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Evaluation of a Hydrophobic Coating Material for Downhole Application, Lab vs. Field Evaluation

A hydrophobic electroless nickel-phosphorus (ENP) coating material has been developed to reduce corrosion-induced iron sulfide scale deposition. The ENP coating has several key advantages to provide corrosion resistance for sour oil and gas applications, including a level of phosphorus imparting superior corrosion resistance in a sour gas environment, a tailored phosphorus level providing a range of super hydrophobic microstructures, and a second material introduced and embedded in the ENP coating during the coating process to impart desired properties such as wear and erosion resistance. The coating material has been qualified through a series of evaluation tests carried out in the lab, including iron sulfide scale formation under HTHP, coating adhesion tests, explosive decomposition, formation of heazlewoodite (Ni3S2), etc. The coating material was installed in downhole completion tubing through a downhole corrosion and scale monitoring (DCSM) tool to monitor coating stability, corrosion, and scaling under real downhole flow conditions in a sour gas well over 3 months. Overall, the field testing has demonstrated that this newly developed coating material can effectively protect the metal coupon against corrosion and iron sulfide deposition. However, the abrasion of the formed surface layer of Ni3S2 and blistering might be a concern for a long-term field application. This paper will comprehensively compare the coating performance evaluated in the lab and field conditions. Long-term evaluation under real field conditions is highly recommended to qualify the coating material for large-scale application in the downhole.
Product Number: 51324-20756-SG
Author: Tao Chen; Feng Liang; Frank Chang; Qiwei Wang
Publication Date: 2024
$40.00
$40.00
$40.00
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