Estimation of Flow Accelerated Corrosion (FAC) in

Process Piping Using CFD Software and Low

Temperature Experimental Determination of FAC.

This presentation includes idea about Flow Accelerated Corrosion (FAC),

FLUENT analysis of KANUPP feeder in order to find FAC in them and
experimental work regarding to study FAC at low temperature.

Flow Accelerated Corrosion (FAC) is a process in which a normally

protective oxide coating dissolves into a rapidly moving water, or a
water/steam mixture.

Principal parameters on
which FAC depends are
temperature, pH, oxygen
content,
and
water
velocity.
This phenomena was
identified as a result of
research
in
France,
Germany, and the United
Kingdom over the past
twenty years.

FAC and Erosion Corrosion (EC) are normally considered same which is
wrong. The differences involves the mechanism by which the protective
film is removed from the metal surface.

In the EC the oxide film is

mechanically removed from a
metallic substrate.

In the FAC process, the

protective oxide film is not
mechanically removed. Rather,
the oxide is dissolved or
prevented from forming, allowing
corrosion of the unprotected
surface.

There is a cleared difference b/w single and double phase FAC. Singlephase FAC produces a scalloped appearance, similar to an orange peel
while Two-phase FAC produces a tiger striped or streaked appearance.

Single-phase FAC case

Two-phase FAC case

FAC rate is peaked in 130-150 oC and is due to fact that at higher

temperature magnetite layer becomes denser and solubility of Fe 3O4
reduces in water.

FAC rate increases with increase in pH of working fluid however

temperature contribution should must keep in mind as it considered a
sort of pH control agent.

FAC: transfer of Fe(OH)+ and Fe(OH)2 is accelerated by not only average

velocity but also turbulence factor which can described on shape factor
bases, higher the Kc higher will be the FAC.

FAC rate also depend on material used, in carbon steel FAC is maximum
while it suddenly decreases according to Cr(+Mo) contents thus FAC in
carbon steel can mitigated with high Cr contents.

FAC rate decreases with increasing Dissolved Oxygen (DO) and it is due
to the hematite formation which prevent FAC more than magnetite layer
that form in common.

Process piping isometric drawing and detail description is used to make

its geometry, meshing, CFD analysis etc.

Parameter

Detail

Feeder title

G-06

Line number

PH-478

Operating

567 0F

temperature at FP
Mass flow rate

27.41 lb/sec

Velocity of fluid

8.3 m/sec

Density of fluid

784.4 Kg/m3

Nominal thickness

5.54 mm

Thinning rate

0.1084 mm/EFPY

Geometry is developed by using Pro/Engineer and then is saved in IGS

format.

GAMBIT is used for meshing. Hex core mesh is used in order to lower cell
counts and improve the quality, this type is generally used for
volumes with complexity near the walls.

flow

Meshed file that has generated is solved in segregated solver, 3D space,

implicit formulation, cell based gradient option and absolute velocity
formulation at steady state condition is set for analysis.

In order to check grid independency (GIT) two grids with different counts
are made and solved to get velocity contours when these give very less
remarkable difference grid independency proved.

Grid Cells = 450,000

Time for solution = 1.25 hrs

Grid Cells = 550,000

Time for solution = 1.75 hrs

Velocity contours and velocity vector are determined.

Contours of wall sheer stress and absolute pressure also give an idea to
predict the location of high corrosion attack.

Discrete phase model enhancement feature can be used to calculate

erosion rate at walls result shows in unit less quantity which in actual
heaving units of length/time.

Further description of model provide more deep analysis of Erosion Rate,

from velocity contours corresponding to maximum velocity erosion rate
of 1.1 mm per year calculated

Here
B
V

=
=

495 (for 2.75mm diameter particles)

7.64 m/sec

So Maximum Erosion Rate is

ERmax

1.1 mm/year

Layout of experimental setup for determination of Flow Accelerated

Corrosion is shown. Open system design is selected in order to examine
phenomena at low temperature.

Centrifugal Pump, water storage tank, pipeline and fitting that used in
setup are shown. Pipe lines of UPVC are used in order to retain integrity
above 90oC.

Water tank

Pump

Pipe lines and Fittings

Specimens Holder different views and coupon used in experiment are

shown, specimens holder is also made of thermal resistance plastic
material.

Assembled setup in operating and non operating condition is shown

while proceeding experimental clip provide better visual aid of completed
experiment.

video.mp4

Main objective of experiment is to determine FAC at low temp which may

further explained as determination of threshold temperature for FAC,
Experimental working conditions are given in table.
Sr

Parameter

Condition

No.
1

Coupon

M.S.

material
2

Coupon area

51.0 cm2

Temperature

90 oC

Total running

12 hrs

time
5

Working

1 atm

pressure
6

Flow rate

0.2947 lit/sec

Fluid velocity

1.338 m/sec

During experiment water chemistry is maintained as of chemistry of

secondary side of

KANUPP or as chemistry of water used in CIAL

experimental rig.

Parameter

Sr No.

Range

LiOH

0.01 g/lit

pH

9 10

Conductivity

20 30 s

Chlorides

1ppm

DO

10 ppb

Hydrazine

20 - 30 ppb

Observations and calculations at end of experiment give the idea of

corrosion rate in coupons maintained at specific conditions, in coupon 2
maximum corrosion rate is observed

Coupo
n
No

Initial
weight
(g)

Final
weight
(g)
110.6067

Change in Corrosion
weight
rate
(g)
(g/cm2
year)
0.0974
1.3941

110.7041

107.783

107.669

0.114

1.6317

108.8162

108.7231

0.0931

1.3326

110.8500

110.7666

0.0834

1.1937

pH and conductivity trend of working fluid during experiment w.r.t time

shows almost constant pH and increasing trend of conductivity; increase
in conductivity is due to addition of crud from old pump.

Sr

Tim

pH

Conducti

No.

vity

(hrs)

(s)

9.32

28.8

9.29

44.6

9.26

51.9

9.26

55.2

9.25

59.9

10

9.24

63.2

12

9.24

67.8

RESULTS AND DISCUSSION

CFD analysis of give the maximum wall thinning rate of 1.1

mm per year, while in the plant the data maximum thinning
rate of feeder is given 0.1084 mm per EFPY.

A great difference in thinning rate is due to neglecting the

welding points in feeder geometry development, Ignoring
chemical addition effect in primary stream etc.

RESULTS AND DISCUSSION (Contd....)

From experiment maximum corrosion rate found in

coupon no 2 because of maximum eddies
formation due to flow pattern.
No evidence of FAC observed on coupons (orange
peel appearance) surface and not remarkable wall
thinning measured.
At 90oC no FAC occurred so there is no need to do
experiment below this temperature.