Selective Bevel Coatings for Abrasion-Resistant Fluid Conduits
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Solution Overview
Problem
Conventional hydraulic fracturing conduits experience excessive wear due to high-pressure slurry abrasion, leading to reduced lifetimes and increased maintenance frequencies, which compromises the uptime and efficiency of fluid systems in oil and gas extraction.
Innovation Solution
A thermal spray coating is applied to the beveled surfaces of conduit sections within the fluid system, enhancing the durability and resistance to abrasive forces, and potentially including metallic alloys like tungsten carbide, to create a hardened surface that resists erosion and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional uncoated conduit is used in high-pressure slurry applications, then the system structure remains simple and manufacturing cost is low, but the conduit experiences excessive wear and reduced lifetime
Solution Approach 1:
The patent applies a composite coating system consisting of a metallic bond coat layer and a ceramic top coat layer. The metallic bond coat (e.g., nickel-based alloy) provides strong adhesion to the conduit substrate and serves as a transition layer, while the ceramic top coat (e.g., alumina, zirconia) provides exceptional abrasion and corrosion resistance. This composite structure combines the advantages of different materials to protect the conduit against slurry-induced wear and extend its service life in hydraulic fracturing applications.
Solution Approach 2:
The patent modifies the surface properties of the conduit by applying a coating that changes the surface hardness, friction characteristics, and chemical composition. The coating process transforms the soft, wear-prone metallic surface into a hard, abrasion-resistant surface with different thermal and chemical properties, enabling the conduit to withstand high-pressure slurry flow without excessive wear.
2Reliability
If a thermal spray coating is applied to conduit surfaces, then wear resistance and durability are improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent applies the protective coating to the conduit during the manufacturing stage, before the conduit is deployed into service. This preliminary action ensures that the coating is properly adhered and cured under controlled factory conditions, and allows for quality inspection before the conduit leaves the manufacturing facility. By performing the coating operation upfront rather than in the field, the overall system reliability is improved without adding operational complexity during maintenance cycles.
Solution Approach 2:
The patent employs thermal spray technology, which uses thermal energy and fluid dynamics to deposit coating material onto the conduit surface. This replaces traditional mechanical coating methods with a thermally-driven process that allows for more uniform coating thickness, better adhesion, and the ability to apply complex ceramic coatings that would be difficult to apply mechanically. The thermal spray process can be automated, reducing manual intervention and improving consistency.
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 coating significantly extends the usable life of the conduit by reducing wear and maintenance needs, ensuring higher system uptime and operational efficiency in high-pressure applications.
Implementation Method 1
A thermal spray coating is applied to the beveled surfaces of conduit sections within the fluid system, enhancing the durability and resistance to abrasive forces
Data Source
AI summary
A fluid conduit system a first conduit section having a first conduit bore extending from a first end of the first conduit section to a second end of the first conduit section, the first conduit bore including a first beveled surface proximate the first end of the first conduit section. The fluid system also includes a second conduit section coupled to the first conduit section and having a second conduit bore extending from a first end of the second conduit section to a second end of the second conduit section, the second conduit bore including a second beveled surface proximate the first end of the second conduit section. The fluid system further includes a coating applied to the first beveled surface and to the second beveled surface.