].

Fig. 8 – Flow phase Vss. failure locationn.

Fig. 7 – Effect of flow
w phase on FAC
C

4 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 The arreas which werre found suscepptible to FAC –

• Reducing aarea of reducerss/inlet area of eexpander.

• Mid partitioon of equal teees.
• Gate valve body seats whhich are threadeed.
• Globe valvee body seats.
• Downstream m side of undeersized control valve body.
• Thermo weells, sampling nnozzles and injection quills.
• Steam pipiing in heating systems. Retuurn condensate
piping & doownstream of fflow meters.

The vvulnerability oof particular components to erosion waas

higherr on componeents where vellocity increasee is significantt.
Fig. 9 – Mechaanism of FAC in piping. – Source – Ref [1] Rate oof erosion ratee was comparaatively higher on reducers &
elbow
ws as in fig. 11. The liquiid erosion-corrrosion usually y
occurss when the corrroding or solidd particles bom
mbard (impingee)
AC EXPERIE
III. FA ENCE
the m
metallic surfacee at an angle ((worst case at approximately y
F
Following prob blems were obbserved on con
ndensate system
m
90°).
with iin very short tiime after comm
missioning:
In parrticular, high-vvelocity wet steam can causee some specific
11. Erosion off HP/MP/LP co ondensate line elbows
e on outeer
forms of impingemeent corrosion ddepicted as steaam erosion withh
longer radiius.
roundeed surface andd showing a larrge number off small cones as
a
22. Erosion off reducers, welld neck flange inner diameteer,
in fig. 12.
bypass vallve joining po oint at downstrream of controol
valve on innlet line to conddensate drums.
33. Erosion on n gate/globe vaalve body. Som me of the valvees
developed leaks from bod dy.
44. Erosion off threads on vaalve body for renewable
r valv
ve
seats. Somme of the bypasss valves starteed passing oncce
the valve operated
o due to
o detachment of valve seats.
55. Erosion off condensate pumpsp casingss (Carbon steeel
material off construction).
66. Leaks form m orifice plate root valve weeld joints on thhe
orifice platte flanges.
77. Erosion off steam turbinee chest valve seats & seatin ng
area, LP glland area, cond denser reinforcement pipes.

The mmost vulnerablle parts in low

w pressure cond densate systemms
were found to be thet locations where
w flow dirrection changees
suddeenly and there is increase in flow velocitiess as indicated in
i Fig. 11 – Erosioon Leaks in Elboows due to two pphase flow
the figg. 10 below. .

F
Fig. 10– Location
ns susceptible to FAC in control valve station Fig. 122- Impingement corrosion/erosioon

5 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 III.A
A. Erosion on reducers:
r valve cracked openned in condenssate service gets eroded fasst
due too higher veloocities. Wire-ddrawing will eventually cu ut
Conccentric reduceers: Various field observatio
ons indicate thaat enouggh of the metaal in a valve sseat that it preevents adequate
most of the failurees in reducers take place at higher velocitty closurre, producing leakage in the system. The operating g
zoness especially at neck area whhere diameter reduction takees personnnel normally complained thhat gate valvess in condensate
place as shown in th
he fig 13 below
w. servicces are not holding. Butt when we examined the
probleematic valves, it explains thhe reason of passing of these
valvess. Sometimes, high velocityy through thee narrow space
resultss in erosion oof valve body itself and it results in hole
formaation on valve bbody.

Fig. 13 – FAC in
i Reducers

Eccen ntric reducerss: Maximum erosion takes pllace on top sidde

of reeducer from where
w shape reduction
r starrts. On straigh
ht
portioon of reducers no erosion tak
kes place as evident from thhe
fig. 14 given below..

Fig. 15,16 – Gate valve Dissc & body seat errosion

Fig. 14 – FAC in Ecccentric Reducerss

III. B
B. FAC Probleem in Gate vallves:

Normmally correct sp pecifications off valves on conndensate servicce

are geenerally overloooked. Valves with threaded body seats fin nd
place in condensatee service. Duee to differentiaal expansion of o
body and seat in acttual operating condition,
c smaall leakages staart
to devvelop initially. Since velocitiees across the valves
v are higheer
threadds of body seaats, these threadds and seats geets eroded in non
time due to wire drrawing effect. Now the valv ve starts passinng
fully due to damag ged seats. It is also experienced that seat of o Fig. 17 – Damage to Boody of angle valvve

6 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 III.C. FAC Problem
m in Globe va
alves:

This pproblem is sim

milar to gate vaalves where ero
osion of thread
ds
takes place in body and seats. Afteer prolong use in service bod
dy
seat bbecomes fully detached afteer erosion of tack
t welding as
a
shown in fig. 18 7 19
1 and passing further increasses.

Fig. 18 – Damage to thrreads in Body seeats.

Fig -21: Dettachment of bodyy seat from valvve body

Somettimes high vellocity throughh this narrow sspace results in n

erosioon of valve boddy itself and itt results in holle formation on
n
valve body itself aas shown in ffig. 22 and it should not be
confussed with defects like casting blow holes.

Fig. 19 – Erosio
on of Globe valv
ve seats (erosion of threads)

If succh valves are operated,

o the loose
l body seaat gets lifted up
u
and ggets struck between valve stem s and bodyy. These valvees
cannoot be operated further and sttarts passing fully
f and in this
condiition it may ressult in further high velocity erosion
e of otheer
pipingg components as shown in fig g. 20 7 21.

Fig. 22 – Erosion in globe valve houusing leading to hole formation

III.D.. FAC in BFW

W pump autom
matic recirculaation valves:

Thesee valves are alsso subjected too FAC / E-C duue to the nature
of theeir operation philosophy. T There are sevveral problem ms
associiated with theese valves inn condensate recycle line :
i) Ero sion: flashing & cavitation rresults trim andd body erosion
n.
ii) Seevere noise aand vibration - flashing aand cavitation n.
iii) L
Leakage - eneergy loss resuulting from ppassing valvess.

Erosioon of cascade valve as show wn in fig. 23 & 24, leads to

damagge to housing and loss of energy due to ppassing valvess.
Improoper metallurgyy selection off components leads to fasteer
Fig. 20 – Erosio
on in valve housiing due to erodeed body seat erosioon and subsqueent damage to vvalve.

7 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 spacerrs form annnular channeel where thhe condensate
accummulates & cannnot flow wiith stream buut continues to
circulaate. This happpens with all guuide blade carrrier in the area
of shroouded rotor blaades.

Fig 26 : Corrossion at Guide blaade carrier and caasing area

Also tthe corrosion of casing as in fig. 26 cann occur due to

blockaage/clogging oof water drains or extraction thereby forcing
g
the wwater back intoo the casing. If this condeensate water is i
carriedd over to steaam path and impacts the bblade, thermall-
fatiguee failure can occur within a short periood. Erosion of o
Figg. 23, 24 – Erosio
on in BFW pump p automatic recirculation valve interm
mediate and loow-pressure bblades is usuaally caused by y
cascade ho
ousing water in the steam m. Operation below desiggn inlet steam m
tempeerature or at llow load can cause condensation in these
III.E. Steam condeensate related erosion in steam turbines: stagess, leading to eroosion problemss.

A varriety of erosion
n problems can
n arise in wet stteam areas:
• W Water droplet impact erosio on, primarily ofo rotating last-
sstage LP turbinne blades.
• S Surface erosiion/corrosion in crossoveer pipes, an nd
pparticularly in LP
L casings and
d blade carrierss.
• W Wire drawing (crevice erosiion) due to steeam leakage in i
ssealing areas.

Figg. 25: Erosion beetween blade row

ws of a LP bladee guide carrier.

It is observed thatt inner diametter of guide blade

b rows geet
effectted due to caaulked in sealling strips, gu
uide blade an
nd Fig. 27, 28 – Erosion of steeam chest & valvve seat

8 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 The opperating condiitions for the CCV and hence tthe downstream
m
pipingg is as follows:
Designn Pressure: 21.11 Kg / cm2
Designn Temperaturee: 217 0C
Flow R Rate: 19.10 mT T / Hour
Pressuure at Inlet: 15..98 Kg / cm2
Pressuure at Outlet: 1.10 Kg / cm2
Tempeerature at Inlett: 200 0C
Tempeerature at Outllet: 175 0C
Densitty: 864.176 Kgg / m3
∆P: 144.88 Kg / cm2

Fig29 : Turrbine LP side lab

byrinth housing erosion
e

Fig.31 – Skketch of the spoool d/s of Control valve

The B
Bill of Material for the sketch is as follows:
0 1. 6” 300 LB, WN FLG, A105 N, STD WT T. RF, B16.5,
IBR.
022. 6” BW, 90 Deg LR Elbow w, A234-WPB, STD. WT.
B16.9, IBRR.
033. 6” X 3”, BWW, ECC RED., A234-WPB, STD. WT.
B16.9, IBRR.
044. 3” SMLS P PIPE, A106-B, STD WT. , BB BE, IBR.
055. 3” X 1.5”, B
BW, ECC RED D., A234-WPB B, STD. WT.
Fig 30 : Erosion of cond
denser support bars
b B16.9, IBRR.
066. 1.5” 300 LBB, WN FLG, A A105 N, SC 800, RF, B16.5,
If steeam quality iss not properly y maintained, it may lead to t IBR.
erosioon of critical components
c lik
ke steam chestt valve seat annd
seatinng area as in figg. 27, 28, 29 & 30. This makees repair of areea There were frequennt failures in the extrados portion of the
difficcult due to acceess problem. w. The failure w
elbow was localized as shown in Figg 32A & B.

AC EXPERIE
IV. FA ENCE: PLATF
FORMER – REFORMATE
R
SPLIITTER:

Frequuent failure in the piping do ownstream of the Condensatte

returnn control vaalve Z231-FV V-504was exp perienced in a
Platfoormer Unit commissioned
c in Dec’ 2008. Feed to th he
Reforrmate splitter is pre-heated in
n Debutanizer FBE
F (Z231-S005
A/B).. Heat to the Reformate
R splittter (Z231-C12)) is provided by
b
MP ssteam Re-boileers (Z231-S26 & S27). The reboilers utilizze
the M
MP steam to reh heat the processs fluid. The co
ondensate outleet
from these two reboilers is routed to th he atmospheriic
condeensate tank viaa the condensaate return contrrol loops Z231 1-
FV-504 & Z231-FV V-505 respectiv vely.
Fig. 32A – Erossion pattern caussed by condensatte droplets

9 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 signifi
ficantly increease the coorrosion rate at elevated
tempeeratures.[5] Hennce, The laborratory analysis of the samplees
indicaates that all thee measured parrameters are ass per predefined
normss. There is haardly any deviiation except in stray casess.
Hencee, it was decidded to redo thee velocity calcuulations for the
defineed CV and its ppiping configurration.

Vi = { (2.4) x Q x Vs } / { A }-------- [5]

Wheree,
Vi: Veelocity of the F
Fluid in (Ft/minn) [Where i = 2 for velocity at
a
6” elbbow & 5 for vellocity at the 1.5” Flange]

Q: Coondensate Floww in (Lbs / Hrr) = 19.10 T/hhr = { (19.10 x

1000) x 2.2046 } Lbbs / Hr = 421077.86 Lbs / hr.

Vs: Sppecific Volumee at Flow Presssure (ft3 / Lbs)

Fig. 32B – Erosion pattern caused by condensaate droplets Area in (in2) [W

Ai: Crross Sectional A Where i = 2 foor c/s area at 6”
elbow
w, 3 c/s area at outlet of 6” x 3” reducer & 5 for c/s area at
a
IV.A. Analysis: the 1..5” Flange]

The vvisual inspectiion of the faiiled elbow ind

dicated that th
he V2=[ { (2.4) x 421077.86 } / { A2} ] x Vs
failurre was due too erosion posssibly due to high
h velocities. A2 = ((22/28)x (D)2 = (22/28) x (1554.81/25.4) 2
Howeever to zero down
d on the ro
oot cause of th
he problem, thhe = 29.11874 in2
condeensate sampless were routineely monitored. The results ofo
the saample were as follows: V2=[ { (2.4) x 421077.86 } / { 29.18874} ] x Vs
=(34662.414) x Vs
TABLE
E1
Lab Monitoring
M of Coondensate Samples Vs = 0.124 (m3 / Kgg) = 0.124 ((3.33)3 ft/ 2.20466 Lbs) = 2.077
O2 ft3 / Lbbs
Iron
pH Cond
ductivity TDS (Dissolved)
(Fe)
*
Considdering flow off saturated steeam at the inleet to the piping
g
8.4 2.4 1.6 0.035 7.0
8.3 2.4 1.6 0.037 5.0
spool,, the calculatedd velocities are:
8.5 2.3 1.5 0.040 7.0
8.4 2.4 1.6 0.035 5.0 V2 = 71191.24 ft/min = 35.999 m/s
8.2 2.3 1.4 0.029 3.0 V3 = 288384.25 ft/minn = 142.06 m/s
7.4 2.4 1.4 0.035 7.0 V5 = 1002820.49 ft/minn = 5144.61 m/s
8.4 2.2 1.7 0.037 5.0
8.3 2.4 1.6 0.037 7.0 Considdering 2 phasee flow of wet stteam (steam & condensate) at a
(* Centrally at Captiive Power Plant)) 80% ddryness fractioon at inlet to thhe piping spooll, the calculated
d
velociities are:
Usuallly, pure steam
m is not aggressive from a co orrosion point of
o
view.. However, if its condensatees are contam minated by CO O2 V2 = 36621.74 ft/min = 18.110 m/s
and ddissolved oxygen it becomes rather corrosiv ve. When steam m V3 = 144265.72 ft/minn = 71.445 m/s
condeenses, liquid formation
f resu
ults and the sy ystem becomees V5 = 511710.22 ft/min = 258.81 m/s
actuaally a two-phaase (vapor-liq quid) system. Normally, th he
wetteer the steam (i.e., the greater the amount off condensation n), Howeever at the dow wnstream of thee Z231-FV-5004 control valve
the m
more corrosive it becomes. It is well known n that the steam
m as thee piping is floaating with the aatmospheric coondensate tank
k,
is acidic because off the decompossition of bicarb bonates resultin
ng the fluuid is almost eqquivalent to saaturated condeensate (and no
ot
in caarbonic acid formation. Att elevated tem mperatures an nd steam)) due to the drop in presssure and tempperature in the
pressuures pH of waater also falls tot 6.0. Naturallly, temperaturre controol valve. Hencce, the calculaated velocitiess of the liquid
and ooxygen contentt are the factorrs that will most aggravate th he condeensate downstreeam of the conntrol valve aree (Parameter Vs
corrosion reactions.. [5]. It has beeen established that an increasse changges to 0.0011 m3 / Kg):
of teemperature up to 180°C reesults in moree than fourfolld
increaase of the corrosion rate of carbon steel in neutraal V21 = 0.3320 m/s
solutiions. Acidic coonditions mak ke the steel surrface extremelly V31 = 1.2265 m/s
susceeptible to locall attack at succh high temperratures. Oxygeen V51 = 4.5580 m/s
even at very smaall concentration as low as 50 ppb wiill

10 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 As per API RP 14E, the recommended simple design criterion
for erosional velocity (Ve) for avoiding fluid erosive wear is :
Ve=C / [ ρm ] (1/2) --------- [6]
Where,
C= 100 for Continuous service
C= 125 for non-continuous service
ρm= Mixture Density.
API RP 14E, states that the fluid velocity should be kept at least
below this fluid erosional velocity. Hence in our case the value
of Veis:
Ve = C / [ ρm ] (1/2)
Ve= 100 / [864.176] (1/2)
Ve= 3.40 m/s
Velocity V51 (4.580m/s) is much greater than the erosional
velocity Ve (3.40m/s) specified in API RP 14E.
IV.B. Conclusions:
Even as this study was in progress, to counter the problem of
failure until a solution for the same was found, a standby spool
was fabricated and made ready for ease of maintenance by
reducing the downtime of the control valve. As the failure was
the result of high velocity combined with drop let impingement
piping size needs to be enhanced to reduce the fluid velocities
to acceptable limits.
The control valve sizing was increases from the earlier 1.5” to
3.0” NB thereby decreasing the critical outlet velocity V51 from
4.580 m/s to an acceptable 1.26 m/s, which is well below the
erosional velocity limit Ve as per API RP 14E.
V. CONTROLOF FAC
V.A. Periodic Assessment of condensate system:
An effective FAC control program should include the
assessment of piping and components at high velocity area. The
assessment should include:
• Component geometry
• Flow velocity
• Water and steam parameters
• Material composition
•Water chemistry (pH, oxygen, oxygen scavenger, CO2,
organics); and
• Operating experience, previous failures
Every plant should have a formal program for prevention of
FAC and Cavitation, starting with an early design review. The
design review should include all the parameters influencing
FAC. In cases where organic water treatment chemicals such as
amines, dispersants and oxygen scavengers are used, their
Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use
effects and the effects of their decomposition products should
be considered.
V.B. Inspection and NDT:
Based on assessment the most susceptible components/critical
location should be selected for inspection so that failures can be
detected in advance. Piping should be inspected after all
orifices, thermowells, sampling nozzles and chemical injection
quills and passing valves. In addition, boiler blow downs, down
comers, headers, drum liners, saturated steam pipes, steam
separation systems, turbine extraction pipes and extraction
valves, feed water heater drain valves and shells, feed water
piping, condensate return piping, condensers , boiler feed water
pump recirculation lines.
Inspection methods for wall thickness monitoring include
ultrasonic wall thickness measurements, X-ray of piping and
other components, pulsed Eddy Current technique where
thickness can be measured without removal of insulation.
Modeling of pipelines should be carried out to determine
critical locations. Implementation of full coverage grids and
predictive plant model helps in monitoring FAC.
Periodic inspection should be also be made as
valves/component may wear over a time. As a minimum,
annual inspection of valve body and bonnet should be
performed with calibrated ultrasonic gauge. In addition to this
automatic recirculation valve of BFW pumps should be
inspected at regular interval.
Severe application may require additional inspection type and
or frequency like thickness measurement grid for accurately
monitoring thickness at critical location.
V.C. Valve orientation and guided disc:
It is observed that the globe valve having stem orientation in
horizontal direction have tendency to vibrate due to cantilever
weight of valve disc. To prevent this globe valve should be
selected with inbuilt guide so that chattering of disc can be
avoided. All globe valves should be operated with stem vertical
and pipe line horizontal. It is also important globe valve should
be designed w.r.to desired operating data like control valves are
designed for specific Cv. Globe valve for steam condensate line
it should not be considered as common piping item which can
be installed anywhere.
Improvements done:
1. Welded body seats with stellited hard facing was
specified for valve seats.
2. Valve stem Guide was specified for guiding the stem
of globe valves.
3. Distance after control valve was maintained min 10
times the diameter.
4. Pressure reducing station requires minimum 20 times
the diameter as separation distance before change of
flow direction.
5. One additional gate valve specified at downstream of
globe valve in a control valve station for condensate
11 Copyright © 2011 by ASME
 service as shown in the schematic Fig. 33
3 given below w. M
Multi cage anti--cavitation trim m for high presssure recovery
This gate valve is to o be used ass a secondarry (F
FL) valve
containmen nt device wheenever bypass globe valve is 4. H
High lift (more than 20% lift) valve to increaase trim life
closed afteer doing mainteenance job on control
c valve. 5. Fuurther Improveement in desiggn by use of pillot valve, flow
sttraightener, oriifice plate to crreate back presssure for
prreventing erosiion.

V.E. Improvementts for tacklin ng FAC in ssteam turbine

systemm & its associaated componeents:
Steamm quality shouldd be monitoredd for steam turrbine on regulaar
basis. Steam condennsate can causee failure of blaades, erosion of
o
steam chest valves and speciallyy LP section cconnected with h
condeenser. Inspectioon/overhaul pllan should be mmade at desired
intervaals so that stteam condensaate erosion prroblem can be
detectted in advance before failure of componentss.

A mettallurgical upggrade has also helped in redduction of FAC C

probleem in these loccations. Groovves in the low--pressure guide
vane ccarrier removee free water via holes to the exhaust casing g
and soo, directly on too the condenseer. This featuree as indicated in
n
fig. 355, substantiallyy reduces the free-water in tthe wet section n
of ourr condensing tuurbines and redduces exhaust sstage erosion to o
Fig. 33 – Schematic show
wing additional valves
v a miniimum.

V.D. Improvements in Automa atic Recircula ation Valves ini

BFWW pumps:
Severral recommen ndations were implemented d to minimizze
abovee mentioned prroblems:
1. 117-4 pH steel Harden
H trim andd bushing to reesist erosion
ccause by flashin
ng and cavitatiion.
2. A Anti-cavitation
n trim to minimmize / avoidancee of
ccavitationSA4779-S41000.  

Fig-35: Drainss in exhaust casinng for draining ffree water

 
Fig-34 –M
Modified Automaatic recirculation
n valve

3. M
Multi-stage antti-cavitation trim for small vaalve
Fig -36: Chhromium rings ffor guide blade ccarrier
M
Multi-hole anti-cavitation trimm for large valv
ve

12 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 Steam turbine manufacturers have considered use of chromium rangeability of 50:1 is acceptable for steam
steel components as shown in Fig. 36, for elimination of wear applications.
of components due to erosion and corrosion. Chromium rings
have been designed in such a way that it can be inserted It is good practice to keep the downstream steam velocity
between guide blade rows without replacing guide blades. With in the valve body typically below 150 m / s for saturated
this wear between stator rows and danger of blade damage can steam and 250 m / s for superheated steam.
be eliminated. There are thermal spray coatings (High Velocity
Oxygen Fuel (HVOF), Atmospheric Plasma Spray (APS) and
This can be achieved by increasing the valve body size,
Arc Wire Thermal Spray technologies) available for repair of
which will also reduce the velocity in the valve outlet and
corroded/eroded area.
the likelihood of excess noise. It is possible to consider a
saturated steam exit velocity of 150 m / s to 200 m / s if the
V.F. Control valves for steam condensate service: steam is always guaranteed to be dry saturated at the valve
The design and material of the control valve must be suitable inlet. This is because, under these circumstances, the steam
for the pressure of the system in which it will be fitted. Control leaving the control valve will be superheated due to the
valve selection requires several other factors to be taken into superheating effect of reducing the pressure of dry
account. The body material must saturated steam.
be selected to suit the application like stainless steel in place of
carbon steel and exotic materials for very special applications,
Following improvements done to prevent FAC:
Factors to be considered while selecting a control valve:
• Control valve size increased ( after taking into
consideration the flashing)
1. Maximum, normal or minimum mass flow or
• Control valve downstream piping size increased and
volumetric flow to be considered
90 degree elbows minimized.
2. Flow medium (this may affect the type of material
used for the valve body and internals).
V.E. Cavitation Behavior of Materials:
3. Upstream pressure at maximum, normal and minimum
The FAC problem occurs mostly in carbon steels. In these
loads. Downstream pressure for maximum, normal
steels, even small concentrations of chromium, molybdenum
and minimum loads.
and copper can improve the FAC resistance.
4. Kv value required.
5. Pressure drop across the valve at maximum, normal
From survey of failure data of carbon steel piping it is observed
and minimum loads.
that use of higher alloys Like P11, P22, weld overlay can
6. Maximum differential pressure for shut-off.
improve the situation by reducing failure time but it is not a
7. Maximum temperature of the medium flowing through
permanent solution unless velocity problem is resolved.
the valve.
Following improvement measures were taken to eliminate the
8. Any special requirements, for example, special gland
condensate system problems:
packing variations; hardened valve seat and plug, soft
seats for absolutely tight shut-off; and others.
1. In some of the cases control valve metallurgy was
9. An application needing on / off control (either fully-
changed to CF8M from WCB.
open or fully-closed) may require a valve
2. Metallurgy of control valve downstream piping and by
characteristic suited to that purpose, whereas an
pass valve piping changed to P11 material from A106.
application calling for continuous control (any degree
3. Condensate Pumps replaced with new pumps having
of opening or closing), might perform better with a
13%Cr metallurgy for casing.
different type of valve characteristic.
4. Welded body seats with stellited hard facing was
10. Method of actuation and type of control to be used;
specified for valve seats in condensate service.
11. Leakage and isolation. Control valves are meant to
control flow rate rather than isolate the supply, and are
V.F. Design Issues:
likely to leak slightly when fully shut. Control valves
The design and operating errors result in erosion in piping &
will be manufactured to a standard relating to shut-off
it’s components, equipment damage, erratic pressure control,
tightness. For steam control valves, a leakage rate of
safety hazards and higher economic losses due to outage of
0.01% is perfectly adequate for most applications.
plant. Following are the issues which occur in normal
12. Turndown. Usually expressed as a ratio of the
operation:
application maximum expected flow to the minimum
controllable flow through a control valve.
13. Rangeability. Usually expressed as a ratio of the valve • Undersized condensate piping downstream of traps,
maximum controllable flow to the minimum • Ignoring the presence of two-phase flow.
controllable flow, between which the characteristics of • Improperly sized condensate return lines,
the control valve are maintained. Typically, a

13 Copyright © 2011 by ASME

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 Downnstream piping g cross-sectionnal area must beb larger by th he steam in condensaate header w which increasees velocity in n
same ratio as the change
c in voluume. Consult steam
s tables fo
or condeensate piping. It is observedd that passingg high pressure
the sppecific volumee of saturated steam for thee two pressures, steam trap will causse sharp increaase in velocityy of condensate
then calculate the ratio of the downstream pressure
p to thhe wo phase flow in piping.
and tw
upstreeam pressure (always
( greateer than 1). Floww rate no morre
than 1.82 m/s to 2.43
2 m/s shoulld be used forr proper sizing g, Whenn steam traps ccause a back-uup of condenssate in a steam m
whilee flow velocity
y should usuallly limited to about 35m/s to t main, the condensatte is carried aloong with the ssteam. It lowerrs
preveent condensate erosion probleems. steam quality and iincreases the potential for water hammerr.
Duringg start up “watter hammer" occurs when sluugs of water are
V.G. Sizing errors and effects: pickedd up at high speeds in a ppoorly designeed steam main n
Undeersized piping introduces
i follo
owing problem
ms: wheree there is a lift after steam traap. As the slugg of condensate
is carrried along the ssteam line it reeaches an obstrruction, such as
a
a bendd or a valve, where it is suuddenly stoppeed. This creates
• Higher preessure drop/ inssufficient flow to point of usee
pressuure waves annd produces a safety hazzard as piping g
of high risk
k of water ham
mmer and erosio on problem.
compoonents can be bblown out by tthe force of water hammer or o
criticaal flange starts leaking after looosening of boolts.
Overssized distributiion piping lead
d to following problems:
p
Consiidering above a properly deesigned steam m systems (both h
• Un necessaary expensive large diameterr piping, biggeer saturaated and superhheated) should include condeensate traps and
d
support foor piping, hig gher installatioon cost, higheer separaators. Steam trraps causes a back-up of ccondensate in a
heat lossess from expensiive condensatee formation du ue steam main header,, the condensaate is carried along with the
to greater surface area of
o steam pie, poor quality of o steam. It lowers steeam quality annd increases thhe potential fo
or
steam quaality caused by formation n of additionaal water hammer.
condensatee.
• Velocity thhrough pressuure reduction station
s must be
b
consideredd when sizing g fittings an nd componentts.
Designer sizing these lines often fail fa to properlly
he significant increase
consider th i in speecific volume of
o
steam withh reduced presssure.

If thee condensate lines are und der sized (by neglecting th he

presence of flash stteam), then thiis results in an
n increased bacck
pressuure and veloccity. The liquid phase could d lead to wateer
hammmer. Severe water
w hammer can cause daamage to steam m
pipingg system, eq quipment and personnel. Increased
I bacck
pressuure can create problem with process equipm ment. A portio
on
of thee pipe will bee occupied by flash steam and a the balancce
with ccondensate.

F
Further Impro ovement done:
• Critical pip ping loop design reviewed and increase in i F ig 37: Erosion oof HP steam tarp body seating arrea and seats
piping sizee, proper confi
figuration of piiping lay out to
t
streamline the flow& reduction in num mber of elbow ws At onne of the plaant improper condensate reemoval led to
helped in reducing
r probleem. crackiing of main LP P header. This header was found moving up p
and ddown due to condensate acccumulation aand release by y
• Orifice flan
nge root valvee threaded conn nection changeed inefficcient steam trapps.
to socket welded
w type connstruction in place of threadeed Followwing should bee done to improove condensate removal from m
connectionn. Plain nipp ples were ussed for valv ve steam headers:
connectionn with orifice plate
p tapping pooints. • Carry out steam trap suurvey and coorrective action n
every six m
month.
V. H. Functioning of steam trapss: • Strainers off steam traps should be cleaaned on regulaar
In moost of the steam system two o reasons have been identifieed basis to preevent clogging of steam trap llines.
for steam trap failurres- • Functioningg of stem traap should be monitored. A
• IImproper sizing g of steam trap
p and downstreaam piping maintenancce program should be establlished to repaiir
• D Dirty/clogged steam
s trap faulty trapss in time. Speccial attention sshould be given
n
to HP/MP ssteam traps.
A prooperly operatin
ng steam trap allows
a condenssate to drain ou ut • Selection oof steam traps w w.r.to numberss of steam traps
of steeam system. Im
mproper functio
oning steam traap either fails to
t & Capacityy should be checked. Coldd condition of o
close or remains oppen. A passingg steam trap alllows release ofo

14 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 return heeader some time gives indication fo or by thee insertion of rrings made of this material aas shown in the
inadequatee capacity of in
nstalled steam trap.
t figuree 39, given beloow.
• In case of repetitive failu
ure of steam trrap consult witth
trap suppliier for hardnesss improvemen nt of steam traap
disc.

V.I. O
On line sealing g clamps:
A steeam leak can become
b biggerr and bigger due
d to the hig gh
veloccity of steam m flow incorp porating a sm mall spray of o
condeensate that gets released from m the opening. Today’s plantts
have higher capacitties and their down time is very costly. An A
area sshowing majorr reduction should be isolated d and offered fo
or
replaccement of com mponents at th he earliest. If plant
p cannot be
b
shutddown due to vaarious reasons, on line sealing g clamps can be
b
installled with propeer risk assessmeent.

It is nnecessary to have
h clear ideaa of thickness reduction areaas
and qquick assessmeent of remainin ng thickness shhould be carrieed
out. Sometimes narrow
n escape due to ruptture of erodeed
pipe/ppiping compon nent observed while carryin ng out thicknesss
surveey. Fig 339: Online sealinng clamp weldedd near flange (too attend leaking
reducerr)

As onnline leak sealiing is a very hhigh risk job, A general Risk

k
matrixx for the online leak sealiing job is givven below fo or
referennce:

TABLE
E2
Risk M
Matrix for onlinee leak sealing- foor lines which caannot be isolated
d
without shuttingg the plant
S.N Activity Hazards Controll Measures
Assessment for
area and
Rupture of
thickness Barricade the arrea.
leaking
01 measurement Use proper safeety gear and ensure
e
pipe/piping
and clear escape rouutes
component
measurement
for clamp
Design of the cllamp to be
Fig 38: Condensate (clamped) line removed
r at suitable opportunity. Clamp reviewed & appproved by
02 Clamp Design
Photto shows dangerss associated withh Flow Acceleratted Corrosion, iff Failure concerned Engiineering
leeaks are not atten
nded in time. department.
Injury due to Standard certifified scaffold to beb
Access to fall from used for access..
03
location height or fall Full body harneess with lifeline tot
On line sealing on these locations is highly risk ky due to loweer of materials. be used.
thicknness of piping g components at leak locatio on. Sealing joob Drilling & Exposure to Heat resistant gloves/ apparel to
shoulld be taken up on priority bassis as leak may y become biggeer online leak hot be used.
04
sealing condensate, Minimum persoonnel allowed to
and bbigger with du ue course of tiime. Area for on line sealin ng preparation steam access job site.
shoulld be selected wherever
w higheer thickness is available. Most 02 nos calibrateed PGs to be used.
suitabble location iss flange OD/B Boss area, straaight portion ofo Hydraulic pumpp should be free
pipe eetc. Crew and welders for thiis job should beb highly skilleed from leak
Over Standard & certtified tools to be
and trrained. Correctt thickness meaasurement is veery important ini
pressurizatio used.
this ccase. It is also necessary
n to monitor
m clampss for any leak in
i n may lead Job should be ddone by competent
futuree and should be b removed anda normalized d at the earliest Injection of to clamp and trained perssonnel.
opporrtunity. online leak damage, Proper threads sshould be made for
05
sealing parent injection nozzlees.
material. equipment Select right seallants for desired
On linne sealing clam
mp may not susstain on longerr duration hencce damage, leak service, Monitoor quantity of
sealinng clamp shou uld be welded to
t prevent faillure of clams asa may get injected sealant
no claamping arrangeement may be available due tot faster erosio
on aggravated. Have a contingeency plan in case
leak increase duuring on line leak
of coomponents. Th his welding job should be considered as a
sealing process
onlinee welding and required safety
y precautions should
s be takenn.

15 Copyright © 2011 by ASME

E

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use

 VI. CONCLUSIONS:
FAC in steam condensate piping causes failures which are
often sudden and catastrophic. In view of this, a systematic
approach for reduction of FAC rates can be adopted so that
reliability and safety can be improved. Following options are
available to reduce FAC rates.
• By using the proper tools, a steam system can be sized
to optimum conditions, with minimum heat loss and
maintenance attention.
• Correct steam pipe sizing is critical not only for
energy efficiency, but also for safety.
• Material changes can be used to replace an entire
system or to repair an especially troublesome area.
However, material replacement may reduce the wear
rate but it will not help much if the damage is caused
by a mechanism other than FAC.
• Provide good quality steam at the required demand
and pressure of the user.
• Monitor steam traps for proper functioning specially
HP, MP steam traps as these may also contribute to
higher increased condensate load.
• Taking flash steam into consideration at d/s of trap,
condensate piping has to be sized based on two-phase
flow (the presence of steam and condensate.
• Steam quality should be monitored for steam turbine
on regular basis. Steam condensate can cause failure
of blades, erosion of steam chest valves and specially
LP section connected with condenser.
Inspection/overhaul plan should be made at desired
intervals so that steam condensate erosion problem can
be detected in advance before failure of components.
• Whenever plant debottlenecking activities are planned,
review should also include condensate piping sizing
and steam traps.
FAC can be reduced by improving following three factors:
Hydrodynamics Parameters
• Flow Velocity
• Component Geometry
• Steam Quality
Water Chemistry
• pH Level
• Oxygen Content
• Temperature
Pipe Material Composition
• Chromium
• Copper
• Molybdenum
For control of FAC long term strategies should be adopted to
tackle problem and determining FAC rates. Critical areas
should be given priority and additional inspections should be
carried out.
Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/30/2016 Terms of Use: http://www.asme.org/about-asme/terms-of-use
Inspection department should adopt following strategy to
monitor FAC -
• Develop measurements strategy that identifies the extent of
component degradation.
• Identify problem areas for additional inspections
• Provide evaluation methods of degradation trends in order
to refine the predictive models.
• Help to focus inspection resources based on models
predicted trends.
• Include condensate piping in Tripod meeting discussion
and Monitor the problematic area.  
Software packages have been developed for assessment of wall
thinning caused by FAC by EPRI, EdF and Siemens. These
softwares can be used with correct input of water chemistry-
temperature, pH, and concentration of oxygen scavenger,
concentration of oxygen and chemistry of water droplets.
REFERENCES
01. Guidelines on pipe wall thinning taking into account
flow accelerated corrosion of water & wet steam
pipelines in ships. Sep’ 08, Nippon Kaiji Kyokai.
02. Recommendations for an effective flow accelerated
corrosion programs. Apr’ 99, EPRI, palo alto, CA
1999, NSAC-202L-R2.
03. Flow accelerated corrosion & cavitation. Jan’ 09,
Otakar Jonas, Water & Waste Digest.
04. Effects of valve trim geometry in flashing service. Dell
Grunenberg, Richards Industries Valve Group,
Cincinnati, USA.
05. Erosion in Elbows in hydrocarbon production
systems: Review Document, TUV NEL Limited. 2003.
06. A study of the erosional / corrosional velocity criterion
for sizing multiphase flow lines, Southwest Research
Institute, San Antanio & Houston, 1989.
07. 70.020.E.04.03 – Elimination / Prevention of Erosion
– Corrosion damage, M/s DDIT Industrieturbinen
GmbH & M/s Siemens. Feb’ 2004.
16 Copyright © 2011 by ASME