Sherwin-Williams launches Pipeclad Frac-Shun ERC technology

Sherwin-Williams Protective & Marine’s new Pipeclad Frac-Shun ERC establishes a new coating class with systems that resist erosion inside pipes near hydraulically fractured wellheads, reducing downtime maintenance costs and increasing drilling productivity. This patent-pending Corrosion Resistant Coating (ERC) technology protects the interior of the pipe from the inherent blasting action of sand particles that move quickly through the pipe. The applied powder coating remains intact far longer than other options, protecting the steel pipe from extensive metal loss that would otherwise lead to potential leaks and early pipe replacement in many operations.

The inside walls of pipes located near wellheads, especially elbows, can be eroded by fracking sand flows in 6 to 18 months or less. This type of erosion also occurs inside storage vessels and tanks, where sandy multiphase fluid flows impinge on interior surfaces. To date, no other coating category, either liquid or powder, has successfully mitigated this erosion. Instead, well operators are accustomed to frequent unplanned maintenance outages following pipeline wall thickness inspections.

"High-velocity fluids containing sand, rock, and other debris flowing through coated fracking tubes create a sandblasting effect similar to the removal of coatings when preparing a surface for a new application." said Kristin Leonard, director of Sherwin-Williams’ Conservation and Marine Energy Division. "Once these coatings disappear, the steel will begin to corrode. New corrosion-resistant coating systems are able to withstand the impact of multiphase flow without corroding or peeling like most coatings. The ERC essentially spits the bullet back out after it’s fired at the surface. Since the coating remains intact, it is impossible for the abrasive fluid to corrode the steel. "

Because Pipeclad Frac-Shun ERC provides a longer performance window for coated pipe, well operators are more likely to run new wellheads for more than 12 months before needing to replace pipe. Erosion exposure is particularly evident in the first year because drilling contents are particularly abrasive during early well operations.

Pipeclad Frac-Shun ERC is applied to the interior of large and small diameter steel pipes to provide maximum corrosion protection. The applied system forms a molecular-scale composite material that provides an ultra-high corrosion resistance barrier, extending the service life of pipe and elbow sections; minimizing lost production time through extended maintenance intervals; and reducing steel loss, damage and leakage during energy extraction.

Various laboratory tests and long-term field trials have confirmed the adhesion and chemical resistance properties of the new Pipeclad Frac-Shun ERC technology. Autoclave testing (using water and hydrocarbon mixtures at high temperatures and pressures representative of wellhead conditions) demonstrated excellent resistance to operating stress and chemical exposure. Additionally, ultrasonic testing of steel pipe coated with the Pipeclad Frac-Shun ERC system confirmed no loss of wall thickness after six months of active wellhead operation. Pipe with controlled coating technology used at the same wellhead showed expected wall thickness erosion. Therefore, Pipeclad Frac-Shun ERC maintains sufficient thickness on the pipe surface to maintain protection.