Advanced Surface Engineering for Petroleum Engineers

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Disciplines: Completions | Drilling | Health, Safety, Environment, and Sustainability | Management | Production and Operations | Projects, Facilities, and Construction | Reservoir

Course Description

Day One: Industrial metallurgy basics - what are the main metals and alloys used in petroleum Eng. - what are their physical, chemical, electrical and metallurgical properties - the fundamental properties of matter which define the use of metallic materials e.g. hardness, toughness, impact resistance, wear resistance, erosion resistance, abrasion resistance, corrosion resistance, fatigue strength, yield strength, ultimate strength, fracture toughness, coefficient of elasticity, young's modulus, illustrative examples to highlight what role each physical property plays in performance and working lifespan of metallic components. oxidation resistance, elevated temperature oxidation resistance, elevated temperature rigidity, hot hardness, retention of sharp edges, extra-ordinarily strong new materials with their special properties.

Day Two: Surface Engineering - an introduction from the humble gas metal spray and electro-deposition e.g. chromium plating up to the newly developed plasma based advanced new surface Eng. techniques, described above. Also advanced surface modification treatments where no coating is deposited by selected ions or radicals are pushed into the metal matrix for enhancing performance and lengthening lifespans e.g. ion implantation, plasma ion nitriding, plasma ion carbonizing, plasma immersed ion implantation etc PTAC which applied 10-15 millimeters thick highly precise cladded deposits, manually and automatically, with minimized metallurgical problems will be described. Stress will be given to super alloys based on Nickel, Chromium and Iron which have a great future in petroleum engineering. Equipment, variants in processing technologies, variants for more sophistication in applying thin film coatings or deeper case depth penetration will also be discussed in detail with an eye on petroleum engg component manufacture, repairs, reclamation and developmental activities.

Day Three: PVD (physical vapor deposition), CVD (chemical vapor deposition), VhT (vacuum heat treatment), PIN (plasma ion nitriding), plasma nitro-carbonizing, plasma carbonizing, Duple Treatments which usually combine two or three treatments e.g. PIN + PVD (wherein a high performance thin film supehard coating e.g. TiCN, CrN or ZrN or highly specialized new coatings may be used), VHT + PIN, Induction hardening + PIN, etc. will all be discussed from equipment, operational point of view and optimization of processing parameters. A list of all popular surface treatments, coatings, or surface modification aims will be discussed. Detailed conjectures made on applying more and more new technologies to petroleum engineering with view to cost saving and simultaneous enhancement of the metal parts and stretching their working lifespans.

Day Four: Testing and Characterization - from optical microscopes up to SEM (scanning electron microscopes for determining the presence of various metallurgical phases, common defects that can be anticipated, how to avoid their formation, Eddy Current Testing with its huge scope for determining non-uniformities both external and internal as defined by equipment manufacturers, chemical analysis, newly developed software for image analysis that provides volumes of information on internal and external metallurgical defects, and future will be discussed. Stress will be given on wear resistance tests, fatigue strength tests, creep resistance tests etc. Advanced new materials e.g. super alloys which are known to be able to combine wear resistance with stability at very high temperatures (up to 1400 degrees C, that is just below the melting point of the alloy) as used in jet engines with with potential to use in drilling and deep earth operations, will be discussed. Cladded materials that combine lower cost and higher performance such as inconel, hastelloys, incoloy, wasp alloy, monel, etc will also be discussed. Conjectures will be-made about the future of industrial materials science married to petroleum engineering.

Copious literature will be distributed including printed material and CD-ROMs.

Learning Level

Advanced

Course Length

4 Days

Why Attend

The course is designed to impart in easily digestible manner, deep knowledge of a wide gamut of newly developed 'advanced surface engineering' technologies that apply either thin film super hard coatings mainly for wear resistance on metal parts, or apply thick coatings or overlays for protection, rebuilding, reclamation and overhaul of highly worn out parts. Existing applications, and future applications are covered.

It analyses deeply all these technologies, well-entrenched in automotive, aerospace and general engineering industries with use of case studies to show how metal parts can benefit by way of enhanced performance and longer working lifespans.

Also included are thermal spray techniques e.g. plasma spray, HVOF, etc., which can apply ceramics on to metal parts for much higher wear resistance. Though not yet common, but most likely to become common DLCs (diamond like coatings) applied to metal parts with PACVD (plasma assisted chemical vapor deposition) are discussed. A wide variety of PVD thin film coatings which are new generation type e.g. TiCN, AlTiN, ZrN, CrN, plus multi-layer coatings, multi component coatings, nano-structured coatings are also discussed. 'Duplex Treatments' now popular with hot forging applications and reverse impact extrusion for defense use, are also covered in details.

PTAC (plasma transferred arc cladding) is one most efficient high speed high purity overlaying process which offers maximum benefit to petroleum engineering, is also discussed. Equipment, processing parameters, processing quirks, use of semi or fully-automated accessories, tests and characterization, current uses and some future uses are also discussed.

Conjectures will be made about the future of Duple Treatments wherein two or three treatments are combined to obtain up to a thousand percent longer lifespan - even more.

Who Attends

Design Engineers, Drilling Engineers, Maintenance Engineers, Metallurgists, Chemical Engineers, Process Engineers, Quality Control Engineers, Automation Specialists, Overhaul Specialists, Planning Engineers, Efficiency Experts

CEUs

3.2 CEUs (Continuing Education Units) are awarded for this 4-day course.

Cancellation Policy

All cancellations must be received no later than 14 days prior to the course start date. Cancellations made after the 14-day window will not be refunded. Refunds will not be given due to no show situations.

Training sessions attached to SPE conferences and workshops follow the cancellation policies stated on the event information page. Please check that page for specific cancellation information.

SPE reserves the right to cancel or re-schedule courses at will. Notification of changes will be made as quickly as possible; please keep this in mind when arranging travel, as SPE is not responsible for any fees charged for cancelling or changing travel arrangements.

We reserve the right to substitute course instructors as necessary.

Instructor