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FAC Risk Assessment and Inspection Plan

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Flow-Accelerated Corrosion (FAC) or Erosions-Corrosion remains a common cause of failure in HRSGs and conventional boilers, yet the underlying causes and solutions have been well understood for more than 25 years.  The two factors influencing the susceptibility to FAC are: a) Unit Design and b) Process Conditions. It is important to know how FAC-prone your HRSG or boiler design are, this will help you optimise your operating conditions to suit that design.

When assessing design factors, the primary question is whether the HRSG/boiler tubes and pipes' geometries and materials are suited to their flow profiles across the range of operating load cases.  Operational factors are primarily concerned with assuring good control of water chemistry parameters (pH, dissolved oxygen or ORP, iron levels).

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Understanding variations in Flow-Accelerated Corrosion Wear Rates in HRSG Evaporator Tubes
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Understanding variations in Flow-Accelerated Corrosion Wear Rates in HRSG Evaporator Tubes

Very large differences in tube wall thinning rates by flow-accelerated corrosion (FAC), or in some cases fluid erosion, are observed in the low-pressure (LP) evaporator tubes of certain HRSG designs. The tubes located near the duct wall and occasionally near the gaps between module bundles have more rapid thinning. Tubes in a given row nominally should have very similar process conditions, both on the gas-side and on the waterside. Different wall thinning rates mean that process conditions differ across the tube row.

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Tetra to present at EDF FAC 2013
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Tetra to present at EDF FAC 2013

Tetra will present their paper 'Evaluating Contributions of Flow-Accelerated Corrosion and Liquid Droplet Impingement to Pipe Thinning in HRSG Evaporator Tubes' at the EDF FAC 2013 conference, on Thursday 23rd at 10h35.

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HRSG Tube Failure Guide, 3rd Ed.
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HRSG Tube Failure Guide, 3rd Ed.

The latest updated edition of Tetra Engineering's HRSG Tube Failure Diagnostic Guide will be published August 15, 2016. Thousands of combined cycle professionals are familiar with Tetra's HRSG Tube Failure Diagnostic Guide; first published during the 'bubble' in construction in the early 2000s.

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