Development of New Generation Electroless Ni-Based Nano-Composite Coating for Oil and Gas Pipelines

Oil and gas pipelines are subjected to severe erosive and corrosive environment. The global cost of such degradation is in the billions of dollars annually. This is in addition to the irreversible damage to life and the environment. This has necessitated the search for superior protective coatings. The traditional method for protecting oil and gas pipeline steels is the use of epoxy-based coatings and in more corrosive areas is combined with cathodic protection and corrosion inhibitors. However, to satisfy the ever increasing demand for energy, today pipelines are operated at higher pressures and temperatures. Under these sever conditions, traditional protection methods do not provide adequate results. The aim of the proposed project is the development of a novel corrosion and wear resistant electroless nickel-based nano-composite coating. Electroless nickel plating involves the autocatalytic reduction of nickel ions without the use of electric current. Electroless nickel exhibits superior corrosion and wear resistance over many commercially available coatings, as well as, high hardness, uniform thickness and good adhesion. The proposed project builds on the vast knowledge and data generated in the previous two QNRF projects dedicated to the understanding of erosion-corrosion synergy and failure of API pipeline steels in CO2 and H2S environments. In this proposal, electroless plating technique will be used to prepare a series of Ni-based nano-composites coatings on API X-series pipeline steels. Nano-particles of TiNi shape memory alloy will be incorporated in the coating, which are expected to provide superior wear resistance and enhanced toughness and impact resistance. The electroless process and coating composition will be tailored to produce the optimum coating for best protection against erosion-corrosion failure. Erosion–corrosion experiments will be carried out on the developed coatings in a rig that simulates service conditions. To ensure an acceptable quality and integrity of the coatings, full microstructural and mechanical characterization of the steel coatings will be conducted before and after each erosion-corrosion experiment. The adhesion strength of the developed coatings will be evaluated. Qatar is a major oil and gas producer in the world and plays a major role in its economy. Pursuing leading edge research would strengthen Qatar's position towards becoming a leader in research and innovation in the field. The Qatari oil and gas industry is known for its commitment to the highest standards for health, safety and the environment throughout its operations. The present proposal will strengthen Qatar's position in preventing pipeline failures and their catastrophic effect on the environment. The proposed research is expected to result in new technology that would be available to the oil and gas and other relevant industries.