Using Metal-Sprayed Coatings to Protect Submersible Electric Pump Motors from the Impact of Complicating Factors in Oil Wells

Abstract

This paper presents an overview of the results of the application of metal-sprayed coatings to protect the outer surface of electric submersible pumps (ESP) from the effects of complicating factors in oil wells. The metal-sprayed coating is applied using hot spraying, and the choice of the method is based on the chemical composition, the materials that are used, and the properties of the finished coating. The most common coatings on the Russian market include monel and austenitic stainless-steel alloys applied by arc metallization or high velocity spraying. Traditional coatings obtained by thermal spraying are characterized by an insufficiently high level of physical, mechanical, and chemical properties. Studies of the abnormal cases of submersible electric motors (SEMs) have shown that the most significant disadvantages of the applied coatings include insufficient resistance to mechanical shock, as well as abrasive wear; higher electrochemical potential in relation to the base metal; violations of the application technology; and significant coating porosity. One of the main reasons for the observed disadvantages is a limited number of traditionally used methods and materials. To solve the problem of using protective SEM coatings and significantly increase their properties, service life, and economic efficiency, it is necessary to use modern scientific achievements in the development of coatings to protect metal surfaces from wear and corrosion, namely, to expand the number of coating methods and materials, work out a methodology for assessing the quality of coatings, and develop a methodology for assessing the economic efficiency of protective coatings. Solving these problems will allow us to make a reasonable technical and economic choice of a specific SEM coating for specific operating conditions.