Justification for the application technologies of protective coating based on the example of oil fields in West Siberian

Corrosion of metal structures represents one of the most serious problems in the oil and gas industry. Its impact is profound. First, corrosion processes cause direct losses, as they often lead to sudden equipment failure. Second, corrosion results in additional economic costs related to repair, equipment replacement, and forced downtime. With increasing requirements for oil production and transportation, corrosion control has become even more critical. This dictates the need to develop new protective materials for metal structures and the application technologies of them. This study focuses on an in-depth analysis of modern developments in protective materials and application technologies for metal structures operating in aggressive environments and under conditions of intensive abrasive wear. The authors of this article identify the most vulnerable components of oil production equipment that are subject to the highest wear rates. The researchers also determines key negative factors, such as high temperature, exposure to hydrogen sulfide, salts, moisture, mechanical friction, and abrasion. The most effective protective materials include tungsten carbide, nitrides and borides of transition metals, particularly titanium. The article pays special attention to application methods of ceramic coating. Methods as high-velocity oxygen fuel spraying (HVOF), physical vapor deposition (PVD), magnetron sputtering, and related processes demonstrate the greatest potential. These methods offer high efficiency, allow precise control of coating properties, and ensure strong adhesion to the substrate. 

1. Davis J. R. The effects and economic impact of corrosion. Corrosion: Understanding the basics. 2000;(164):62–66.

2. Al-Moubaraki A. H., Obot I. B. Corrosion challenges in petroleum refinery operations: Sources, mechanisms, mitigation, and future outlook. Journal of Saudi Chemical Society. 2021;25(12):101370. https://doi.org/10.1016/j.jscs.2021.101370

3. Kolesova S. B., Mironychev V. G., Borkhovich S. Yu. Sovremennye tekhnologii izvlecheniya nefti i gaza. Perspektivy razvitiya mineral'nosyr'evogo kompleksa. Izhevsk: Izdatel'skiy dom "Udmurtskiy universitet"; 2016. (In Russ.).

4. Mishchenko I. T. Skvazhinnaya dobycha nefti. Moscow: Neft' i gaz, RGTU im. Gubkina; 2003. (In Russ.).

5. Markin A. N. Nizamov R. E. SO2 Korroziya neftepromyslovogo oborudovaniya. Moscow; 2003. (In Russ.).

6. Nasyrov A. M., Maslennikov E. P., Nagumanov M. M. Tekhnologicheskie aspekty okhrany okruzhayushchei sredy v dobyche nefti. Izhevsk: Paratsel's Print; 2013. (In Russ.)

7. Saleh B., Fathi R., Shi H., Wei H. Advanced Corrosion Protection through Coatings and Surface Rebuilding. Coatings, 2023;13(1):180. https://doi.org/10.3390/coatings13010180

8. Kumar S. S. A., Bashir S., Ramesh K., Ramesh S. New perspectives on graphene/graphene oxide based polymer nanocomposites for corrosion applications: the relevance of the graphene/polymer barrier coatings, Progress in Organic Coatings. 2021;154(1):106215. https://doi.org/10.1016/j.porgcoat.2021.106215

9. Georgiev D. Open innovations 2014: events, trends, promising developments. Nanoindustry. 2014;7(53):20–35. (In Russ.).

10. Othman N. H., Ismail M. C., Mustapha M., Sallih N., Kee K. E., Jaal R. A. Graphene-based polymer nanocomposites as barrier coatings for corrosion protection. Progress in Organic Coatings. 2019;(135):82–99. https://doi.org/10.1016/j.porgcoat.2019.05.030

11. Chzhu Tszyan, Agrauol Gorav, Soma Chakraborti. Nanopokrytiya dlya izdelii. Russian Federation. Patent No. 2012139313. 17 February 2011. URL: https://rusneb.ru/catalog/000224_000128_2012139313_20140327_A_RU/

12. Abrashov A. A., Grigoryan N. S.,Vagramyan T. A., ZHilenko D. Yu. Zashchitnye keramicheskie oksidno-titanovye nanopokrytiya. V sb. Sbornik tezisov dokladov satellitnoy konferentsii KHKH Mendeleevskogo s''ezda po obshchey i prikladnoy khimii. V Mezhdunarodnaya konferentsiya-shkola po khimiche-skoy tekhnologii. Volgograd, 16–20 maya 2016. Volgograd : Volgogradskiy gosudarstvennyy tekhnicheskiy universitet; 2016. Р. 171–173. (In Russ.).

13. Shikunov S. L., Ershov A. E., Kurlov V. N. Novye podkhody k polucheniyu keramicheskikh kompozitsionnykh materialov i zashchitnykh pokrytiy na osnove karbida kremniya. In: trudu konferentsii KHimiya tverdogo tela i funktsional'nye materialy–2016", ХI seminar "Termodinamika i materialovedenie". Ekaterinburg, 20–23 sentyabrya 2016. Ekaterinburg: Ural'skoe otdelenie RAN, 2016. Р. 338–340.

14. Tigunov L. P., Pikalova V. S., Bykhovskii L. Z. Legiruyushchie metally Rossii. Mineral'no-syr'evaya baza: sostoyanie, ispol'zovanie, perspektivy razvitiya. Chernaya metallurgiya. Byulleten' nauchno-tekhnicheskoi i ekonomicheskoi informatsii. 2017;(12):3–11. (In Russ.).

15. Raza A., Abdulahad S., Kang B., Ryu H. J., Hong S. H. Corrosion resistance of weight reduced AlxCrFeMoV high entropy alloys, Applied Surface Science. 2019;(485):368–374. https://doi.org/10.1016/j.apsusc.2019.03.173

16. Fu Y., Li J., Luo H., Du C., Li X. Recent advances on environmental corrosion behavior and mechanism of high-entropy alloys, Journal of Materials Science & Technology, 2021;(80):217–233. https://doi.org/10.1016/j.jmst.2020.11.044

17. Babichev A. P., Ivanov V. V., Popov S. I., Dontsov N. S. Features of the mechanism of chemical-mechanical vibrating zinc coating formation. Strengthening technologies and coatings. 2018;(14-2):51–54. (In Russ.).

18. Qi C., Weinell C. E., Dam-Johansen K., Wu H. Assessment of anticorrosion performance of zinc-rich epoxy coatings added with zinc fibers for corrosion protection of steel. ACS omega. 2023;8(2):1912–1922.

19. Bailey J. R., Biediger E. A. O., Bangaru N.-R. V., Ozekcin A., Jin H., Yen C. S.-H. et al. Devices with coatings for operation of oil and gas wells. Russian Federation. Patent No. 2 529 600 C2. 20 August 2009. (In Russ.) URL: https://searchplatform.rospatent.gov.ru/media/National/RU/C2/2014/09/27/0002529600//DOCUMENT.PDF

20. Kameneva A. L., Bublik N. V. Method for producing corrosion-resistant coating. Russian Federation. Patent No. 2 768 053. 24 November 2021. (In Russ.). URL: https://searchplatform.rospatent.gov.ru/media/National/RU/C1/2022/03/23/0002768053//document.pdf

21. Kartapova T. S., Gilmutdinov F. Z., Vorobev V. L., Reshetnikov S. M, Borisova E. M. Method of application of mixed carbon-nitrogen protectivecoating to increase corrosive stability of iron. Russian Federation. Patent No. 2 659537 C1. 26 September 2017. (In Russ.). URL: https://rusneb.ru/catalog/000224_000128_0002659537_20180702_C1_RU

22. Zhabin A. N., Nyafkin A. N., Serpova V. M., Krasnov E. I. Methods of physical vapor deposition for the manufacture of metal matrix composites (review). Proceedings of VIAM. 2020;11(93):68–75. (In Russ.). https://doi.org/10.18577/2307-6046-2020-0-11-68-75

23. Gil'manov T. I. Obzor tekhnologii naneseniya iznosostoikikh pokrytii. Innovation science. 2022;(4-1):10–12. (In Russ.).

24. Druzhnova Ya. S. Development of methods for thermal spraying of hardening tires based on tungsten and chromium carbides (review). Proceedings of VIAM. 2022;10(116):100–115. (In Russ.) https://doi.org/10.18577/2307-6046-2022-0-10-100-115

25. Kluonis, A. S., Plotnikov S. A. Obzor sovremennykh metodov naneseniya iznosostoykikh pokrytiy i ikh sravnitel'nyy analiz. In Innovatsionnye resheniya v tekhnologiyakh i mekhanizatsii sel'skokhozyaystvennogo proizvodstva. Gorki: Belorusskaya gosudarstvennaya sel'skokhozyaystvennaya akademiya; 2023. Р. 284–287. (In Russ.).

26. Baldaev L. Kh., Baldaev S. L., Ignatova S. A., Kozlov N. S., Mazilin I. V., Man'kovskii S. A. et al. Method of electric arc spraying of coating. Russian Federation. Patent No. 2715827 C1. 18 october 2019. (In Russ.). URL: https:// rusneb.ru/catalog/000224_000128_0002715827_20200303_C1_RU

27. Isakaev M.-E. Kh., Mordynskii V. B., Katarzhis V. A. Electric arc spraying device. Russian Federation. Patent No. 2530580. 18 June 2013. (In Russ.). URL: https://rusneb.ru/catalog/000224_000128_0002530580_20141010_C1_RU/

28. Chujko A. G., Kuzjaev F. F., Rakoch A. G., Chujko K. A., Kudrjavtsev A. M., Shvetsov A. Ju. Ball valve shut-off member and method of its production. Russian Federation. Patent No. 2347126 C1. 02 May 2007. (In Russ.). URL: https://rusneb.ru/catalog/000224_000128_0002347126_20090220_C1_RU/

29. Grenaderov A. S., Solovyov A. A., Oskomov K. V., Zhulkov M. O. Dependence of mechanical and tribological properties of a-C : H : SiO x films on the amplitude of substrate bias voltage. Zhurnal tekhnicheskoi fiziki. 2021;91(8):1286– 1292.(In Russ.) https://doi.org/10.21883/JTF.2021.08.51106.15-21