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Canada's oil sands are the third largest deposit of crude oil in the world, and consist of a mixture of sand, water, and bitumen. Due to an aggressive operating environment that includes abrasive sands and corrosive chemicals, oil sands equipment and process piping often experience severe wear and erosion-corrosion, which can lead to the risk of equipment failures, plant downtime or, even worse, environmental leaks [1]. For more than half a century, oil sands producers have collaborated with materials suppliers, equipment fabricators, and technology providers to develop wear technologies to reduce downtime and improve operational reliability.
Additive manufacturing (AM) has received attention from the oil sands industry in recent years. Oil sands producers use AM technologies to fabricate parts with complex geometries that are difficult or impossible to make via conventional manufacturing. AM can also enable rapid iteration of design ideas and printing of prototypes directly from 3D CAD models quickly and cost-effectively. 3D printed cemented carbide and other wear-resistant materials have been investigated to improve operational reliability and reduce production costs. As AM is still in the early development stages, oil sands producers need to understand the capabilities and limitations of the various 3D printing processes available, comprehensively identify and validate suitable applications for their use. This paper reviews the current 3D printing technologies for making cemented carbide wear-resistant materials and emphasizes the
In the mid-1990s, the US Navy’s technical community, led by Naval Sea Systems Command (NAVSEA), recognized existing coatings used to protect the inside of ships’ tanks were failing on average 5-8 years after application. The high cost to blast and recoat over 11,000 tanks every 5-8 years, not counting submarines and aircraft carriers, was prohibitive. To address this issue, the Navy conducted a study to analyze the problem and decided to replace these legacy coatings with high solid epoxy coatings.1
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Oil field operating company’s (1) flowline network in North and West Kuwait (NWK) has over 3000 wells connected through 6” carbon steel pipelines flowing from wellhead to the nearest Gathering Center (GC). Untreated wet crude is transported through the flowlines to GC’s directly or passing through the Remote Headers and Manifold (RHM) to GCs. In RHM, mixing of the wet crude takes place before it is sent to GC’s via transfer lines for further separation. The flowlines are laid aboveground except at road crossings where they are buried.
Asset owners spend significant monies each year on the construction of new and the maintenance of existing infrastructure. More than ever, these funds can be difficult to procure and budget. The owners include, both municipal and industrial entities and funds are limited in most cases, therefore, asset service life is very important to all parties.