Parameters Influencing Flow-Accelerated Corrosion (FAC) in The Secondary Side of Nuclear Power Plants

Abstract

Thermal power plants have reported excessive pipe degradation because of Flow-Accelerated Corrosion (FAC) since the 1960s. Common features have been the use of carbon steel in regions of high flow rate and high turbulence with a water chemistry of modest alkalinity and free of oxidizing agents. It can be concluded that the main parameters that affect FAC are flow dynamics, water chemistry and composition of the materials used in pipework and components. A clear indication of FAC is the rapid wall thinning, usually in the presence of distinct flow-related markings, or scallops, on the surface. On more than one occasion, FAC has been responsible for large pipe failures that have led to serious damage and in some cases fatalities. After such a failure at the Mihama-3 PWR in 2004, a collaborative research program between Canada and Japan was initiated to improve the understanding of FAC by studying both the individual and the synergistic effects of feed-water system parameters. In an experimental water loop, three test sections were installed in series. Test section 1 contained probes made of the carbon steel of interest to measure on-line the FAC rate and electrochemical corrosion potential (ECP). Test sections 2 and 3 contained surface analysis probes for examination after removal via optical, SEM and Raman, techniques. The effects of flow and other parameters on FAC were studied using probes of different bore size, different material and several flow rates. Experiments were performed under neutral and ammoniated chemistries in de-oxygenated and oxygenated water. Threshold concentrations of oxygen to stifle FAC were determined. The individual and combined effects of system variables have now been determined in some detail and are presented here.