Pressurized CVD-ALD Coating for Well Tool Interior Corrosion
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Solution Overview
Problem
Well tools used in downhole operations are prone to internal corrosion and abrasion due to exposure to fluids like hydrogen sulfide and mercury, leading to reduced lifespan and operational issues.
Innovation Solution
A hybrid coating system utilizing chemical vapor deposition (CVD) and atomic layer deposition (ALD) processes within a pressurized cell to apply protective coatings on the interior surfaces of well tools, creating a sealed deposition chamber for efficient and portable surface coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a coating is deposited on the interior surface of a well tool to protect against corrosion and abrasion, then the tool lifespan is extended, but the cost and complexity of the coating system increases due to the need for specialized deposition equipment
Solution Approach 1:
The patent applies parameter changes by transitioning from vacuum-based deposition to pressurized gas-phase deposition. The well tool is coated in a pressurized environment (1-100 psig) rather than vacuum, allowing for simpler equipment while achieving effective coating deposition through pressure-driven gas flow and reactant delivery
Solution Approach 2:
The invention utilizes pneumatic principles by employing pressurized gas flow to deliver reactants to the well tool interior surfaces. A pressurized gas source (1-100 psig) forces reactant gases through the tool, enabling coating deposition without vacuum equipment, thereby reducing system complexity while maintaining coating effectiveness
2Reliability
If a hybrid coating system utilizing CVD and ALD processes is implemented, then the protective coating effectiveness is improved, but the manufacturing complexity and process control difficulty increase
Solution Approach 1:
The patent merges CVD and ALD processes into a single integrated system operating under pressurized conditions. The hybrid approach combines the bulk deposition capability of CVD with the precise layer-by-layer control of ALD, achieving superior coating protection while using one unified pressurized reactor rather than separate vacuum chambers for each process
Solution Approach 2:
The invention changes the operating parameters from vacuum to pressurized environment (1-100 psig), allowing both CVD and ALD processes to occur simultaneously in the same chamber. This parameter change simplifies the overall system architecture while maintaining the benefits of hybrid coating approaches for enhanced protective effectiveness
3Ease of operation
If a pressurized cell system is used instead of commercial vacuum chambers, then the portability and accessibility of the coating system is improved, but the manufacturing precision and coating uniformity may be compromised
Solution Approach 1:
The patent uses pneumatic principles to achieve coating deposition in a pressurized cell (1-100 psig). Pressurized gas flow patterns are controlled to ensure uniform reactant distribution throughout the well tool interior, achieving coating uniformity without requiring vacuum equipment, thus maintaining system portability and accessibility
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 system effectively resists physical wear and chemical reactions, extending the lifespan of well tools by providing a durable protective barrier against corrosive and abrasive elements, and can be used at various locations without the need for expensive commercial vacuum chambers.
Implementation Method 1
A controller is in electronic communication with the pressurized cell and is configured to control introduction of one or more pulses of the reactant gas from the pressurized cell into a flowing stream of inert gas in a pressurized cell line
Implementation Method 2
A hybrid coating system utilizing chemical vapor deposition (CVD) and atomic layer deposition (ALD) processes within a pressurized cell to apply protective coatings on the interior surfaces of well tools
Data Source
AI summary
A coating system for coating, with a surface coating process, an interior surface of a housing defining an interior volume, having: a first closure and a second closure to sealingly engage with the housing; one or more first flow lines and second flow lines fluidically coupled to the first and second closure, respectively; a pressurized cell comprising a pressurized gas comprising at least one reactant and at a pressure of greater than a pressure within the housing, wherein the pressurized cell is fluidically coupled to a pressurized cell line comprising one of the first flow lines or second flow lines; and a controller in electronic communication with the pressurized cell and configured to control injection of a pulse of the pressurized gas into a flow of inert gas in the pressurized cell line, whereby the pulse is introduced into the interior volume, coating the interior surface with a coating layer.