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<p>Flow-accelerated corrosion (FAC) in carbon steel elbows is a major cause of failure in nuclear power plant piping. This study develops a predictive model for the localized FAC distribution by integrating a computational fluid dynamics (CFD)-derived geometric influence factor,<i> K</i> (<i>g</i>), with experimental corrosion rates. Experiments were conducted in a FAC loop using array electrodes embedded in an elbow under controlled water chemistry (pH = 9.1, T = 120&#xa0;°C) at flow velocities of 2, 4, and 6&#xa0;m/s. The local FAC rates, determined electrochemically, revealed that the maximum corrosion consistently occurs on the outer wall of the elbow, aligning with field observations. Concurrently, CFD simulations quantified the <i>K</i> (<i>g</i>) factor, which describes the acceleration of mass transfer at any elbow location relative to a straight pipe. The spatial distribution of this CFD-derived<i> K</i> (<i>g</i>) factor was validated against the experimental data. The final model, formulated as the product of<i> K</i> (<i>g</i>) and the straight pipe FAC rate, demonstrated good agreement with measured values, providing a robust tool for predicting localized wall thinning in elbow pipes.</p>

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Modeling and validation of flow-accelerated corrosion in carbon steel elbows

  • 期刊论文

  • 发表日期：

    2025年12月9日

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  • Zhenhao Chu,
  • Xiaojiang Zhai,
  • Xiaodong Si

摘要

Flow-accelerated corrosion (FAC) in carbon steel elbows is a major cause of failure in nuclear power plant piping. This study develops a predictive model for the localized FAC distribution by integrating a computational fluid dynamics (CFD)-derived geometric influence factor, K (g), with experimental corrosion rates. Experiments were conducted in a FAC loop using array electrodes embedded in an elbow under controlled water chemistry (pH = 9.1, T = 120 °C) at flow velocities of 2, 4, and 6 m/s. The local FAC rates, determined electrochemically, revealed that the maximum corrosion consistently occurs on the outer wall of the elbow, aligning with field observations. Concurrently, CFD simulations quantified the K (g) factor, which describes the acceleration of mass transfer at any elbow location relative to a straight pipe. The spatial distribution of this CFD-derived K (g) factor was validated against the experimental data. The final model, formulated as the product of K (g) and the straight pipe FAC rate, demonstrated good agreement with measured values, providing a robust tool for predicting localized wall thinning in elbow pipes.