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Oil, gas and petrochemical markets

Surface Treatments Solutions
Typical Failure
Providing Solutions

MIC AND THE OIL, GAS AND PETROCHEMICAL INDUSTRY

The major problem of premature failures is not necessarily the cost of repairing the items, but the loss of operating time. Any technique where premature failure can be prevented and the times between overhaul periods extended must be a consideration in today's cost conscious market. This is particularly relevant to the onshore and offshore oil and gas industry where components are exposed to harsh environments and operating conditions.

Preventing component failure

Metal Improvement Company (MIC) are specialists in enhancing the performance and extending the life of critical components such as turbines, pumps, compressors, steel tubing systems, welded structures and assembles by solving the issues of metal and corrosion fatigue, stress corrosion cracking, fretting, spalling and wear. These failures account for more service and maintenance stoppages than any other issues relating to engineered components.

Our range of specialist surface treatments form an integral part of the manufacturing process and are designed to reduce maintenance and whole life costs by extending plant and equipment life, examples of these surface treatments include controlled shot peening, laser shock peening, Everlube® coatings and thermal spray technology as detailed below.

Onsite Service Work

Where it is not practical to process components through our network of divisions, we also have specialist onsite crews who can be mobilized at short notice to a specific worldwide location in order to undertake processing to the same high quality standard using mechanically controlled equipment. Our teams are experienced in dealing with site conditions and complying by the strict controls necessary to conduct the processing onsite.

Approvals

In order to meet the demands of the latest oil and gas requirements we now have in place AS9100 Rev C, NADCAP and ISO 9001/2008 approvals as well as numerous prime customer approvals. For our Everlube® Products an experienced NACE quality team, also a new suite of dedicated electrostatic spray equipment, desiccant air dryers, 5 x 4m oven and 7 x 5m spray booth as well as a full range of laboratory testing and process verification procedures.

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Questions and feedback

If you would like to ask us a question regarding oil, gas and petrochemical applications, please use our contact form. Alternatively, view our global locations page to see where we operate.

We would also welcome any feedback.

MIC services

Controlled shot peening

Shot peen forming

Thermal spray coatings

C.A.S.E™ isotropic super finishing

Peenflex protective mouldings

Peentex architectural finishes

Read about critical protection from material failures

Surface Treatment Solutions

Controlled Shot Peening and Laser Shock Peening
The premature failure of many components can be directly related to residual tensile stresses induced by manufacturing methods and unexpected service conditions. We can change these to beneficial residual compressive stresses and therefore extend component life. This is achieved through the technique of controlled shot peening or laser shock peening. They are recognised and trusted processes used extensively in the aerospace and automotive industry.

Controlled shot peening can also be applied to various welded applications such as change of section areas and areas of high stress intensity to control stress corrosion cracking and corrosion fatigue of welded structures.

Thermal Spray Coatings
We have just introduced our experienced thermal spray capability to our UK Derby Division. These coatings provide thermal protection, abrasion resistance, high temperature oxidation/corrosion resistance and solid particle erosion control. As well as for new production, thermal spray coatings are also suitable for the repair and overhaul of components bringing them back to OEM specification.

Everlube® Products
Our range of Everlube® coatings and products are widely used to provide both corrosion protection and dry film lubrication. The range includes Everslik 1201/1301 which is a core coating system consisting of an extremely tough and durable coating primer with salt spray resistance of 2500hrs, followed by the application of a high loading MoS2 based dry film lubricant. This coating system is typically used for pumps, valves, connectors, actuator systems and shafts, fasteners and jack screws.

For more information on our range of Everlube® coatings and their characteristics please contact our E/M Coatings Division or download our Coatings Matrix.

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Typical failure modes and applications

Typical failure modes are:

Metal fatigue
Corrosion fatigue
Corrosion
Stress corrosion cracking
Fretting
Galling
Spalling
Wear

Applications:

All rotating components where life improvement is desired
Gas turbine generator sets
Steam turbine and diesel driven generator sets
Turbo expander sets
Air cooled heat exchangers and fans
Centrifugal and HP fluid pumps
Compressors
Control and safety valves
Drill collars and drill string components
Welded parts, assemblies and structures
Containers, holding and pressure vessels
Angel hair reduction caused by friction at the wall of transfer piping

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Protection from material failures

Fatigue
Fatigue is defined as: cumulative, localised and permanent damage caused by repeated fluctuations of stress, sometimes below the static design stress of the structure. Shot peening the finished part to remove the residual tensile stresses caused by manufacture significantly reduces the applied load/stress which can extend the life and strength of the component significantly.

Stress corrosion cracking (SCC)
SCC is a phenomenon characterised by deep fissuring of the surface and occurs when a susceptible alloy in contact with a corrosive environment is subjected to a sustained tensile stress which may be well below the elastic limit of the material. SCC can be avoided if tensile stresses resulting from manufacture or in-service use, are converted to compressive stresses by shot peening.

Extending the life of welded components
The residual tensile stress from welding is created because the weld consumable is applied in its molten state, when it is at its maximum heat and expansion. It then bonds to the base material. As the weld cools rapidly, it is unable to shrink because it has already bonded to the cooler, stronger base material. The net result is a weld that is essentially being "stretched" by the base material and residual tensile stresses result.

Welded structures whether new or repaired can be shot peened to convert tensile stresses to compressive thus extending the life of the structures.

Corrosion fatigue
Corrosion fatigue is the failure of components in corrosive environments associated with cyclic applied loading. The failure mechanism is similar to that of SCC but is driven by the cyclic application of tensile stress rather than by a sustained tensile stress. Shot peening surfaces to introduce compressive stresses can extend component life considerably.

Engineered coatings for pumps and valves
MIC is the leading developer and applicator of engineered coatings to solve problems caused by the aggressive environments in which pumps and valves operate particularly in the oil and gas industry.
Coatings can be applied that address service conditions, including wear, corrosion, erosion, seizing, steam and extreme temperatures (-420°F to 1800°F/-251°C to 982°C), as well as applicable aesthetic standards.

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