A Look at How Innovative Surface Technologies are Supporting New...

A Look at How Innovative Surface Technologies are Supporting New Challenges in Oil and Gas

Manufacturing Technology Insights | Friday, September 16, 2022

Fremont, CA: Over the past 40 years, oil and gas reserves have undergone a significant transformation that presents new and significant challenges upstream, midstream, and downstream across the industrial value chain.

Modern technology and supply chain solutions have advanced tremendously as a result. Light metals' particular properties are crucial in tackling these problems and enabling future technologies.

Greater pressures and higher temperatures are two complex operating parameters brought on by the unconventional revolution, which brought onshore shales and tar sands with offshore fields stretching into deeper and colder waters and further drilling depths (HPHT).

Developing commercially feasible oil and gas prospects in these new, uncharted places at a competitive price and an acceptable risk level is one of the largest engineering challenges the company has ever faced. But additionally, this sector is unafraid of challenging issues.

Industry objectives have altered, requiring new approaches to material choice

Due to adjustments in production and supply around the globe and work in more challenging environments, such as caustic HPHT wells, priorities have altered. The main focus of studies is to increase operating savings and lengthen asset lifespans.

One way to extend the life of assets and improve operating efficiency is to select materials that can withstand the challenges of extracting unconventional and HPHT deposits. Thanks to advancements in surface coating technology, material scientists and engineers may now choose light metals with unique properties that were previously unfeasible in these situations, such as aluminum, magnesium, titanium, and valve metals.

The difficulties in choosing materials for oil and gas utilization

Research estimates that the total yearly cost of corrosion in the oil and gas production sector will be 1.372 billion dollars. However, this amount might be divided into 320 million dollars for corrosion-related capital expenditures, 589 million dollars for surface pipeline and facility expenses, and 463 million dollars annually for downhole tube costs.

Locally focused corrosion and environmental-aided cracking are the two primary forms of degradation affecting steel and light metal alloys often used for upstream manufacturing applications—especially those considered to be HPHT, Arctic, or sour. Measurable hydrogen sulfide concentrations characterize

sour fields. Acid-bearing fluids, sulfur and hydrogen sulfide found in crude oil, saline water, and HPHT conditions like oil processing facilities that may reach 600°C are just a few of the corrosion challenges that must get tackled upstream, middle, and downstream. The industry's consistent production across the supply chain depends on the ability to manufacture components and systems that can withstand these physically and chemically challenging circumstances. Thanks to anti-corrosion technologies like specific surface coatings, light metals may now be employed in a larger range of oil and gas supply chain applications, enabling engineering solutions to use their favorable features.

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