EXPLORATION • DRILLING • FIELD SERVICES
Rod pump product with the intermetallic coating
the tubing wall, eventually wearing a hole through it. T e more deviations and/ or the greater severity of doglegs in the wellbore, the more frequently rod wear will occur. Many technologies have been developed to increase the mean amount of time between these failures, including rod guides, abrasion-resistant internal plastic coatings, poly liners and others, but none provided satisfactory increased life of downhole tubulars. A new coating system outperforms many others. Majorpack’s duplex coating consists of intermetallic and polymer coatings. T e intermetallic layer is a diff usion zinc coating, chemically more active than iron, which works as a protective layer against the corrosive atmosphere within wells. It covers 100% of the pipe’s internal and outer diameters, and its threads and connections. Its micro- hardness is several times higher than Grade E steel, which provides excellent resistance to mechanical wear. T e top layer is a liquid epoxy-phenolic
that provides an additional layer of corrosion resistance, as well as deposit
Majorpack will be expanding its facilities in 2019
mitigation. T is duplex coating system is the best solution for oil wells, protecting against CO2
temperatures and abrasive wear. On average, tubulars with the MPAG coating systems last three to fi ve times longer than non-coated tubulars. According to NACE International, the cost of corrosion in the US oil and gas industry is US$27 billion. Other sources show that microbiologically infl uenced corrosion (MIC) accounts for over 20% of the total. MIC constantly increases as reservoirs become sour from water injection systems that increase oil production. When pipe is exposed to water containing microorganisms, they attach themselves to the surface of the pipe and create a biofi lm. Electrochemical conditions at the point where the biofi lm meets the metal can change, which may induce corrosion due to acid production, iron oxidation, and the creation of H2
and H2 S. The coating extends the life of tubulars 14
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In a prolonged third-party lab test, water samples were collected from three US basins known for MIC. T e lab measured the levels of adenosine triphosphate (ATP), acid producing bacteria (APB), and sulphate reducing bacteria (SRB) at diff erent times. ATP is a nucleotide that is the primary source of energy in all living cells. New discoveries were made after each measurement. T e fi rst is that the ATP levels began
S corrosion, high
to reduce, which could suggest that the diff usion zinc intermetallic layer is killing living cells. T e second discovery was that the levels of APB didn’t fall. However, the coated samples remained completely intact. T is could suggest that the zinc layer is impervious to APB. T e third discovery was that the SRB levels in each sample either declined drastically or were eradicated, suggesting that it killed the SRB. T e system extends the life of tubulars in all types of corrosive environments. Many fi eld trials have shown the coating system to improve the life of tubing by up to four times (which signifi cantly reduces operational expenditure and project downtime, thereby enhancing revenue streams). In a test in fi ve wells located in Russia, coated wells operated for an average of 992 days, compared to 324 for uncoated tubulars. Finally, oil producers have a solution to the problem of pipe corrosion and Majorpack is working to develop its business portfolio and establish manufacturing plants in Texas and also to expand its product sales network both in the USA and internationally.
Andrei Baev is CEO & Christopher Wilkins is vice president at Majorpack.
www.majorpack.com
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