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The use of High-Velocity Thermal Spray (HVTS) technology has been well adopted for sour conditions; particularly where low, or locally low, pH conditions result in corrosion and shell thinning. High alloy systems resistant to low pH or acidic conditions are effective at providing a metallurgical barrier, protecting the underlying substrate from material loss. Moreover, HVTS processes have also been employed for mitigating environmentally induced cracking (EIC) in sour service. This paper discusses the suitability and performance of modified HVTS alloys for service where high pH general corrosion or caustic cracking (CSCC) may occur. Extensive testing has been undertaken in both ambient and high pressure and temperature autoclave conditions to better understand material performance in caustic environments. While Nickel Alloy 200 and Monel 400 may be deemed appropriate based on traditional material selections, thermal spray process considerations in the material deposition and the impact of ancillary elements in the process stream, such as halides, render these alloys unsuitable. More complex Nickel alloy cladding systems are evaluated in this study with suitable material recommendations for remediation without the deleterious heat impact of welding or to protect surfaces where heat affected zones have been created and post weld heat treatment is problematic.
This paper will explore several variables which affect the tungsten carbide coating material deposited by a high velocity thermal spray process (HVTS) on Oil & Gas components such as valve sealing components (gate, ball, seat) and on other equipment (pistons for example on BOP’s or Blow Out Preventers). The purpose of coating these components is to gain wear/abrasion resistance as well as to impart some corrosion resistance.