High performance coatings are required to protect oil and gas piping assets globally. Failure of these assets due to erosion and/or corrosion can lead to significant revenue losses and downtime. When new oil wells are opened, a significant volume of fluids and solids are transported at high velocities though these lines. Oil well head temperatures approaching 50°C+ contain high H2S and/or CO2 concentrations at pressures exceeding 500 psi which pose unique challenges for existing coating systems. These factors challenge current coating properties/performance and require testing analogous to field conditions.

This paper explores the development of erosion coating systems having erosion performance similar or better than steel when exposed to silica sand (particle size < 50μm) traveling up to 30m/sec. The new coating systems have sufficient erosion performance in wet (60°C/140°F; stirred) and dry environments for up to 28 days. Upon exposure to produced water at elevated temperatures (60°C/140°F) and pressures (100 - 800psi) in autoclave conditions, the coating systems have excellent adhesion and appearance, without blistering nor swelling. Additionally, existing and new test protocols for designing erosion coatings will be discussed.