Course Catalogue.

Mitigating The Risk Of Flow-Accelerated Corrosion

7 Professional Development Hours

After participating in this course, you will be able to do the following:

  • Understand the mechanisms of both types of Flow-accelerated Corrosion (FAC)
  • Diagnose FAC in your system
  • Understand how key parameters control the rate of FAC
  • Identify the type of components and areas of the plant that are most susceptible to FAC
  • Mitigate the risk of FAC in the design and operational phases
  • Discover the impact of cycling and part-load operation on the rate of FAC
  • Understand the advantages and limitations of chemical treatment additives in controlling FAC
  • Learn how to mitigate the risk of FAC


Flow-accelerated corrosion (FAC) is regarded as an increasingly common and very insidious type of failure mechanism in steam generation systems across many industries - from power generation to petrochemical. FAC is predominant in Heat Recovery Steam Generators (HRSGs) of combined-cycle and cogeneration plants. The proper management of FAC is of paramount importance since fatal injuries to workers have occurred in several power plants, and hundreds of piping and equipment failures have led to production losses and rising maintenance costs.

There are two types of FAC - single-phase and two-phase FAC, quite different in character and root cause. The troubleshooting of FAC can be complex, and distinguishing between the two types is essential to understanding the issues in contention and to the amelioration of the FAC problem. Many key variables play a role in FAC - mainly system hydrodynamics (system geometry, fluid velocity, steam quality, temperature), materials of construction as well as operating practices. Water or cycle chemistry, however, plays a relatively minor role. All of the above complexities have created confusion and conflicting opinions amongst independent power industry players worldwide.

This course presents several case studies together with Best Practice guidelines that are invaluable to owners and current operators of combined cycle/cogeneration plants as well as those involved in all design phases of such projects, through the potential incorporation of these best practices at the earliest possible stage.

Course Outline:

  • FAC Primer
  • How to diagnose FAC in your system (failure morphology and other leading indicators)
  • Distinguish between the two types of FAC (this is a critical step to understanding and controlling FAC)
  • Learn about the areas and components that are susceptible to FAC attack
  • Understand how key parameters control the rate of FAC (temperature, pH, ORP, fluid turbulence, metallurgy, design and operational factors, etc.)
  • Discover the impact of cycling and part-load operation on the rate of FAC
  • Learn about FAC Management Programs
  • Witness several case studies in industry

Who Should Attend

  • Plant Managers
  • Operation Managers
  • Maintenance Managers
  • Plant Engineers
  • Utilities Engineers
  • Technologists
  • Project Managers in the Chemical, Petrochemical, Chemical Processing and other industries
  • Reliability Engineers
  • Operators
  • Risk Management
  • Anyone involved in Plant Asset Management
  • Anyone involved in industrial steam generation systems
Course Rating

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Almost all of EPIC's courses offer :

  • Continuing Education Units (CEUs) and
  • Professional Development Hours (PDHs)

These course credits will help attendees earn training requirements for their associations or provincial governing bodies.

This course can be customized and delivered to a group at your facility saving time and money.
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