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Wednesday, March 14, 2018   By: MM [2231] 1 Stars

We recently experinced some leakage in one of our low pressure heaters. Please could someone have a look at the photo and confirm if it looks to be a case of FAC?



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Wednesday, March 14, 2018   By: Murphy [21] 4 Stars
Although a photo or picture is worth a thousand words, your photos dont show FAC or flow assist corrosion at this level of magnification. If your tubes are leaking they maybe from FAC on the shell side, but you will have to have the leaky tubes removed for a closer eval.


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Sunday, March 18, 2018   By: basem belal [2194] 2 Stars
your photos refer to good situation of tubes, but this is not the case to take a decision from theses photos.
I tested a leakage case in low pressure heaters in a 660 MW power plant, the reason was very clear for us that there was small air leak into the condenser causes increasing in solved gases in condensate water and last one lead to tube failure of low pressure heater.
hope I helped you in my answer

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Sunday, March 18, 2018   By: Ross Burns [390] 5 Stars
Excellent responses to your question on flow assist corrosion or generically Erosion-Corrsion.

Erosion-Corrosion is a form of corrosion where the corrosion is accelerated by fluid flow.

Condenser tubes have experienced this based on my knowledge, but the cause is the result of the coolant flow at high flow rates like 5 ft per sec or more, and when the flow is above 10 or 15 ft per sec flow the rate then the failure is in days, and this would be say using Admiralty Brass. Also, the saltwater has to be corrosive enough when the passive protective layer is removed on the Admiralty Brass.

So, when the corrosion protective film get broken down from the high flow or high velocity of the coolant, then we are going to experience erosion-corrosion of tubing in a shell and tube heat exchanger. When the tubing is removed, then we can see the damage with the naked-eye.

In a heat exchanger such as a feedwater heater the tube are long enough so laminar flow is unlikely at some length down the tube, so turbulent flow is likely, but that does not mean high-velocity flow. However turbulent flow is a cause for erosion-corrosion in the event the coolant is corrosive at some level. So, we have to keep this in mind.

From the steam side the erosion-corrosion can occur from steam condensate impingement.

Unfortunately, the photos are really nice, but they are unhelpful in determining your erosion-corrosion, which is also called flow assisted corrosion or FAC.

Ross Burns

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High Sulfite Residual
By: Ross. [390]

First, I want to say that large amounts of Sodium Sulfite NaSO3 becomes a contaminate because it will produce foaming and other problems, but foaming is the primary problem.

Your 500-psi Water Tube Boiler is seems to have reasonable level of residual Sodium Sulfite NaSO3 remaining in the boiler water. Nice pH too.

Your 300-psi Waste Heat Recovery Boiler has twice what I would expect for Sodium Sulfite NaSO3 at ranging 80-ppm to 100-ppm. pH is good so you are getting a good yield.

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