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Increase the reliability of oil field equipment with the use of technology for modification of corrosion resistant thermal spray coatings

UDK: 621.793
DOI: 10.24887/0028-2448-2020-4-68-73
Key words: corrosion, oil field equipment, corrosion-resistant thermal spray coatings, 3D-microanalysis, microstructure, structure formation, high-alloy powder materials, a new approach to the selection and modification of thermal spray coatings
Authors: R.D. Bakaeva (Gubkin University, RF, Moscow), L.Kh. Baldaev (Technological Systems of Protective Coatings Ltd., RF, Shcherbinka), D.Z. Ishmukhametov (Technological Systems of Protective Coatings Ltd., RF, Shcherbinka), A.Yu. Rashkovskiy (NLMK PJSC, RF, Lipetsk), T.G. Dmitrieva (Systems for Microscopy and Analysis LLC, RF, Moscow), A.P. Ryzhov (Systems for Microscopy and Analysis LLC, RF, Moscow), N.G. Anufriev (Frumkin Institute of Physical Chemistry and Electrochemistry of RAS, RF, Moscow), S.K. Kim (PermNIPIneft Branch of LUKOIL-Engineering LLC in Perm, RF, Perm), V.V. Bykouski (PermNIPIneft Branch of LUKOIL-Engineering LLC in Perm, RF, Perm)

Oil fields developed by LUKOIL-Komi LLC differ significantly in their lithology, depth of occurrence, and state of productive formations. To maintain reservoir pressure and enhance the oil recovery Company uses injection of mineralized waste water, surfactants, various chemicals, and high-temperature steam. The high content of carbon dioxide and hydrogen sulfide in the fluids of the Usinskoye and Vozeyskoye fields is the cause of abnormally high corrosion damage to oilfield equipment. The corrosion rates of local sections of oil collecting reservoirs are on average 3.5 mm per year. Corrosion of pumping and compressor pipes are developing even more actively: in some localized areas speeds reach 25-30 mm per year. The corrosion situation at the facilities of LUKOIL-Komi LLC is the basis for the development and implementation of a set of anti-corrosion measures, including various methods and technologies for surface protection, aimed at improving the operational reliability of well equipment and pipeline systems.

Increase the reliability of field equipment for oil and gas is possible through in-depth analysis of corrosion and mechanical processes. The solution of the problem of creating and implementing new corrosion resistant materials for field equipment for oil and gas includes comprehensive analysis of operating conditions and potential changes during the implementation of various geological and engineering operations at the oil field, and evaluation of equipment corrosion-mechanical state. The doping system of the source material (powder for spraying) should be selected in accordance with the classical concepts of certain chemical elements influence on strength and corrosion resistance. Selection and adaptation (modification to the required state) of the structural and phase composition of the initial powder material and coating should be made for specific operating conditions. It is necessary to test the resulting coating in the well. Technological solutions should be developed for each field, taking into account the depths and characteristics of field equipment.

Problems of increasing the reliability of oil and gas field equipment in LUKOIL-Komi LLC are common for oil and gas industry enterprises. The article describes an example of the analysis of the applicability of corrosion and wear-resistant thermal spray coatings for various components of oilfield equipment.

References

1. Bakaeva R.D., Baldaev L.Kh., Ishmukhametov D.Z. et al., Peculiarities of structure formationin gas-flame sprayed coatings producedfrom corrosion-resistant 316L metallic powder (In Russ.), Metallurg, 2018, no. 4, pp. 76–83.

2. Merkushkin E.A., Berezovskaya V.V., Korrelyatsionnaya zavisimost' potentsiala pittingoobrazovaniya i pokazateley PREN i MARC dlya austenitnykh korrozionnostoykikh staley (Correlation between the pitting potential and the PREN and MARC indices for austenitic corrosion-resistant steels), Collected papers “Innovatsii v materialovedenii i metallurgii” (Innovations in materials science and metallurgy), Proceedings of IV International Interactive Scientific and Practical Conference, Yekaterinburg: Ural Federal University named after the First President of Russia B.N. Yeltsin, Institute of Materials Science and Metallurgy, 2015, pp. 355–358.

3. Bakaeva R.D., Baldaev L.Kh., Ishmukhametov D.Z., Rashkovskiy A.Yu., Peculiarities of structure formation of gas-thermal coating formed by hvaf method from powder material based on Fe-Cr14-Ni6-Si3 (In Russ.), Metallurg, 2018, no. 7, pp. 81–86.

4. Bakaeva R.D., Baldaev L.Kh., Ishmukhametov D.Z. et al., Comparison of methods used to assess the porosity of gas-thermal spray coatings (In Russ.), Praktika protivokorrozionnoy zashchity, 2017, no. 4(86), pp. 41–53.

5. Khan F., Enzmann F., Kersten M. et al., 3D simulation of the permeability tensor in a soil aggregateon basis of nanotomographic imaging and LBE solver, J Soils Sediments, 2012, V. 12, 86 p., URL: https://doi.org/10.1007/s11368-011-0435-3

Oil fields developed by LUKOIL-Komi LLC differ significantly in their lithology, depth of occurrence, and state of productive formations. To maintain reservoir pressure and enhance the oil recovery Company uses injection of mineralized waste water, surfactants, various chemicals, and high-temperature steam. The high content of carbon dioxide and hydrogen sulfide in the fluids of the Usinskoye and Vozeyskoye fields is the cause of abnormally high corrosion damage to oilfield equipment. The corrosion rates of local sections of oil collecting reservoirs are on average 3.5 mm per year. Corrosion of pumping and compressor pipes are developing even more actively: in some localized areas speeds reach 25-30 mm per year. The corrosion situation at the facilities of LUKOIL-Komi LLC is the basis for the development and implementation of a set of anti-corrosion measures, including various methods and technologies for surface protection, aimed at improving the operational reliability of well equipment and pipeline systems.

Increase the reliability of field equipment for oil and gas is possible through in-depth analysis of corrosion and mechanical processes. The solution of the problem of creating and implementing new corrosion resistant materials for field equipment for oil and gas includes comprehensive analysis of operating conditions and potential changes during the implementation of various geological and engineering operations at the oil field, and evaluation of equipment corrosion-mechanical state. The doping system of the source material (powder for spraying) should be selected in accordance with the classical concepts of certain chemical elements influence on strength and corrosion resistance. Selection and adaptation (modification to the required state) of the structural and phase composition of the initial powder material and coating should be made for specific operating conditions. It is necessary to test the resulting coating in the well. Technological solutions should be developed for each field, taking into account the depths and characteristics of field equipment.

Problems of increasing the reliability of oil and gas field equipment in LUKOIL-Komi LLC are common for oil and gas industry enterprises. The article describes an example of the analysis of the applicability of corrosion and wear-resistant thermal spray coatings for various components of oilfield equipment.

References

1. Bakaeva R.D., Baldaev L.Kh., Ishmukhametov D.Z. et al., Peculiarities of structure formationin gas-flame sprayed coatings producedfrom corrosion-resistant 316L metallic powder (In Russ.), Metallurg, 2018, no. 4, pp. 76–83.

2. Merkushkin E.A., Berezovskaya V.V., Korrelyatsionnaya zavisimost' potentsiala pittingoobrazovaniya i pokazateley PREN i MARC dlya austenitnykh korrozionnostoykikh staley (Correlation between the pitting potential and the PREN and MARC indices for austenitic corrosion-resistant steels), Collected papers “Innovatsii v materialovedenii i metallurgii” (Innovations in materials science and metallurgy), Proceedings of IV International Interactive Scientific and Practical Conference, Yekaterinburg: Ural Federal University named after the First President of Russia B.N. Yeltsin, Institute of Materials Science and Metallurgy, 2015, pp. 355–358.

3. Bakaeva R.D., Baldaev L.Kh., Ishmukhametov D.Z., Rashkovskiy A.Yu., Peculiarities of structure formation of gas-thermal coating formed by hvaf method from powder material based on Fe-Cr14-Ni6-Si3 (In Russ.), Metallurg, 2018, no. 7, pp. 81–86.

4. Bakaeva R.D., Baldaev L.Kh., Ishmukhametov D.Z. et al., Comparison of methods used to assess the porosity of gas-thermal spray coatings (In Russ.), Praktika protivokorrozionnoy zashchity, 2017, no. 4(86), pp. 41–53.

5. Khan F., Enzmann F., Kersten M. et al., 3D simulation of the permeability tensor in a soil aggregateon basis of nanotomographic imaging and LBE solver, J Soils Sediments, 2012, V. 12, 86 p., URL: https://doi.org/10.1007/s11368-011-0435-3


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