Materials Used in Sea Water System

Materials Used in Sea Water System

Material Selection
Materials Used in Sea Water System
Materials Used in Sea Water System
Introduction
Sea Water &Corrosion
Composites
Ni Base alloys
Titanium Alloys
Copper alloys
Cooling purpose
Oil field water injection
Fire-fighting
Desalination plants
Main use of sea water
4- Oil and gas production
Industrial Applications
1- Shipping
2- Offshore
3- Power plants and
coastal industrial plants
Causes of Abrupt failures of water cooling system usually
related to:
- Corrosion - Scales
Biological Proliferations
Fouling
A- System design
B- Equipment and material selection
C- Maintenance
Main materials used in sea water system
1- Steel alloys (high alloy steel 254 SMO and cast iron )
2- Stainless steel (316 L & duplex stainless)
3- Copper alloys (Cu-Ni& 5% Ni Al bronze)
4- Titanium alloys (Pure Ti &23 (Ti-6Al-4VELI))
5 - Composite material
seawater-cooled
condensers
offshore and marine
applications
valves and pumps
offshore and marine
applications
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
Carbon steel and Cast iron
require considerable maintenance
over the life of the plant.
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 Component
High reliability - low
maintenance
cost system
Galvanized steel Pipe Copper-base
90-10 Cu-Ni
Steel Flanges - Cast or forged 90-10
Cu-Ni
- Steel welded overlayed
with Cu-Ni
- Gunmetal
60/40 brass/naval brass Tubeplates - Nickel aluminiumbronze
- 90-10 Cu-Ni
Aluminiumbrass 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 aluminiumbronze
- Admiralty Gunmetal
- Ni-resist Type D2
Gunmetal Pump impeller - Monel Alloy 410
- Alloy 20 (CN7M)
- Stainless steel (CF3 and CF8)
- Nickel aluminiumbronze
Naval brass Pump shaft - Monel Alloy 400 or 500
- Stainless steel (type 316)
- Nickel aluminiumbronze
Cast iron Strainer body - Ni-resist iron type D2
- Nickel AluminiumBronze
- Cast Cu-Ni
- Gunmetal
Galvanized iron Strainer Monel alloy 400
Component Concentration
(mg/l)
% of total salt
Chloride
18,980 55.04
Bromide
65 0.19
Sulfate
2,649 7.68
Bicarbonate
140 0.41
Fluoride
1 0.00
Boric acid
26 0.07
Magnesium
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
Composition of sea water
Effect of sea water on corrosion resistance
Chemical Effect
Carbonates and Sulfates
Chlorination Effects
pH
Geographical Variations
Temperature Effects
Velocity Effects
Salt Precipitation, Deposits and
Bio-fouling and Sediments Effects
Fouling
Bioforms
Localized Variations
Dissolved Oxygen
Characteristics
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 AluminiumBronze 0.80 38-42
Types of corrosion
Mode of Corrosion Copper
based
alloys
Stainless
Steel 316
Stainless Steel 6
Mo and Duplex
Titanium
Alloys
General Corrosion
Resistant/Su
sceptible
1
Resistant Resistant Resistant
Crevice Corrosion
Susceptible Susceptible Susceptible (>25C) Resistant (<80C)
2
Pitting Attack
Susceptible Susceptible Resistant Immune
Stress Corrosion
Susceptible
1
Susceptible
(>60C)
Resistant Resistant
3
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 Application
23 (Ti-6Al-4VELI) Taper Stress Joints
Drilling Riser
Fire Water Systems
Sea Water Lift Pipes
Ballast Water Systems
Anchor System Pipework
Penetrations and Manholes
Penetration Sleeves
Fresh Water Pipework
Sea Water Pipework
Seawater systems, fire, ballast and
produced water Pipework
Gravity Based System
Booster Lines
23
2 (Commercially Pure)
2
2
2
2
2
2
2 (110 tons)
2 (300 tons)
2(500 tons)
9 (Ti-3Al-2.5V)
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
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
Composites
Composite material applications
No Application
1 Composite Grids/ Gratings
2 Hand rails & Ladder Components
3 Aqueous Piping System
4 Water & fuel storage tanks, Vessels
5 Low pressure composite valves
6 Spoolabletype thermosetting tubes
7 Sump Caissons and pull tubes
8 Cable support systems
9 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)
Chromium-free nickel alloys (UNS NO4400 & UNS NO 10001)
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
67 nickel- 33 copper (UNS NO4400) and
70 nickel - 28 molybdenum (UNS NO 10001)
Alloy 400 has been widely
used in seawater
The alloy possesses
excellent resistance to high-
velocity seawater
Care should be exercised when
specifying alloy 400 for thin-wall
products such as exchanger tubes
Its general corrosion rate in quietly moving
seawater ranges from approximately 0.1- 1.0 mpy.
Pits in alloy 400 tend to self-stifle
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
Ni Base alloys
Copper-tin, copper-aluminium and copper-zinc alloys
Nominal composition per cent
Alloy Copper Tin Zinc Aluminium Other
Admiralty
Gunmetal
88 10 2 - -
Leaded
Gunmetal
85 5 5 5 -
Leaded
Gunmetal +
nickel
86 7 2.5 - 2.5% Lead
2% Nickel
Nickel
aluminium
bronze
85 - - 10 5% Iron
5% Nickel
Aluminium
brass
76 22 2 0.02% Arsenic
Typical compositions of alloys commonly used in seawater systems
Copper alloys system in piping
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 brassand 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
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
Piping
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 valveare :
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.
Dezincification of a 60-40 brass stem from a bronze valve
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
Copper alloys system in valves
Materials for seawater valves in non-ferrous pipe systems
Type of valve Body material
Ball, disc, or
seat material
Stem
material
Butterfly
valves
Gunmetals
5% nickel aluminiumbronze
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
Membrane
valves
Rubber lined cast iron
Rubber
(membrane)
Not critical
as there is
no seawater
content
INTERACTIONS WITHIN THE SYSTEM
1- Make the "key" component of a more noble material. For example, use copper-base
alloy trim in a cast iron valve body.
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:
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