Corrosion Behaviour of Cupronickel 90/10 Alloys in Arabian Sea Conditions and its Effect on Maintenance of Marine Structures

The composition of seawater plays a very significant role in determining the severity of corrosion process in marine assets. The influential contributors to the general and pitting corrosions in marine structures include temperature, dissolved oxygen (DO), salinity, PH, chlorides, pollutants, nutrients, and microbiological activities in seawater. The Cu-Ni (90/10) alloy is increasingly used in marine applications such as heat exchangers and marine pipelines because of its excellent corrosion resistant properties. Despite the significant advancements in corrosion shielding procedures, complete stoppage of corrosion induced metal loss, especially under rugged marine environments, is practically impossible. The selection of appropriate metal thickness is merely a multifaceted decision because of the high variability in operating conditions and associated corrosion rate in various seawater bodies across the globe. The present research study aims to analyze the early phase of corrosion behavior of Cu-Ni (90/10) alloy in open-sea conditions as well as in pollutant-rich coastal waters of the Arabian Sea. Test samples were placed under natural climatic conditions of selected sites, followed by the mass loss and corrosion rate evaluation. The corrosion rate in the pollutant-rich coastal waters was around five times higher than in the natural seawater. A case study on marine condenser (fitted with of Cu-Ni 90/10 alloy tubes) is presented, and a risk-based inspection (RBI) plan is developed to facilitate equipment designers, operators, and maintainers to consider the implications of warm and polluted seawater on equipment reliability, service life, and subsequent health inspection/ maintenance.