WALL COLMONOY OIL & GAS INDUSTRY

Transcription

1 WALL COLMONOY OIL & GAS INDUSTRY

2 Wall Colmonoy is a global materials engineering group of companies engaged in the manufacturing of surfacing and brazing products, castings, and engineered components across aerospace, automotive, oil & gas, mining, energy and other industrial sectors. Known for our unique proven way of creating superior performing alloys that enhance engineered components, we pride ourselves on long-term strategic customer collaboration that produces value-added ideas and creative solutions. Combining over 75 years of engineering technology with a progressive, visionary outlook, Wall Colmonoy offers customers trusted, customised expertise that results in smart innovation and shared growth. PROGRESSIVE COLLABORATION FOR SUPERIOR PERFORMANCE. WORLDWIDE.

3 WALL COLMONOY OIL & GAS INDUSTRY Wall Colmonoy s hard-surfacing products and engineered components are used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, our range of Surfacing Alloys have successfully extended the useful life of the industry s equipment and machinery from harmful corrosion and wear. Our specially formulated alloys, COLMONOY (nickel-based) and WALLEX (cobalt-based), have outstanding metallurgical and physical properties making them ideally suited to solving wear problems in the Oil & Gas Industry. The alloys are applied in a wide range of proven surfacing and thermal spraying techniques, including Laser Cladding, PTA, HVOF, and Spray & Powder Welding. Wall Colmonoy also manufactures precisely cast and machined components. Made from our superior performing Colmonoy or Wallex Surfacing Alloys or customerspecific alloys using Investment, Centrifugal, Sand Cast or Vacuum Cast Processes. Engineered components are designed to optimise wear, corrosion, abrasion and heat resistant properties. For more than 75 years Wall Colmonoy has served the Oil & Gas Industry with highquality, hard-surfacing alloys, precisely engineered components, expert application consultation and field assistance. Our Manufacturing facilities in North America and Europe are equipped with modern laboratory and testing facilities. Our products are manufactured to quality standards set by international and national industrial associations. We maintain quality assurance to ISO

4 SURFACING ALLOYS FOR OIL & GAS MAXIMISING PERFORMANCE & EXTENDING THE USEFUL LIFE OF ENGINEERED COMPONENTS What makes our products different? Our range of Colmonoy and Wallex Surfacing Alloys are an excellent defense against wear mechanisms such as abrasion, erosion, corrosion and high-temperatures encountered in service. As the world s leading manufacturer of nickel-based hardsurfacing alloys, Wall Colmonoy coatings have been extending the service life of industrial parts for over 75 years. What is hard-surfacing? Hard-surfacing is the application of a layer of wear-resistant alloy to a part for the purpose of extending the machine s service life. This can be performed on worn parts to replace metal lost through wear and on new parts when wear is anticipated. What is the benefit? Parts protected with our Surfacing Alloys Colmonoy or Wallex - last significantly longer than unprotected parts. This means: fewer replacement parts needed less labor required to install them minimise down-time TYPES OF SURFACING POWDER PRODUCTS: Atomised nickel and cobalt alloys containing combinations of tungsten, chromium, chromium carbide or tungsten carbide for specific applications. In fabricating new parts, inexpensive base metals may be used because our Surfacing Alloy coatings withstand wear. Our Surfacing Alloys are available as powder, rods, wires and castings to suit different application methods. Crushed premium alloy form with high surface area and dense coatings for superior wear-resistance. Composite alloy particles of tungsten carbide in nickel or cobalt matrix; designed to resist sliding abrasion and abrasive wear. 3

5 PRECISION COMPONENTS FOR OIL & GAS DESIGNED TO OPTIMISE WEAR, CORROSION, ABRASION, AND HEAT RESISTANT PROPERTIES An Integrated Approach - Casting, Heat Treating and Machining all from One Source Machining facilities include EDM, wire cutting, CNC grinding, honing, milling, lapping and turning. Wall Colmonoy s precisely engineered components are used throughout Oil & Gas industry. The components are made from wear, heat, and corrosion resistant Colmonoy, Wallex, or customer-specific alloys designed to optimise wear, corrosion and heat resistant properties. Our technical team has amassed a wealth of skill, knowledge and know-how turning designers and engineers rigorous requirements into economically viable solutions. Our expert engineers select the optimum alloy and process to suit specific needs. Components are either as cast or fully machined from air or vacuum melted castings made by investment, sand, or centrifugal techniques. Components for Oil & Gas Industry are produced using Wallex alloy and manufactured according to API standards include: l CASTING METHODS: Investment offers design flexibility, close dimensional control, consistency & repeatability, cost savings. Centrifugal Spun is used to produce high integrity densely structured, cylindrical components like bushes and sleeves. Sand is typically used to produce larger components in smaller batches. It is capable of making mostly complex shapes using relatively inexpensive wood or resin patterns. Ball Valves Clamp Plates and Pads Plugs and Flow Control Cages Rotors Stem Guides Valve Seats Wall Colmonoy s on-site laboratory and test facilities are fully approved and can certify goods to customers specific requirements. Wall Colmonoy has an ongoing commitment to high quality manufacture and offer certification to nationally and internationally recognised standards. Vacuum Casting is used for alloys where tight compositional control and low inclusion counts are required - difficult to achieve when using conventional air melting and casting. All components can be offered in the as cast, Each engineered component goes through a reassuringly stringent inspection process before final delivery. 4

6 APPLICATIONS FOR OIL & GAS INDUSTRY Extending the useful life of the industry s equipment, gears, and machinery from harmful corrosion and wear DRILLING Blowout Preventors, Operating Pistons - Colmonoy 52, 5 Cable Drill Bits - Colmonoy 88 Centrifugal Pump Parts and Wear Rings - Colmonoy 52, 5, 62, 6, 72 Choke and Kill Pins - Colmonoy 52, 5 Clamp Plates and Pads -Wallex 6 Compressor Rod Sleeves - Colmonoy 62 Compressor Rods - Colmonoy 62, 6 Downhole Pump Plungers Colmonoy 42, 4, 52, 5, 62, 6 Drilling Rigs (Idler Shaft) - Colmonoy 75 Drill Bits, Stabilisers, Steering Pads - Colmonoy 25, , , F Oil Drilling Rig Wash Pipes - Colmonoy 62, 6, 69, 88 Radial Bearings, Drill Motors - Colmonoy 68, WallCarb Riser Pins - Colmonoy 52, 5, 62, 6, 45 Steel Body Bits - Colmonoy 750 Mud Motor Radial Thrust Bearing with WallCarb coating on inside Clamp Plate and Kickers used for Downhole Drilling - Cast in 17/4 PH Steel Down Hole Pump Plunger sprayed and induction-fused with Colmonoy 62 Colmonoy 25F cementing tungsten carbide inserts onto an Integral Stabiliser for Oil & Gas Exploration Industry 5

7 APPLICATIONS FOR OIL & GAS INDUSTRY REFINING Baffle Grids (Catalyst) - Colmonoy 62, 6 Catalytic Cracker Throats - Colmonoy 62, 6 Thermowell Protecting Plates - Colmonoy 62, 6, 88 Thermowells - Wallex 42, 50, Colmonoy 62, 6, 88 Hydrocyclone Castings - Wallex 6 Machining of a Thermowell Thermowell Tip - Wallex 6 Hydrocyclone Casting - Wallex 6 FRACTURING Fracturing Pumps Plungers Colmonoy 62, 88, 6, 62H, 88H, 72 Fracturing Pump Plunger using Colmonoy 88 Colmonoy 52 fused onto a plunger with propane 6

8 APPLICATIONS FOR OIL & GAS INDUSTRY PUMPING Ball Check Cages - Colmonoy 52, 5, Wallex 6 Blowout Preventors, Operating Pistons - Colmonoy 52, 5 Centrifugal Pump Parts and Wear Rings - Colmonoy 52, 5, 62, 6, 72 Choke and Kill Pins - Colmonoy 52, 5 Oil Pump Sleeves - Wallex 55 Oil Rod Couplings - Colmonoy 62, 6 Oil Well Pump Wear Rings - Colmonoy 52, 5 Inducer Casting - Wallex 6 Oil Well Pump Plungers - Colmonoy 62, 6, 88 Oil Well Rod Guides - Colmonoy 62, 6 Polish Rods and Liners - Colmonoy 52, 5, 62 Pump Plungers (Triplex) - Colmonoy 62, 6, 635, 88, 730 Pump Rods, Sleeves and Seal Faces - Colmonoy 62, 6 Pump Shafts (Caustic) - Colmonoy 62, 6 Pump Sleeves (Hot Oil) - Wallex 50 Pump Sleeves and Bushings - Colmonoy 69, 88, 705 Spiral Rod Guides - Colmonoy 62, 6 Sucker Rod Couplings Colmonoy 62, 6 Vertical Gas Pumps (Propane and Butane) - Colmonoy 52, 5 Pump Sleeves - Wallex 50 Sucker rod coupling spray and induction fused on a Carousel with Colmonoy 62SA Pump plunger sprayed with Colmonoy 52 Rotor Cast and Machined - Wallex 6 7

9 APPLICATIONS FOR OIL & GAS INDUSTRY VALVES Catalytic Slide Valve Gates (Seats) - Colmonoy 88 Flow Control Valve parts - Colmonoy 62, 6 Gate Valve Seats - Colmonoy 42, 4, 84 Oil Well Safety Valves - Colmonoy 62, 6 Plug Valves - Colmonoy 42, 4, 52, 5, Wallex 50 Plugs and Flow Control Cages - Wallex 6 Ball Valves - Colmonoy 52, 5, 69SC, 88, Wallex 50 Stem Guides - Wallex 6 Valve Gates - Colmonoy 52, 5, 84, 730 Valve Stem Seats (Ammonia) - Colmonoy 62, 6 Slide Valve Carrier - Wallex 6 Valves (Stationary Engines) - Colmonoy 52, 5 Wedge Valves (Steam) - Colmonoy 52, 5 Plug Casting - Alloy Grade C Ball Valve HVOF sprayed, PTA or TIG welded - Wallex 6 Plug valve spray and fused with Spraywelder- Colmonoy 52 Ball Valve TIG repaired - Wallex 6 Rotating gates HVOF coated with Colmonoy 88H Valve repair Laser Cladding - Wallex 6 8

10 WEAR DEMANDS ADDRESSING THE INDUSTRY S DEMANDS There are various types of wear prevalent in the Oil & Gas Industry. Our alloys are industry standards for wear-resistant performance. We have developed new alloys and enhanced others to meet your wear surfacing demands. TYPES OF WEAR Adhesive, or galling, occurs from metal-to-metal contact between processing equipment such as screws and barrels. Contacting metal surfaces subject to extreme temperatures often momentarily weld together and then crack upon separation, depositing metal particles in the material being processed. Corrosion results from chemical reactions between processing equipment and the material being processed. Corrosive agents such as acid attack at the surface of machine or equipment parts and components. Corrosion Galling Abrasive wear is caused by hard particles gouging or chipping the surfaces of machine parts. These abrasive particles are usually sands, mud, rock or metal pieces dislodged by adhesive wear. Erosive wear, is similar to abrasive wear except the particulate is suspended in a fluid that impinges on the part. Erosive Abrasive Combinations of wear are common. Often corrosive fluids cause corrosion products (ie. Rust) to be formed. This corrosion product is then able to act as an abrasive or erosive media. 9

11 OUR SURFACING ALLOYS COMBATTING WEAR PREVALENT IN OIL & GAS INDUSTRY Colmonoy (nickel-based) ALLOY NOMINAL COMPOSITION (%) HARDNESS COMMENTS B C Cr Fe Mo Si W Ni Others HRC Bal Bal Bal Bal Bal Bal Cu: Bal Bal Bal Bal Bal Bal Bal Mn: < < <0.5 Bal Nb: HRB** Bal Co: Bal Co: Bal Co: Bal Co: Bal 30-40* Bal 25-31* Dressing and re-dressing steel and nonmagnetic parts 50% WC 50% WC Use as a buffer layer with / on non-magnetic parts 35% WC 50% WC 50% WC 35% WC Atomised, crushed or composite powders to be used with most laser cladding and PTA cladding equipment. Reamers; hole openers, steering pads, stabilisers, drill bits etc F Bal Co: 5.5 *Depending on method of deposition **Depending on application type and parameter settings 52 Composite blend matric for stabilisers, drill bits, and steering pads for oil & gas extrusion Wallex (cobalt-based) <3.00 < <3.00 Co:Bal Co:Bal Co:Bal Co:Bal >58 35% WC 10

12 APPLICABLE SPECIFICATIONS There are several specifications that are applicable to Colmonoy hard-surfacing products. The most common of which are outlined below. CLASSIFICATION ROD PRODUCTS EQUIVALENT POWDER PRODUCTS ERNiCr-A Colmonoy 4 Colmonoy 4 ERNiCr-B Colmonoy 5 & 56 Colmonoy 52, 53, 56 ERNiCr-C Colmonoy 6 Colmonoy 62, 63 DESIGNATION MIL-RNiCr-B-1 MIL-RNiCr-C-1 PRODUCTS Colmonoy 5 & 56 Rod Colmonoy 6 Rod UNS DESIGNATION PRODUCTS N99644 Colmonoy 4 N99645 Colmonoy 5 N99646 Colmonoy 6 GENERAL ELECTRIC NATIONAL ASSOCIATION OF CORROSION ENGINEERS GE P50YP164 Colmonoy 6 NACE MR Colmonoy 4, 5 & 6 11

13 APPLICATION PROCESSES PLASMA TRANSFERRED ARC PTA Machine applying coating to a downhole tool Photo courtesy of Lion Engineering Ltd (Great Yarmouth) HVOF Colmonoy 88 HVOF sprayed to Pump Sleeve LASER CLADDING Colmonoy 88 Laser Cladded to Pump Sleeve SPRAYWELDER Colmonoy 52 sprayed by a Spraywelder System to Down Hole Pump Plunger We also provide hard-surfacing products for wire or rod application. EQUIPMENT NOMINAL PARTICLE SIZE RANGE (μm) MESH SIZE Spraywelder J-3 System Fusewelder Torch M-cut PTA P1: P2: P3: HVOF H1: H2: H3: Laser / / / 325 P1: 80 / 210 P2: 100 / 230 P3: 120 / 270 H1: 230 / 625 H2: 270 / 625 H3: 325 / /

14 HIGHLIGHTED PRODUCTS HARD-SURFACING ALLOYS FOR OIL & GAS Colmonoy 52 Colmonoy 52 is a premium nickel-based alloy powder produced by inert gas atomisation. The particle size distribution is closely controlled and optimised for application with the Model J-3 Spraywelder TM System. Photomicrograph of Colmonoy 52 applied by the Sprayweld process and fused (original at 50x). Colmonoy P2 Colmonoy P2 PTA is a composite blend of a gas atomised nickel-based alloy powder and 60% by weight monolithic tungsten carbide. The combination of an extremely tough matrix and very hard carbide produces an exceptional impact and wear resistance combination. A dense carbide distribution with small inter-carbide spacing allows for a large surface area of tungsten carbide to be exposed to wear environment to provide maximum service life. Photomicrograph of Colmonoy P2 showing carbide distribution in PTA Weld Over-lay (etched with marbles reagent, original at 100x magnification). Colmonoy 730 Colmonoy 730 is composite blend consisting of a highly corrosion resistant nickel-chromiumtungsten matrix and fine, extremely abrasion resistant tungsten carbide particles. This unique combination provides excellent protection against both corrosion and abrasion. This makes it an ideal coating for pump plungers operating at temperatures up to 1200 F (650 C). Photomicrograph of Colmonoy 730 (original at 50x) 13

15 HIGHLIGHTED PRODUCTS (CONTINUED) Colmonoy 88 US PATENT NO. 5,141,571 This patented alloy contains chromium, tungsten borides and carbides for maximum abrasion and corrosion resistance. Its premium chemistry provides product versatility and excellent wear resistance properties. In fact, its chemistry is such that bi- and tri- metallic hard phases are precipitated throughout the alloy during the manufacturing process and during fusion of the coating. Photomicrograph of Colmonoy 88 (original at 200x) This hard-phase formation occurs due to the specific compositional relationship between the elements of tungsten, chromium, boron, silicon, and carbon. Rapid quench gas atomisation is utilised to allow nucleation of hard phases during the manufacturing process. This distribution of hard phases produces the exceptional wear characteristics of this alloy. As an integral part of Colmonoy 88 alloy, these hard phases do not sink or settle out during the application process as would the carbides in a blended composite powder. Thus, the first layer and the last layer are virtually the same. As a pre-alloyed homogeneous powder product, there is no need for concern about segregation of carbide and matrix or unexpected loss of hard phases during the coating process. G -65 DRY SAND ABRASION TEST VOLUME LOSS CUBIC (mm) This chart compares abrasive wear test results of several materials under the same conditions. The relatively low volume loss proves the superiority of Colmonoy 88 to all but the hardest of materials. Hardness (Rockwell C) 61 Melting Range: Density 9.9gm/cc Solidus 987 C (1810 F) Apparent Density 4.8gm/cc Liquidus 1182 C (2160 F) 14

16 HOT HARDNESS Colmonoy 62 alloy outwears hardened steel by up to twenty times High hot hardness is a valuable asset for a hard-surfacing alloy, even where it doesn t appear that heat is a contributing factor to the wear problem. One of the most important reasons why Colmonoy 62 alloy outwears hardened steel by up to twenty times is that the Colmonoy alloy maintains a higher degree of its initial hardness under high temperatures than steel. While some steel can be made initially harder by heat treatment, the surface will become soft under the heat of friction to a point lower than that of Colmonoy or Wallex under like conditions. It then wears more rapidly. Colmonoy and Wallex alloys regain most if not all of their original hardness upon cooling. Rockwell C Scale Hardness of Gas Welded Alloy Deposits Colmonoy (nickel-based) ALLOY TEMPERATURE 21 C (70 F) 315 C (600 F) 427 C (800 F) 538 C (1000 F) 650 C (1200 F) Wallex (cobalt-based)

17 HOT HARDNESS CHART COLMONOY AND WALLEX COATING Colmonoy (nickel-based) Wallex (cobalt-based) ROCKWELL C SCALE HARDNESS ROCKWELL C SCALE HARDNESS TEMPERATURE - F ( C) KEY 16

18 Tight spray patterns and high spray rates to produce dense, wear resistant overlays WALL COLMONOY S HARD-SURFACING EQUIPMENT Spraywelder TM System The Spraywelder TM System offers tight spray patterns and high spray rates to produce dense, wear resistant overlays. The Model J-3 is the culmination of more than 65 years of technical innovation following the invention of our first thermal spray gun. High Spray Rates - up to 8 kg/hr with standard model, and 14 kg/hr with high-output unit. Dense coatings flame energy of up to 92,000 BTUs and increased target efficiency deliver hot metal spray particles to the base metal. The final result is a strong, dense overlay. The Spraywelder TM is easy to operate, safe and versatile. It has built-in efficiency: Tight spray patterns Reliable The J-3 Spraywelder TM is designed from our vast field experience and built for years of daily use with a proven record of success. 19mm 3/4 inch 98% of the spray powder hits the part within a 19 mm (3/4 in) target when using the D nozzle at kg (10-12) lbs/hr. 17

19 The culmination of more than 65 years of of technical innovation THE 5-STEP SPRAYWELD PROCESS: 1. SURFACE PREPARATION The surface to be overlaid should be clean and free of oil or oxides. Surface preparation involves the following: Degreasing Undercutting Grit Blasting Our Nicrobraz Green Stop-Off may be applied to prevent thermal spray materials from bonding to adjacent surface areas. 2. PREHEATING Preheating time varies with the type of base metals: Mild steels (<0.25% Carbon): <149 C (<300 F) Austenitic stainless steel (300 series): C ( F) Martensitic steel (4340 and 400 series): C ( F) 3. SPRAYING To produce a uniform, mechanically bonded overlay, the following resources are needed: Spraywelder TM including pistol, panel, and hoses Spraywelder TM grade powder Oxy-acetylene or oxy-propylene gases Compressed air Variable-speed turning device (as a lathe) Clean, dry air 4. FUSING The objective of fusing is to transform the mechanical bond created in the spraying operation into a metallurgical, or welded bond. Most common methods include oxy-fuel torch, controlled atmosphere furnace or induction. The Colmonoy and Wallex overlay and base metal surface must reach a temperature between C ( F) (based on powder selection), at which point the overlay will wet and bond with the base surface without running or losing its shape. 5. FINISHING Wall Colmonoy s Spraywelder TM powders are easily finished by grinding or machining. For finishing recommendations, request a technical data sheet. 18

20 WCL_Oil-&-Gas-Brochure_ENG_ WORLD HEADQUARTERS WALL COLMONOY 101 W. Girard Madison Heights, MI Tel Fax Web EUROPEAN HEADQUARTERS WALL COLMONOY Alloy Industrial Estate Pontardawe Swansea Wales (U.K.) SA8 4HL Tel +44 (0) Fax +44 (0) Web WALL COLMONOY. PROGRESSIVE COLLABORATION FOR SUPERIOR PERFORMANCE. WORLDWIDE. CINCINNATI LOS LUNAS OKLAHOMA CITY PUNE (INDIA) WALES (U.K.) WINDSOR (CANADA) The information provided herein is given as a guideline to follow. It is the responsibility of the end user to establish the process information most suitable for their specific application(s). Wall Colmonoy Limited (UK) assumes no responsibility for failure due to misuse or improper application of this product, or for any incidental damages arising out of the use of this material. Copyright 2017 Wall Colmonoy Limited. All rights reserved.