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Importance Of Quality Control Of Wear Resistant Overlays In Oil Sands Production Operations.

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Canadian Oil Sands mining operations have been producing oil from sand ore from the early 1960s. Oil Sands mainly consists of high hardness quartz, silica, bitumen and water. Bitumen production processes include mining the sand, washing it with hot water, slurry transportation, tailing disposal and bitumen production. Abrasion, gouging wear, impact wear, erosion and erosion-corrosion are predominant degradation mechanisms in Oil Sand mining operations.

Product Number: 51322-17838-SG
Author: Satya Kompally, Jeff Liu
Publication Date: 2022
Industries: Oil and Gas , Test Method , Cathodic Protection , Corrosion Monitoring and Control
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Equipment and piping in Oil Sands operations are subject to erosion, abrasion and impact wear while handling dry ore and wet slurry. Wear resistant overlays play a very important role in extending the service life of various equipment and piping in Oil Sands production operations. Tungsten carbide overlays and chromium carbide overlays are widely used to increase the wear resistance of equipment and piping. Bonding with the base material, overlay chemistry, carbide distribution, carbide volume fraction, dilution, and through thickness hardness are all important factors in determining the wear resistance and service life of overlays. Qualification and production testing are necessary to ensure the quality of the overlays. Service life of overlays depend on the quality control process adopted during the fabrication process.

Wear resistant overlays have been in use for a very long time. Lots of work has been done in the last 10 years to increase the service life of overlays and minimize unexpected premature failures. A significant part of this work was focused on quality control and testing requirements of the overlays. This resulted in new testing methodologies and improved inspection requirements.

Equipment and piping in Oil Sands operations are subject to erosion, abrasion and impact wear while handling dry ore and wet slurry. Wear resistant overlays play a very important role in extending the service life of various equipment and piping in Oil Sands production operations. Tungsten carbide overlays and chromium carbide overlays are widely used to increase the wear resistance of equipment and piping. Bonding with the base material, overlay chemistry, carbide distribution, carbide volume fraction, dilution, and through thickness hardness are all important factors in determining the wear resistance and service life of overlays. Qualification and production testing are necessary to ensure the quality of the overlays. Service life of overlays depend on the quality control process adopted during the fabrication process.

Wear resistant overlays have been in use for a very long time. Lots of work has been done in the last 10 years to increase the service life of overlays and minimize unexpected premature failures. A significant part of this work was focused on quality control and testing requirements of the overlays. This resulted in new testing methodologies and improved inspection requirements.

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