The oil and gas industry continuously faces dilemmas regarding its
operation efficiency. Contractors are more demanding of extreme
performance coating materials that offer exceptional performance, reduce
plant downtime and increase service intervals - all with constant
respect of the environmental constraints.
Deep drilling
exploration and oil sand exploitation are two of the more challenging
applications which require innovative coating solutions for longer
operating times which are under more severe abrasive and corrosive
environments and at higher pressures than regular drilling.
Exploitation techniques often requires separation of the water from
oil. During operation, huge problems of abrasion occur thus reducing the
life of pipes, elbows, pumps, separators, casings, etc.
Downhole
tools for drilling are subject to combined stresses such as abrasion,
erosion, impact, corrosion and contact pressure. Because their
non-sufficient fracture toughness, the traditional 'commodity' tungsten
carbide coatings can't withstand all of these stresses simultaneously.
Constant
research and development efforts conducted thermal sprayed coatings
and hard-faced overlays to become more and more complex with feature
enhancements allowing for more severe operating conditions as well as
coating life improvement.
The improvement has been achieved with
important innovations by alloying proprietary powders with tungsten carbide/metal powders, nano WC/Co, macro WC and/or superfine WC/Co
materials. They are mixed with hard and tough metal matrixes which
offer exceptional hardness, abrasion/erosion wear resistance and
corrosion resistance - and consequently with improved fracture
toughness. These grains can be used as powder or converted into
electrodes, flexicords and tungsten carbide ropes. These new materials
can be sprayed, PTA cladded or brazed with a flame welding torch.
The
Hardkarb flexicord or high velocity thermal spray processes allow to
produce high abrasion and erosion resistant WC coating with improved
fracture toughness. The metal matrix can be chosen from Cobalt,
Cobalt-Chrome, Nickel or Ni-Cr-Mo alloys if petrochemical corrosion is
present. The usual thickness of these coatings ranges from 0.3mm to 1mm
(0.01-in to 0.04-in).
In regards to hard-facing techniques,
versus arc welding, the flame welding (brazing) technique is still the
best suited technique to avoid decomposition of WC tungsten carbide and
allows to produce tungsten carbides welded overlays that contain the
lowest content of brittle W2C phases. The usual thickness of these
hard-faced overlays ranges from 1.5mm to 1mm (0.06-in to 0.2-in).The
brazed overlays combine abrasion resistance, contact pressure
resistance as well as rupture toughness in the final coating.
Improving the coating materials would only be the halfway to the
objective, if equipment improvements have not been made. Traditional
coating equipment provides limited effectiveness because it is primarily
intended for external surfaces and not internal ones. New thermal
spray equipment is available for applying coatings to internal
diameters. Thermal spray equipment is capable of applying internal
coatings down to ~ 6 inches with expected lengths of up to 12 feet.
With
a large emphasis on coating performance, the thermal spray industry
accomplishes innovative solutions and contributes to create and bring
new and highly differentiated products to the market in a
cost-effective and efficient time frame.