Sea Water System Design

PIPING
Cu-Ni is used for piping systems in a wide range of sizes. To obtain the high performance achievable
from Cu-Ni, particular attention should be given to using alloy compositions which comply to
international standards, maintaining flow velocities within accepted limits, avoiding areas of local
turbulence and extended exposure to polluted water and ensuring good commissioning/start up
practices.
Guidelines For Good Surface Film Formation:

Clean dirt, lubricants and debris from the system.

Avoid introduction of solid matter by installation of strainers.

Use clean, unpolluted seawater or fresh water for hydrotesting. If polluted water has been
used, it should be disposed of quickly and the pipework rinsed properly with clean sea water
or fresh water. If subsequent long stagnant conditions are expected, blow dry the systems.

The commissioning of a system with intermittent flow, such as a fire fighting system should
be conducted in sea water with low levels of suspended matter e.g water from the open sea.
However, the seawater has to be replaced by oxygenated water within 4-5 days to avoid
putrefaction.

Ferrous ions from additions of ferrous sulfate or by installation of simulated iron anodes can
improve film formation and help protect against sulfides in waters.

Mature film formation depends on seawater temperature but can take up to 3 months to
achieve. Particular care to avoid extended exposure to sea water polluted with sufides is
required during that time.

A system with continuous pumping activity, such as a cooling system, can be operated under
normal design flow conditions. In sea water and water containing high levels of suspended
matter, the minimum flow rate should be above 0.5-1m/s (as it depends on pipe diameter as
well) to prevent deposits forming. In sea water containing entrained sand the flow rate should
be decreased by 1-1.5m/s

Guidelines for Prevention of Erosion Corrosion:

Control Flow rate

The maximum flow rate should not exceed the maximum designed flow rate.

Applied flow rate depends upon alloy, pipe diameter and specification used, e.g BS MA 18,
DIN 85004-2. Typically, these may be:
Alloy

90-10 Cu-Ni
70-30 Cu-Ni
66-30-2-2 Cu-Ni-Fe-Mn

Typical maximum Flow Velocity, m/s

3.5
4.0
6.5
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Sea Water System Design

For short duration, flow velocities of 10-15 m/s are acceptable

Guidelines for Shutdown and Standby Conditions:

Conditions in the system
Clean seawater or fresh water with-out
Polluted seawater or fresh water where
Duration
deposits
deposits are present
Commissioned system:
Avoid high flow rates
If possible, drain the system and fill
with clean seawater or fresh water
4-6 days Keep the system filled
New system: Clean the system and fill with
clean seawater or fresh water.
Possibility I:
Clean the system and fill with clean
seawater or fresh water
Replace the water by oxygenated clean
Keep the system filled and replace the
> 4-6 days
water every 2-3 days.
water by oxygenated water every 2-3 days
Clean the system and keep it dry.
Possibility II:
Clean the system and keep it dry.

Guidelines for Chlorination:

Recommended levels for residual content:
For continuous dosage, 0.3 ppm with a maximum of 1 ppm

For intermittent dosage, a level of 0.5 ppm

Simultaneous chlorination and ferrous sulfate treatments are not recommended

Connection Guidelines:

The mismatch of pipe ends should not exceed the half of wall thickness, however it has to be
less than 2 mm
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Sea Water System Design

The preferred maximum depth of excessive weld root penetration depending on pipe diameter
ex DIN 85004 is:

Nominal pipe diameter [mm]

The max. protrusion of the welding root [mm]

<40

1.5

50-150

2.0

175-250

2.5

>300

3.0

Guidelines for Correct Piping Design and Installation:

Streamlining minimises pressure drop, required pumping power and probability of erosion
attack
Run piping as directly as possible

Consider the effect of r/d-ratio for bends and the effect of sudden enlargement and
contractions on the pressure drop . Bend radii r greater or equal to 1.5d or angled branches are
preferable.
Choose square stub-end flanges and cut the gasket flush with the inner surface of the pipe. If
rolled-over type flanges are used, the design velocity should be reduced by 0.25-0.5 m/s.
Cut gaskets flush with the inner pipe diameter
Control the flow with least number of valves.
Ensure operators have means to control and measure flow rates.
Ask the valve manufacturer for data related to the effect of weld geometry on the pressure
drop in the system. In most instances there are considerable variations for nominally similar
valves.
Provide a downstream distance 5 x ID from pumps and valves to bends.

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