AGENDA Corrosion in Wet Flue Gas Desulfurization (FGD) Systems 1 st Supplemental Project Meeting Charlotte, North Carolina EPRI Offices: Building 2 Auditorium January 27-28, 2011 TIME Activity Lead Thursday, January 27, 2011 – open meeting (prospective participants welcome) 8:00 am Breakfast All 8:30 am Welcome to EPRI G. Offen – EPRI 8:45 am Introductions & Goals for Meeting T. Hart (Utility Chairman) -American Electric Power, C. Dene, J. Shingledecker - EPRI 9:00 am Review of Recent Industry Experience with Alloy 2205 in Wet FGD Systems J. Shingledecker – EPRI 10:00 am Break 10:30 am Content of EPRI Supplemental Project – Corrosion in Wet FGDs C. Dene, J. Shingledecker – EPRI 11:30 am Q/A about working with EPRI All 12:00 pm Lunch All 1:00 pm Characterizing Chemistry to Help Understand Corrosion Issues C. Dene – EPRI G. Blythe, URS Corp. 1:45 pm Preliminary Results of Data Collection and Outline of EPRI Root Cause Analysis B. Tossey – DNV, Columbus 2:30 pm Break All 3:00 pm Group discussion All 5:00 pm Adjourn 7:00 pm Dinner Friday January 28, 2011 – Closed Meeting (open to all funders of the ‘Corrosion in Wet FGDs’ Supplemental Project) 8:00 am Breakfast All 8:15 am Review of workscope, timelines, etc J. Shingledecker, C. Dene 9:00 am Review of draft deliverable – FGD Inspection Guideline M. Schwartzwalder – SES 10:00 am Break All 10:30 am Additional questions on root cause analysis B. Tossey – DNV, Columbus 11:00 am Non Destructive Evaluation (NDE) S. Walker - EPRI 11:30 Other issues All 12:00 pm Lunch All 1:00 pm Wrap-up admin issues, next meetings, etc C. Dene, J. Shingledecker – EPRI 2:00 pm Adjourn
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AGENDA Corrosion in Wet Flue Gas Desulfurization (FGD) Systems
1st Supplemental Project Meeting Charlotte, North Carolina
EPRI Offices: Building 2 Auditorium January 27-28, 2011
TIME Activity Lead Thursday, January 27, 2011 – open meeting (prospective participants welcome) 8:00 am Breakfast All 8:30 am Welcome to EPRI G. Offen – EPRI 8:45 am Introductions & Goals for Meeting T. Hart (Utility
Chairman) -American Electric Power, C. Dene, J. Shingledecker - EPRI
9:00 am Review of Recent Industry Experience with Alloy 2205 in Wet FGD Systems
J. Shingledecker – EPRI
10:00 am Break 10:30 am Content of EPRI Supplemental Project –
Corrosion in Wet FGDs C. Dene, J. Shingledecker – EPRI
11:30 am Q/A about working with EPRI All 12:00 pm Lunch All 1:00 pm Characterizing Chemistry to Help
Understand Corrosion Issues C. Dene – EPRI G. Blythe, URS Corp.
1:45 pm Preliminary Results of Data Collection and Outline of EPRI Root Cause Analysis
B. Tossey – DNV, Columbus
2:30 pm Break All 3:00 pm Group discussion All 5:00 pm Adjourn 7:00 pm Dinner Friday January 28, 2011 – Closed Meeting (open to all funders of the ‘Corrosion in Wet FGDs’ Supplemental Project) 8:00 am Breakfast All 8:15 am Review of workscope, timelines, etc J. Shingledecker, C.
Dene 9:00 am Review of draft deliverable – FGD
Inspection Guideline M. Schwartzwalder – SES
10:00 am Break All 10:30 am Additional questions on root cause analysis B. Tossey – DNV,
Columbus 11:00 am Non Destructive Evaluation (NDE) S. Walker - EPRI 11:30 Other issues All 12:00 pm Lunch All 1:00 pm Wrap-up admin issues, next meetings, etc C. Dene, J.
• These Guidelines for the 2205 Alloy Meeting participants are not legal advice! They are intended to enhance compliance with the letter and spirit of the antitrust laws.
• No set of guidelines can guarantee immunity from legal problems, but observing the following rules should minimize the potential for straying into questionable antitrust territory.
• If a participant has a question, he or she should contact their own company counsel
In any discussions of goods and services offered in the market by others, including competitors, suppliers, and customers.
2205 Alloy Meeting Antitrust Guidelines (cont’d)
We Will Not Recommend
Use of particular vendors, contractors, or consultants for non-EPRI projects; we will not promote commercial products or services of third parties.
Be Accurate, Objective, and
Factual
Pricing, production capacity, or cost information, market strategies, business plans, and/or other competitively sensitive information, unless that information is publicly available.
For advice from your own Legal Department if you have questions about these guidelines or about a particular situation or activity at EPRI.
Ask
Review and Understand
The “2205 Alloy Meeting” Antitrust Compliance Policy, available at 2205 Alloy meetings and from the EPRI Program Managers.
Do Not Agree With Others
To discriminate against, or refuse to deal with (i.e., “boycott”), a supplier; or to set price, divide markets, or allocate customers.
Corrosion in Wet Flue Gas Desulfurization Systems
Introductions and Meeting Goals
T. Hart Utility Chairman, American Electric Power C. Dene, J. Shingledecker EPRI1st Supplemental Project Meeting EPRI Offices - Charlotte, NC January 27-28, 2011
• Industry Alert: provide entire industry (not just EPRI members) with critical information on corrosion observations in alloy 2205 FGD absorber vessels
• Introduce and answer questions on a new EPRI supplemental project open to the industry: Corrosion in Wet FGDs
• Technical Presentations:– Role of process chemistry and monitoring– Preliminary results from industry survey
• Industrial Feedback and Discussion– What specific questions do we need to be asking to
address root cause in this project?– What are we missing and what do you need?
EPRI acknowledges the contributions of the following utilities and their personnel who shared their experience, knowledge, and ample visual examples of corrosion damage which made this presentation possible
• American Electric Power (AEP)• Duke Energy• WE Energies
• In 2005, EPRI completed a survey on the material performance for 12 components in 42 FGD systems including: ductwork, absorbers, recycle tanks, etc.
• For absorber vessels– 36 used stainless steel or carbon steel lined with stainless
steel or nickel-based alloys with few reported major problems• Minor issues with claddings• Corrosion in mixing zones• Metallics being considered as replacements for other organic liners or rubber
– First installation of 2205 was ~2004 (no experience prior)
Why Duplex? – Process Chemistry Considerations (Alloy Selection Chart 2 of 3)
• 2205– Mild Chlorides– Moderate pH
• Poorer performance compared to 317LMN
Adapted from: W.H.D. Plant. “The Cost-Effective Use of Nickel Alloys and Stainless Steels for Chimneys (Stacks) in Air Pollution Control Systems.” Corrosion 2000. Paper No. 00577.
• Locating corrosion is only as good as your inspection techniques– Proper cleaning of scale and deposits– Serious corrosion may only be indicated with small surface
features• Role of microstructure is unclear• Corrosion is affecting:
– Weld metal and heat-affected-zones (HAZ)– Base metal– Regions of improper fabrication techniques– Multiple designs– Times as short as 2 months and through-wall leaks recorded
in less than 1 year of service• Mechanisms reported:
– Crevice corrosion, underdeposit corrosion, MIC (suggested for one case, dismissed by another)
• One utility reported corrosion was so extensive:– 65% of horizontal welds repaired– 50% of vertical weld repaired– 3 leaks were discovered after welding
• Questions on weld repair– What filler metal?– How do you remove all corrosion
products?– What about the new heat-affected-zone?– When do I need to repair (i.e. how do I
know I’ve violated a minimum wall thickness? Corrosion on
• Duplex 2205 is being used extensively in many Wet FGD designs
• Significant corrosion has been observed by multiple utilities utilizing different designs
• Effected areas– Base metal, weld metal, heat-affected-zones, and
areas of improper fabrication– Not limited to absorber vessels– Proper inspection is critical to finding corrosion– Underdeposit corrosion, crevice corrosion, and MIC all
reported mechanisms• Short and long-term mitigation strategies are now being
• Widespread reports of corrosion in Wet FGD Systems constructed with duplex 2205
• At the request of the EPRI Generation Council (October 7- 8, 2010) EPRI convened a meeting with utility members in November 4, 2010 (Charlotte, NC)– 47 participants representing 15 members– Meeting goals
• Review industry experience with 2205
• Determine appropriate actions for EPRI & Industry
• Is everyone doing an adequate job inspecting these units? • What is the cause of the corrosion?• Are alloys beyond 2205 in jeopardy?• Do we have consistent fabrication practices across the
industry? – Lots of questions on surface finish, welding, etc
• What are my options for repair and how do they perform?• What about coatings, alternate alloys, etc?
– Are there options for testing without large scale installation?
a. Develop root cause analysis (RCA) procedure Presentation later today - we need this group to bring forward as many specific questions as possible to properly do a RCA
b. Collect data from industry Initial spreadsheet collection is complete and analysis is ongoing. Missing and additional information will be collected through site visits, assessments, phone calls, etc.
c. Review of relevant literature Initiated
d. RCA Report & recommendationse. Inspection techniques and guideline
Draft report complete, provided to project funders for review (Jan. 21, 2011)
Task 3. Fabrication guidelines for construction of metallic FGD systems – Year 1
• Provide consistent guidelines for proper fabrication practices– Avoid iron contamination– Ensure proper surface preparation
• Provide welding guidance for FGD construction (some conflicting guidance in industry today)– Duplex stainless steels– Stainless steels and nickel-based alloys– Clad construction– Heat input, thickness, welding sequence, filler metal
Task 6. Corrosion in FGD Materials Interest Group meetings – Years 1 & 2
• Minimum of 2 meetings per year (aim for 3 in first year)• Conduct webcast/conference calls as appropriate for task
items or deliverables which require reviews• Meeting Dates
– 1st Meeting: January 27-28, 2011: EPRI Offices Charlotte, NC
– 2nd Meeting (after agreement with funders): June 20-21, 2011: Orlando, FL (prior to EPRI 2nd Int. Conference on Welding and Fabrication Technology for New Power Plant Components – Nuclear & Fossil)
• EPRI trace element balance data for 7 coal-fired units with limestone wet FGD systems:– Average Mn balance closure around units – 85%– Average calculated contribution of limestone to Mn
found in FGD output streams – 107%– Results suggest ~all Mn comes from limestone
• EPRI data for Mn concentrations in limestone from 8 LSFO wet FGD systems:– Range: 31 – 349 ppm– Average: 125 ppm– Standard Deviation: 99 ppm– Anecdotal data show even greater variability (3 ppm to
• URS has had good luck with Beckman (BKA57197 [silver/silver chloride reference]) probe
• Measurements are relative to the reference electrode, so be sure to note reference electrode type with data
• Most meters do not have a calibration adjustment, but ORP standards are available– Zobell solution – 231 mV with Ag/AgCl– Thermo Orion standard – 215 mV with Ag/AgCl– Check before and after reading
• Measure at the same time, place as pH• Do not take reading until temp. readout is steady, matches temp.
during pH measurement– ORP reading may not ever steady out – just read value when
temp. readout is steady– Measurement is not exact, ±10-20 mV is adequate
• Some important questions…that may already have answers– What analyses have been completed by utilities? Why?– What are the corrosion design criteria?– Is MIC a factor?– Is galvanic corrosion a factor near welds?– What conditions lead to corrosion rates > 250 mpy?– Should regular inspections be performed? On what interval?
• We will come back to this.
• State of the art– EPRI Report over the past 20+ years– Technical papers– Utility internal reports; lab data, field data, failure analysis
• 1. C. Kepner, B. Tregoe, “The Rational Manager” 2nd Edition, 1976• 2. J.P. Dimmer, R.A. Wood, D.N. Williams, W.E. Berry, J.H. Payer, “Failure-Cause Analysis - Fossil-Fired Power Parts” EPRI Report CS-2029 September 1981• 3. G. H. Koch, J. A. Beavers, T. K. Christman, “Evaluation of Flue Gas Desulfurization Materials in the Mixing Zone: R. D. Morrow Sr. Generating Station,” EPRI
Report CS-5476.• 4. G. H. Koch, N. G. Thompson, J. M. Spangler, “The Effect of SO2 Scrubber Environments on Alloy Corrosion,” EPRI Report CS-4697.• 5. G. H. Koch, J. A. Beavers, T. K. Christman, “Materials Testing in Synthetic FGD Environments,” EPRI Report CS-3740.• 6. H. S. Rosenberg, G. O. Davis, B. Hindin, A. K. Agrawal, W. J. Sheppard, G. H. Koch “Guidelines for FGD Materials Selection and Corrosion Protection,” EPRI
TR-100680 V2.• 7. G. H. Koch, N. G. Thompson, J. L. Means, “Effects of Trace Elements in Flue Gas Desulfurization Environments on the Corrosion of Alloys – A Literature
Review,” EPRI Report CS-4374.• 8. N. Sridhar, L.H. Flasche, J. Kolts, “ Corrosion and Mechanical Properties of Duplex Stainless Steel Weldments,” J. Metals 37, 1985.• 9. ASTM A923-06, “Standard Test Method for Detecting Detrimental Intermetallic Phases in Duplex Stainless Steel.”• 10. N. Sridhar, L.H. Flasche, J. Kolts , ”Effects of welding parameters on localized corrosion of a duplex stainless steel,” Material Performance, December 1984,
page 51.• 11. N. Sridhar, J. Kolts, “ Effects of Nitrogen on the Selective Dissolution of a Duplex Stainless Steel,” Corrosion Volume 43, No. 11, 1987.• 12. J.W. Fourie, F.P.A. Robinson, “Literature Review on the influence of weld-heat inputs on the mechanical and corrosion properties of duplex stainless steel,” J.
S. Afr. Inst. Min Metall, Volume 90, No. 3, 1990.• 13. Effect of electrolyte composition on the active to passive transition behavior in H2SO4/HCl solutions,” I-Hsuang Lo et al, Corrosion Science 48 (2006) 696-
708.• 14. A. Agrawal, G. Koch, R. Ross, “Corrosion Performance of Duplex and Austenitic Stainless Steels in Simulated SO2 Absorber Environments,” Corrosion 1996,
Paper 96449.• 15. D. C. Agarwal, “Alloy Selection Methodology and Experiences of the FGD Industry in Solving Complex Corrosion Problems; The last 25 years,” Corrosion
1996, Paper 96447.• 16. ASM Metals Handbook, Volume 13C, 2006.• 17. ASTM G48, “Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric Chloride Solution.”• 18. R. E. Avery, W. L. Mathay, D. Gandy, “Material Performance in Flue Gas Desulfurization (FGD) Systems –Experience of 42 Fossil Fuel-Burning Plants,”
AIRPOL 2007, NACE.• 19. R. E. Avery, W. L. Mathay, W.H.D. Plant, “Utilization of Nickel-Containing Alloys for FGD Systems in N. America and Europe,” Corrosion 1996, Paper 96455.• 20. D. Caudill, G. Koch, “Corrosion of Carbon Steel Substrate Under C-276 Wallpaper,” Corrosion 1996, Paper 96450.• 21. DOE/NETL “Demonstration of Innovative Applications of Technology for the CT-121 FGD Process, A DOE Assessment,” Report 1177, 2002 (2002/1177).• 22. M. G. Fontana, Corrosion Engineering 3rd Ed., 1986.• 23. J. Grubb, J. Fritz, B. Parks, R. Polinski, “A 6% Mo Stainless Steel for Flue Gas Desulfurization,” Corrosion 2000, Paper 00583.• 24. K, Hjuler, K. Dam-Johansen, “Mechanism and Kinetics of the Reaction between Sulfur Dioxide and Ammonia in Flue Gas,” Industrial Eng. Chem. Res., V31,
Number 9, 1992.• 25. FGD Technology, National Research Council, 1980.• 26. J. Peultier, F. Barrau, J. Audouard, “Corrosion Resistance of Duplex and Super Duplex Stainless Steels for Air Pollution Control Process Systems,” Corrosion
2005, Paper 05316.• 27. B. S. Phull, W. L. Maythay, R. W. Ross, “Corrosion Resistance of Duplex and 4-6% Mo-Containing Stainless Steels in FGD Scrubber Absorber Slurry
Environments,” Corrosion 2000, Paper 00578.• 28. H. S. Rosenburg, H. M. Grotta, “NOx Influence on Sulfite Oxidation and Scaling in Lime / Limestone Flue Gas Desulfurization (FGD) Systems,” Environmental
Science and Tech., V14, Number 4, 1980.• 29. B. C. Syrett, “Corrosion Control in Electric Power Plants,” Corrosion Science, V35, Numbers 5-8, pp. 1189 – 1198, 1993.• 30. R. Zauter, T. L. Ladwein, “Recent Experiences with Stainless Steels in Flue Gas Desulfurization Plants,” Corrosion 2000, Paper 00579.
• The RCA 2011 schedule is:– Literature review by the end of Q1 – Draft report by the end of Q2– Member comments incorporated by end of Q3– Final report and wrap up at the end of 2011
• The goal is to leverage experience to generate a complete, rapid response– Knowledge gaps need to be addressed quickly