cladding | Nanomaterials
cheaper than using solid stainless steel alloy, MesoCoat points out that conventional metallurgical and mechanical cladding technologies have limitations. Metallurgical clad pipes are normally made using
Above: The internal coating is fused to the pipe internal surface using a high intensity HDIR lamp
Right:
MesoCoat claims its CermaClad
pipe technology could be cost- competitive with epoxy in the future
roll-bonded clad plate which is then bent and welded to form the pipe. Although this is a high productivity process, it results in a considerable area of weld, particularly in pipes larger than 14 inches (35.6 cm) diameter that require spiral welding (clad plates are not large enough to produce longitudinally welded pipes at this size). And weld failure is the single most common reason for pipeline leaks. Mechanically-lined (bi-metal) pipe, which makes up a
significant portion of the clad pipe market, is less costly than metallurgical clad alternatives but provides only minimal contact between the inner and outer. This can lead to an increased risk of buckling, wrinkling and disbonding under stress, as well as during reeling and the application of external coatings. Such pipes can also lead to concerns over uniformity and reliability. An air gap, for instance, coupled with the mixture of materials can present challenges in non-destructive testing inspections that may contribute to risks associated with reliability.
There is a growing need for high performance
coatings in the oil and gas industry, according to Mesocoat. The International Energy Agency estimates that more than 70% of remaining oil and gas reserves are highly corrosive and an increasing share of global oil and gas production is now offshore. Exploiting these corrosive reserves, and especially the high pressure high temperature reserves found offshore, is likely to require pipes and components that can withstand extremely corrosive constituents. Deepwater oil and gas production involves hydrocar-
bons, produced water (brine), carbon dioxide, hydrogen sulphide and other chemicals. Under high pressures and temperatures, brine can form acidic mixtures that cause general corrosion and pitting of pipes and solid mineral deposits (scale) that inhibit flow. In ultra-deep- water wells the temperatures and pressures can be extreme – up to 250˚C and 25,000 psi (172 MPa). Produced water can have high salinity and this can form different types of scale, as well as accelerate corrosion and initiate stress corrosion cracking. Pipelines operating in such hostile environments need specific protection, and clad pipes have often been looked at to provide this protection. Clad pipe is typically produced by cladding a low cost
carbon steel substrate with a corrosion resistant stainless steel or nickel alloy. While cladding carbon steel pipes is
20 PIPELINE COATING | September 2015
Nanocomposite solutions Convinced that the exploitation of new deepwater reserves would require high corrosion resistance pipes, and having identified limitations in performance and limited availability of current cladding solutions, MesoCoat looked at ways to use its existing nanocom- posite technology. The company developed a new class of thermal spray coating materials - Particulate Composite Powders (which it markets under the PComP name). These materials are nano- or near nano-structured, ceramic-metal composites formed with a nanocomposite core and an outer binder coating and produced using a combination of low friction, high wear resistance and good corrosion resistant materials. The nanocomposite core provides high wear
resistance and low friction. The binder coating protects the internal core from heat and also provides corrosion resistance, toughness, ductility, resilience and improved deposition efficiency. The PComP coating materials are designed to be
compatible with existing thermal spray application systems. “PComP is not just a product, but a manufac- turing methodology. By using this methodology, MesoCoat can combine a variety of materials that would normally not go well together, leading to better corrosion and wear protection,” says Ghildyal. “PComP are the only thermal spray powders that lead to coatings that are both hard and tough. However, despite the hardness the coatings do not flake when bent.”
www.pipeline-coating.com
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