Materials Used in Sea Water System

Materials Used in Sea Water System

Introduction
Material Selection
Sea Water &Corrosion
Titanium Alloys
Composites

Ni Base alloys
Copper alloys

Main use of sea water

Oil field water injection

Fire-fighting

Desalination plants

Industrial Applications

1- Shipping

2- Offshore
3- Power plants and
coastal industrial plants

Cooling purpose
4- Oil and gas production

Causes of Abrupt failures of water cooling system usually

related to:

A- System design

B- Equipment and material selection

- Corrosion

- Scales

Biological Proliferations

C- Maintenance

Fouling

Main materials used in sea water system

1- Steel alloys (high alloy steel 254 SMO and cast iron )

seawater-cooled
condensers

2- Stainless steel (316 L & duplex stainless)

offshore and marine

applications

3- Copper alloys (Cu-Ni& 5% Ni Al bronze)

valves and pumps

4- Titanium alloys (Pure Ti &23 (Ti-6Al-4VELI))

offshore and marine

applications

5 - Composite material

oil gas and piping

system

6 Ni Base alloys

Sea water services

Corrosion data on materials in high velocity test

Alloy

Corrosion rate

Seawater Velocity

Grey cast Iron

13

38

Carbon steel

9.5

40

Monel Alloy 400

0.010

43

Monel alloy K-500

0.010

43

Stainless steel

0.005

43

Economic Factors for materials selection

1-A low initial cost system
require considerable maintenance
over the life of the plant.

Carbon steel and Cast iron

Such a system is a reasonable choice in areas where labor costs are low
and material is readily available

2-A high initial cost system

Alloy materials

if correctly designed and fabricated, will

require minimum maintenance and will
function reliably

Rising labor costs in most industries and need for high reliability in
capital intensive plant has produced a trend to this type of system

Seawater piping systems

Minimum first cost - high
maintenance
cost system

High reliability - low

maintenance
cost system

Component

Galvanized steel

Pipe

Steel

Flanges

- Cast or forged 90-10

Cu-Ni
- Steel welded overlayed
with Cu-Ni
- Gunmetal

60/40 brass/naval brass

Tubeplates

- Nickel aluminium bronze

- 90-10 Cu-Ni

Aluminium brass

Tubes

- 70-30 Cu-Ni
(particularly 2% Fe + 2% Mn)
- 90-10 Cu-Ni

Cast iron or leaded Gunmetal

Pump casing

- Cast Cu-Ni
- Nickel aluminium bronze
- Admiralty Gunmetal
- Ni-resist Type D2

Gunmetal

Pump impeller

- Monel Alloy 410

- Alloy 20 (CN7M)
- Stainless steel (CF3 and CF8)
- Nickel aluminium bronze

Naval brass

Pump shaft

- Monel Alloy 400 or 500

- Stainless steel (type 316)
- Nickel aluminium bronze

Cast iron

Strainer body

- Ni-resist iron type D2

- Nickel Aluminium Bronze
- Cast Cu-Ni
- Gunmetal

Galvanized iron

Strainer

Monel alloy 400

Copper-base
90-10 Cu-Ni

Composition of sea water

Component

Concentration
(mg/l)

% of total salt

Chloride

18,980

55.04

Bromide

65

0.19

2,649

7.68

140

0.41

Fluoride

0.00

Boric acid

26

0.07

1,272

3.69

Calcium

400

1.16

Strontium

13

0.04

Potassium

380

1.10

Sodium

10,556

30.61

Total

34,482

99.99

Sulfate
Bicarbonate

Magnesium

Effect of sea water on corrosion resistance

Chemical Effect

Salt Precipitation, Deposits and

Bio-fouling and Sediments Effects

Carbonates and Sulfates

Fouling
Chlorination Effects
Bioforms
pH

Geographical Variations

Localized Variations
Dissolved Oxygen

Temperature Effects

Characteristics

Velocity Effects

Design Effects
Crevice Geometry and Surface
Finish Effects

Sea water velocity

Corrosion data on materials in high velocity test
Alloy

Corrosion rate

Seawater Velocity

Grey cast Iron

13

38

Carbon steel

9.5

40

Ni-Cu Alloy 400

0.010

43

Ni-Cu alloy K-500

0.010

43

Stainless steel 316

0.005

43

Gun metal (85/5/5/5)

1.30

40

Nickel Aluminium Bronze

0.80

38-42

Types of corrosion
Mode of Corrosion

Copper
based
alloys

Stainless Stainless Steel 6 Titanium

Steel 316 Mo and Duplex Alloys

General Corrosion

Resistant/Su
sceptible1

Resistant

Resistant

Resistant

Crevice Corrosion

Susceptible

Susceptible

Susceptible (>25C)

Resistant (<80C)2

Pitting Attack

Susceptible

Susceptible

Resistant

Immune

Stress Corrosion

Susceptible1

Susceptible
(>60C)

Resistant

Resistant3

Corrosion Fatigue

Susceptible

Susceptible

Susceptible

Immune

Galvanic attack

Susceptible

Susceptible

Resistant

Immune

Microbiological
Corrosion (MIC)

Susceptible

Susceptible

Susceptible

Immune

Weld/HAZ Corrosion

Susceptible

Susceptible

Susceptible

Resistant

Erosion Corrosion

Susceptible

Resistant

Resistant

Highly Resistant

1. Dependent on Pollution level/sea water chemistry

2. Grades 7,11,12, 16,17,20,21,24, 28,29 resistant to at least 200C
3. Standard Grade 5 has finite susceptibility, Grade 23 (ELI) has improved K1SCC values

Titanium alloys
Titanium is as strong as steel, yet 45% lighter. The high strength,
low density and corrosion resistance of titanium contribute
positively towards cost reduction. Weight saving is of great
importance for offshore platforms
Titanium requires no corrosion allowance so equipment can
be designed to satisfy the minimum requirements for
mechanical strength and handling

The number and variety of applications of titanium and titanium alloys

offshore continues to increase. From no more than a few hundreds of kilos
in chlorination systems and heat exchangers twenty years ago, total
consumption now approaches three thousand tons.

Titanium alloys applications in sea water systems

Titanium alloy grade
23 (Ti-6Al-4VELI)
23

Application
Taper Stress Joints
Drilling Riser

2 (Commercially Pure)

Fire Water Systems

Sea Water Lift Pipes

Ballast Water Systems

Anchor System Pipework

Penetrations and Manholes

Penetration Sleeves

Fresh Water Pipework

2 (110 tons)

Sea Water Pipework

2 (300 tons)

Seawater systems, fire, ballast and

produced water Pipework

2(500 tons)

Gravity Based System

9 (Ti-3Al-2.5V)

Booster Lines

Composites
Composites are fast taking over as superior alternative to other
traditional materials even in high pressure and aggressive environmental
situations. Composites have become attractive candidates for
applications in oil gas, piping system, topside applications, down-hole
tubing in sub-sea, and others

Composite piping system

Composite handrails and

grids/gratings

Composite coil tube

Composites
Composite Piping System (Glass Reinforced Epoxy (GRE) )
Glass Reinforced Epoxy (GRE) piping system offers complete solution for offshore
environment against highly corrosive fluids at various pressures, temperatures, adverse
soil and weather conditions (especially in oil exploration, desalination, chemical plants,
fire mains, dredging, portable water etc.)

Composite Pressure Risers

Composite riser is the pipeline that connects the rig of the water surface to the well
bore at the seabed

Caissons at offshore
platforms

Composite material applications

No

Application

Composite Grids/ Gratings

Hand rails & Ladder Components

Aqueous Piping System

Water & fuel storage tanks, Vessels

Low pressure composite valves

Spoolable type thermosetting tubes

Sump Caissons and pull tubes

Cable support systems

Modular paneling for partition walls

10

High pressure accumulator bottles

11

Flexible & Floating Risers, Drill pipe

12

Sub sea structural components

13

Boxes, housings and shelters

14

Fire water pump casing & sea water lift pump casing

15

Tendons

16

Offshore bride connecting between platforms

17

Blast & Fire protection

Ni Base alloys
Nickel with no other significant alloying elements (UNS NO2200)
readily losing its passivity and suffering pitting and
crevice corrosion. General corrosion rates as high as
8 mpy are possible in polluted seawater.

little used in seawater

Chromium-free nickel alloys (UNS NO4400 & UNS NO 10001)

67 nickel- 33 copper (UNS NO4400) and
70 nickel - 28 molybdenum (UNS NO 10001)

Alloy 400 has been widely

used in seawater

Its general corrosion rate in quietly moving

seawater ranges from approximately 0.1- 1.0 mpy.

The alloy possesses

excellent resistance to highvelocity seawater

Pits in alloy 400 tend to self-stifle

Care should be exercised when

specifying alloy 400 for thin-wall
products such as exchanger tubes

Ni Base alloys
Nickel-chromium alloys, with and without molybdenum.
625 (NO6625), alloy C-276 (N10276),
and alloy C-22 (NO6022)
Alloying elements such as, chromium
and molybdenum make the alloys
possess superior crevice corrosion
resistance compared with lesser
alloyed nickel alloys.

It is considered for seawater

service where there is a potential
for crevice corrosion

Nickel Aluminum Bronze

This alloy has a good combinations of
mechanical properties and corrosion
resistance

It has been used in wide variety of

marine applications including
valves and fittings, ship propellers,
pumps, pump shafts, valve stems
and heat exchanger waterboxes

Ni Base alloys
Nickel Aluminum Bronze

This alloy has a good

combinations of mechanical
properties and corrosion
resistance

It has been used in wide

variety of marine applications
including valves and fittings,
ship propellers, pumps, pump
shafts, valve stems and heat
exchanger waterboxes

Copper alloys system in piping

Typical compositions of alloys commonly used in seawater systems
Copper-tin, copper-aluminium and copper-zinc alloys
Nominal composition per cent
Alloy

Copper

Tin

Zinc

Aluminium

Other

Admiralty
Gunmetal

88

10

Leaded
Gunmetal

85

Leaded
Gunmetal +
nickel

86

2.5

2.5% Lead
2% Nickel

Nickel
aluminium
bronze

85

10

5% Iron
5% Nickel

Aluminium
brass

76

22

0.02% Arsenic

Typical compositions of alloys commonly used in seawater systems

Alloys of nickel and copper

Nominal composition per cent
Alloy

Copper

Nickel

Iron

Other

90-10 Cu-Ni

Remainder

10

1.5

1.0 Mn (max)

70-30 Cu-Ni

Remainder

30

0.6

1.0 Mn (max)

70-30 Cu-Ni (high

iron)

Remainder

30

2.0

2.0 Mn

70-30 Cu-Ni+Cr

Remainder

30

0.7

1.6 Cr

Ni-Cu Alloy 400

31.5

66

1.35

0.9 Mn

Cast Ni-Cu Alloy

BS 3071

30.5

66

1.35

1.6 Si

Ni-Cu Alloy K 500

31.5

66

1.35

1.9 Mn 2.8 Al
0.5 Ti

Cast Ni-Cu Alloy

BS 3071 NA3

29

64

2.0

4.0 Si

Copper alloys system in piping

Two copper-base alloys have been widely used for seawater
handling, namely aluminum brass and 90-10 Cu-Ni
When using non-ferrous piping the
system must be designed on the basis of
water velocity in order to avoid
impingement attack

Piping

Copper

0.75 m/s

Aluminum
brass

2.5 m/s

90-10 Cu-Ni

3.0 m/s

70-30 Cu-Ni

3.5 m/s

submarine

Copper alloys system in Piping

The current trend is towards the use of 90-10 Cu-Ni
1- Its better weldability. Although aluminum brass can be welded using aluminum
bronze filler
2- Its high stress corrosion resistance. 90-10 Cu-Ni does not normally require any stress
relief heat treatment after fabrication. Aluminum brass requires stress relief to avoid
the possibility of stress corrosion cracking to which it is susceptible in seawater

3- Its good experience. Some reports showed that, only nine cases of premature
failure over a period of 20 years. This is a remarkable result considering the
large tonnage of the alloy in use throughout the world.

Copper alloys system in valves

Many corrosion problems in seawater systems occur in
valves. Often such problems are due to the use of steel or cast
iron valves with non-ferrous piping. Although the life of such
valves in a steel or cast iron pipe system is short (i.e., two to
three years) when fitted in a alloy system, it may be less than
a year due to the galvanic effects from the piping.
The three main components of a valve are :
1- The body
2- Valve seats
3- The shafts or stems

Copper alloys system in valves

1- The body
The basic low cost valve used in ferrous pipe systems has a cast iron body
with 60-40 brass internals. Depending on design, corrosion rates of several
millimeters per year can occur on the body. The body cathodically protects
the internals (until a layer of graphitic corrosion product forms) and the
valve will function for two to three years.

Upgrading of valve body materials to give higher reliability requires the use of
alloys with good corrosion resistance. Such materials are copper base alloys such
as nickel aluminum bronzes, Admiralty and leaded gunmetals and cast Cu-Nis. All
these alloys are characterized by good resistance to static seawater (necessary for
shut-down conditions) and to flowing seawater.

Copper alloys system in valves

2- Valve seats and stems
The material of Valve seats should have high resistance to fast flowing seawater
such as, stainless steels, nickel-base alloys and Monel alloy 400.

Experience shows that when manufacturers

upgrade the body material they often use the
same materials for seats and stem as in a cast
iron valve, i.e., 60-40 brass. Under these
conditions the life of the valve internals is
extremely short because, having lost the
cathodic protection of the ferrous body, they
fail by dezincification in a few months

Dezincification of a 60-40 brass stem from a bronze valve

Copper alloys system in valves

Materials for seawater valves in non-ferrous pipe systems
Body material

Ball, disc, or
seat material

Stem
material

Butterfly
valves

Gunmetals
5% nickel aluminium bronze
Rubber-lined cast iron (provided a
seal is fitted at the stem)
Cast 70-30 Cu-Ni

5% nickel
aluminium
bronze
Cast 70/30 Cu-Ni
Cast Monel alloy
Stainless steel
(Type 316)

Ni-Cu alloys
400 or K500
Stainless
steel
(type 316)
5% nickel
aluminium
bronze

Globe, gate, or
ball valves

As above, except that rubber lined

valves should be avoided

As above

As above

Rubber
(membrane)

Not critical
as there is
no seawater
content

Type of valve

Membrane
valves

Rubber lined cast iron

INTERACTIONS WITHIN THE SYSTEM

Galvanic Effects
Wherever possible, components of similar galvanic potential should be used for
construction of the system. Where this is not possible, the following guidelines
should be used:

1- Make the "key" component of a more noble material. For example, use copper-base
alloy trim in a cast iron valve body.
2- Ensure that the material of lower potential is present in a much larger area
than the more noble material so that the accelerated corrosion of the anode is
spread over a large area.
3- Paint the more noble material. This can be beneficial as it reduces the cathode
area even when the paint film is incomplete. An imperfect paint film on the
anode would intensify attack at breaks in the paint.

Thank You Very Much