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for ACC
FAC and
Cycle Chemistry
Session
Barry Dooley
ACCUG 2018
Colorado Springs, USA
9th – 11th October 2018
ACC Come in Many Sizes
But the FAC / Corrosion damage is the same worldwide with all chemistries
and plant types (Based on assessment/inspection work conducted in Australia, Canada, Chile,
China, Cote
Courtesy d’Ivoire, Dubai, India, Ireland, Mexico, Qatar, Abu Dhabi, South Africa, UK and US)
of Eskom.
Typical ACC Damage
Corrosion/FAC in ACC and The Consequences
• High concentrations of iron around the cycle
- Boiler/HRSG deposits (expensive chemical cleaning)
- Boiler/HRSG Tube Failures (overheating and TF)
- Steam Turbine Deposits (including aluminum)
• Need for Iron Removal Processes
- Condensate Polishing and/or Filters
• Limitations around the cycle
- Condensate polishing (may have to change mode)
• Overall an ACC “controls” the unit cycle chemistry
- International Guidelines now available for ACC
and two-phase flow (IAPWS Volatile Guidance 2010, 2015)
The ACC Corrosion Index to
Compare and Categorize
Corrosion and Track
Improvments
DHACI
DHACI 4
DHACI 3
DHACI 3
The FAC / Corrosion damage is the same worldwide with all cycle chemistries
and plant types
and what Holes at Tube Entries Look Like
DHACI 5
Inspections Worldwide show the same Features
Combined Cycle with ACC after ~ 15,000 hrs, pH 9.1.
DHACI 4
Concentration of Two-phase
FAC beneath Supports
DHACI 4
Concentration of Two-phase
FAC beneath Supports
To Understand the Corrosion Here we need to
Understand the Environment in the PTZ
Generation of the ACC Environment is in the PTZ
Droplets <0.1µm
<100µm
L-0 and
L-1
Blades
Liquid Films
<120µm
DHACI 2
DHACI 4
Damage takes time to arrest (15 Months with pH 9.8)
DHACI 4 DHACI 2
What Guidance is Currently Available?
http://acc-usersgroup.org/
ACC.01
Original Issue: May 12, 2015
Revision due: May 12, 2018
IAPWS
Technical Guidance Documents
for
Fossil and Combined Cycle Plants
(with particular relevance for plants with ACC)
IAPWS Technical Guidance Documents (TGD)
for Plants with ACC
• Procedures for the Measurement of Carryover of Boiler Water and
Steam (September 2008). This document includes the procedures to
measure carryover from drum boilers to assist in preventing steam turbine
failure/damage.
• Steam Purity for Turbine Operation (Sept 2013). This document covers
guidance for a wide range of turbines (fossil, nuclear, industrial,
geothermal, etc) and failure mechanisms. It includes customizations for
plants using amines and with carbon dioxide.
Consensus of 24 Countries
24
Achievable Total Fe & Cu Levels – Different
Plant Types/Optimized Chemistry
(Indicative that FAC/Corrosion is “under control”)
Feedwater
OT: Total Fe = < 1 μg/kg
AVT: Total Fe = < 2 μg/kg
AVT (Mixed): Total Fe & Cu = < 2 μg/kg
HP/LP Heater Drains: Total Fe & Cu = < 10 μg/kg
HRSG Evaporators/Drums
AVT/PT/CT: Total Fe = < 5 μg/kg
Air - cooled Condenser (ACC)
ACC Outlet: Total Fe = < 10 μg/kg (ppb)
Post Condensate Filter: Total Fe = < 5 μg/kg (ppb)
25
Discussion
Items for
ACCUG 2018
ACCUG 2018
Colorado Springs, USA
9th – 11th October 2018
2
7
FFA/FFAP FFP
ACC “Arrests” with FFAP
DHACI 4
Cross member
appear to repair
using FFAP
DHACI 1
Air In-Leakage
Previous Presentations at ACCUG in 2010, 2013 and 2016
Sources of AIL on Plants without ACC
Low pressure steam turbine / condenser expansion joints
Low pressure steam turbine shaft seals
Low pressure steam turbine instrumentation lines
Steam turbine district heating heat exchanger in hot well
Low pressure feedwater heaters (including piping, drains, valves, etc.)
High pressure feedwater heaters (emergency drains out of service)
Condenser drains
Condensate pump seals
Turbine gland steam condenser
Condensate polisher (possibly when shut down)
Makeup water lines if left open during operation
Vacuum breakers
Rupture disks
Safety valves
Condenser tube sheet to shell joints
Source: IAPWS TGD to be published 2018
Sources of AIL on Plants without ACC
Condenser wall cracks
Condenser instrumentation and connections (sight glasses, level
transmitters, etc.)
Air removal equipment suction components (such as steam jet air ejectors)
o Condensate drain seals
o Drains
o Isolation valves
o Flanged and threaded connections
o Air jets
o Shaft seals
Orifice flanges, piping flanges
Valve stems
Condenser manway covers
Suction side of boiler feedwater pumps (pump seals)
Flash tanks, desuperheating tanks, and connections