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SAPC IADC Chapter MeetingSMART Coatings using Thermal Spray in the Oil & Gas Industry

26th November 2015

Dr Bryan Allcock

CEO Services

SAPC IADC Chapter Meeting 26th November 201502

Contents

• Define the Operating Environment by Zone

– Above (atmospheric)

– In (Intertidal)

– Below (Subterranean)

• Examples of applications in each of these Zones

– Dealing with complex environments

• Use of SMART inorganic sealants to extend the operational

performance and life expectancy of components and

structures.

• Conclusions and Inferences.

Defining the Environment

Atmospheric Zone

Tidal Zone

Subterranean Zone

03 SAPC IADC Chapter Meeting 26th November 2015

04

Zoning

Atmospheric

Corrosion Corrosion is mildest in the

centre of the Intertidal Zone and harshest at the turbulent edges

of the upper and lower tidal region. In the atmospheric and Submerged Zones, oxidation

rates are in equilibrium with the environment. In the

Subterranean Zone, a combined corrosion and wear

mechanism prevails.

Intertidal Zone

(Upper)

Intertidal Zone

(Lower)

Submerged Zone

Subterranean

Zone


Atmospheric Zone

Coatings for Aggressive Service Environments


Atmospheric Zone

• Current coatings offer:

– Corrosion resistance OR

– Anti-skid OR

– Heat resistance

• SMART coatings offer

– Corrosion resistance and Anti-Skid and Heat resistance.


Atmospheric Zone Surface Engineering


Atmospheric Surface Engineering Characteristics

• Conventional organic coating systems are

highly susceptible to mechanical damage on

offshore structures.

• Maintenance of these coatings is extremely

expensive but is essential if the structure is to

meet design life requirements.

• Surface preparation and coating application

is extremely labour intensive.

• Full-scale fully automated mechanised

Triplex-TSA coating system for decks,

gantries and walk-ways providing

mechanical, thermal and anti-skid as well as

corrosion protection.


0

09

Method of Application


10

Repair-ability

• One of the key advantages of Triplex TSA applied coating systems is their

ability to be repaired in situ.

• Localised mechanical damage salvage allows for vastly extended life

expectancy.


11

Tidal Zone / Submerged zone



12

Tidal Zone / Submerged Zone


– 15 years life AND

– Tend to be thick AND

– Are difficult to repair


– 40 years life, relatively thin and are relatively easy to repair and

are SELF HEALING.


13

Tidal Zone

Surface Engineering


14

Tidal Zone - Characteristics


15

Tidal Zone – Surface Engineering Characteristics

• Steel corrosion allowance, paint

systems and cathodic protection

(where feasible).

• Prohibitive increases in

structural mass and lack of

sufficiently durable paints.

• 10-15 year Life Expectancy

• Al-Zn-In Coating, Sealplex 6a

sealed.

• Increased impedance and

electro-potential.

• Self healing system capable of

withstanding mechanical

damage indicative of Intertidal

zone.

• 40 year design life


16

Tidal Zone Test Results

• Comparison of AlZnIn Sealed

Intertidal coating system and

conventional paint system and

TSA – conventional paint system.

• Samples scribed to form series of

heavily scratched surfaces.

• Self-healing nature of AlZnIn

Sealed system shows dramatic

increase in life expectancy.

• Test environment – accelerated

salt spray (ASTM B117) with

mechanical damage.

• Life expectancy of AlZnIn-Sealed

system in excess of 40 years.


17

Subterranean Zone



18

Subterranean Zone


– Corrosion resistance OR

– Wear resistance

– Destructive to substrate when compromised

– In-flexible and low resistance to impact


– Corrosion resistance and wear resistance and non-conductive

(no bi-metallic corrosion effects if damaged) and have increased

toughness.


19

Subterranean Zone

Surface Engineering


20

Subterranean

Surface Engineering

• Directional Drilling applications

dominated by chrome plating (Cr6+).

• Typically 80 to 300 hours before coating

destruction effecting stator performance.

• Carbide coatings sealed with Selaplex 2a

extend life to between 1800 and 3000

hours.


21

Subterranean Zone – Surface Engineering

Characteristics

Failure Mechanism For SealPlex®

Treated

Hard Face Coatings

Temperature

Trans-granular after treatment with SealPlex®

Inter-granular no SealPlex®

Treatment

Str

ain

to F

rctu

re


22

Conclusion & Inferences

• Atmospheric, Intertidal and Subterranean severe operating environments

require a SMART surface engineering approach.

• Anti-skid decks and walkways require a triplex system which is resistant to

mechanical damage.

• Intertidal zones can now exceed 40 years life expectancy and are self-

healing

• Re-engineered Subterranean directional drilling tools can expect to exceed

traditional surface engineered tools by up to 2 orders of magnitude in life

expectancy.

• The use of inorganic paint systems (ceramic paints) in conjunction with

thermal sprayed coating systems in Oil & Gas exploration has redefined the

boundaries of life-expectancy and performance.

• Coatings in Oil and Gas just got SMART!


23

MEXICO

UK

NORWAY

RUSSIA

UAE

CHINA

S. KOREA

SINGAPORE

Monterrey

Newcastle

Stavanger

Moscow

Dubai

Dalian

Incheon

Busan

Singapore

CANADA

USA

MEXICO

AUSTRIA

BELGIUM

SWITZERLAND

FRANCE

UK

Montreal

Wisconsin

Jacksonville

Mexico City

Vienna

Brussels

Zurich

Paris

Redditch

SWEDEN

SPAIN

POLAND

CZECH

ITALY

HUNGARY

EGYPT

SERBIA

Gottenburg

Madrid

Gliwice

Prague

Milan

Pecs

Cairo

SAUDI ARABIA

CHINA

THAILAND

JAPAN

Al Khobar

Shanghai

Bangkok

Kawasaki

Osaka

Sendai

Nagoya

Kanto

Kyushu

OILTEC SERVICE

CENTRES


24

Thank You


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