POWER2011-55222
POWER2011-55222
ABSTRACT
Various studies conducted for replacing these components by
Flow accelerated corrosion (FAC) is a combined form of
higher schedule fittings & pipes but it did not improve the
erosion, corrosion and Cavitation. This is prominent in steam
situation except for slight increase in life of these components.
condensate lines which results in fast reduction of thickness in
Velocities were calculated at various locations and higher
piping, piping components and valves. It is estimated that this
velocity, condensate impingement/cavitation was found as root
problem is faced by majority of plants. There has been an
cause of problems. This problem was solved by various
increased emphasis on correcting these problems due to fatal
methods like using higher metallurgy P11, P22 material, line
accidents that occurred in 1986, 1995, 1996 and 2004 at
size increase with increase in control valve sizing, lay out
various locations around the world. [3] After commissioning
changes etc. This helped in improving reliability of condensate
of the plant, Steam condensate system erosion/corrosion
system and reducing risk associated with failure of piping.
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 This paper presents a variety of cases where single-phase and
on line sealing points were replaced during available two-phase steam flows, caused erosion-corrosion damage
opportunity. mainly at turn points of elbows and valves. It was observed that
the presence, even of a small amount of the vapor phase can
In some cases plant shutdown was taken to replace leaking significantly increase the velocity of the condensate. This paper
piping components & these incidents resulted into revenue describes the mechanism of failures by study of the failed
loss to company. Aggressive inspection programs were taken components, operating conditions & piping lay out.
up for thickness measurement on condensate lines and as a
proactive measure, elbows were encapsulated with higher size In this study velocity of steam /condensate at reducing section
elbows, reducers by on line welding/furmaniting with special was found to be very high. Other various contributing factors
clamps. Similarly gate and globe valves in condensate service like control valve / piping sizing, metallurgical requirements,
also started failing as a result of erosion of body seat rings. effectiveness of steam traps, flow velocity and valve design
Globe valves installed on bypass lines of control valves were (globe & gate) were also studied. The main causes of the
found passing. Once these valves were operated for failures are discussed and recommendations are provided to
maintenance of control valves they could not be closed. In rectify the root cause of the problems & avoid similar problems
some cases valve body developed leak due to high velocity in the future.
erosion.
.
• 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.
Most oof the above faactors have a vvery strong, expponential effecct
on thee material wearr rate.
F
Fig. 10– Location
ns susceptible to FAC in control valve station Fig. 122- Impingement corrosion/erosioon
Fig. 13 – FAC in
i Reducers
III. B
B. FAC Probleem in Gate vallves:
Fig. 19 – Erosio
on of Globe valv
ve seats (erosion of threads)
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.
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.
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:
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]
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
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
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)
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.