Dual-Coated Pipe Section for Corrosion and Abrasive Wear
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Solution Overview
Problem
Existing pipes used in the oil and gas extraction industry face challenges with corrosion resistance and abrasive wear, particularly when dealing with fluids containing high water content, hydrogen sulphide, carbon dioxide, and hard solids, where current coatings like plastic wear protection layers and metallurgically clad pipes have limited service life and material compatibility issues.
Innovation Solution
A pipe section design featuring a support layer of a metal base material with a first metal coating applied by welding in the end regions and a second metal coating sprayed using a thermal spraying process in the intermediate regions, providing enhanced corrosion resistance and abrasive wear protection while allowing for cost-effective manufacturing and flexible material selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a plastic wear protection layer is applied to steel pipes, then corrosion resistance is improved, but service life deteriorates due to quick wear by abrasive wear
Solution Approach 1:
The patent changes the material parameter of the coating from plastic to metal, fundamentally altering the wear characteristics while maintaining corrosion resistance. The metal coating material is selected to have both corrosion resistance and high resistance to abrasive wear, resolving the contradiction between these two properties.
Solution Approach 2:
The patent creates a composite structure consisting of a steel pipe base material combined with a metal coating layer. This composite material approach allows combining the strength and formability of steel with the corrosion and wear resistance of specialized metal coatings, achieving both protection needs simultaneously.
2Object-affected harmful factors
If metallurgically clad pipe sections are used, then corrosion and wear resistance is improved, but material compatibility issues arise requiring sufficient metallurgical compatibility for strong diffusion bridge
Solution Approach 1:
The patent changes the bonding mechanism parameter from metallurgical diffusion bonding to mechanical adhesion through thermal spraying. This allows greater freedom in material selection, as the coating material does not need to be metallurgically compatible with the base material, only adherent through mechanical and chemical bonding at the interface.
Solution Approach 2:
The patent introduces a transition layer or interface zone between the base material and coating that facilitates adhesion without requiring full metallurgical compatibility. This intermediary zone allows different material combinations to be used, increasing versatility while maintaining protection performance.
3Object-affected harmful factors
If hydromechanically clad pipe sections are manufactured, then corrosion and wear resistance is improved, but manufacturing complexity increases due to required end face closing and sealing welds
Solution Approach 1:
The patent extracts the cladding process from the complex hydromechanical expansion method and replaces it with a simpler thermal spraying process. This eliminates the need for end face closing, expansion equipment, and multiple sealing welds, significantly reducing manufacturing complexity while maintaining coating effectiveness.
Solution Approach 2:
The patent replaces the mechanical hydromechanical expansion system with a thermal energy-based spraying system. This substitution simplifies the manufacturing process by eliminating complex mechanical expansion equipment and multi-step welding procedures in favor of a more straightforward thermal deposition process.
4Object-affected harmful factors
If deposition weld is used to bond inner coating to outer pipe, then corrosion and wear resistance is improved, but manufacturing time increases and heat input causes material mixing
Solution Approach 1:
The patent replaces the deposition weld process with thermal spraying, substituting a slow, heat-intensive welding process with a faster, controlled thermal deposition process. This increases manufacturing speed while avoiding the material mixing and heat input problems associated with welding.
Solution Approach 2:
The patent changes the bonding process parameters from welding conditions (high heat input, slow process) to thermal spraying conditions (controlled heat, fast process). This parameter change maintains the protective function of the coating while dramatically improving manufacturing productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed pipe section design achieves robust corrosion resistance and abrasive wear protection, extending the service life of pipes in harsh environments, while reducing material costs and the complexity of cladding processes compared to traditional methods.
Implementation Method 1
a second coating (130) consisting of a second metal coating material (131) in the intermediate region (118) of the inner surface (114) of the support layer (110), wherein the second coating (130) is sprayed onto the support layer (110) using a thermal spraying process
Implementation Method 2
a first coating (120) consisting of a first metal coating material (121) in each end region (117) of the inner surface (114) of the support layer (110), wherein the first coating (120) is welded to the support layer (110)
Data Source
AI summary
A pipe section includes a support layer consisting of a metal base material. The support layer has an inner surface, at least two pipe section ends each having an end region, and an intermediate region. Each end region of the inner surface of the support layer has a first coating consisting of a first metal coating material. The first coating is welded to the support layer. The intermediate region of the inner surface of the support layer has a second coating consisting of a second metal coating material. The second coating is sprayed onto the support layer using a thermal spraying process and has a second thickness. The second thickness is less than or equal to 2500 μm.