Thermal Spray Coatings for Corrosion Protection in the Oil and Gas Industry
The oil and gas industry has been using metal spray coatings for decades. And there’s a reason for it.
Protecting Onshore and Offshore Infrastructure
At Metallisation Ltd, we provide anti corrosion coating solutions designed to help oil and gas businesses protect critical assets and extend the working life of components operating in demanding conditions. With decades of experience in metal and thermal spray coating technology, we work with clients across offshore, onshore and subsea applications to deliver coatings that perform where they are needed most.
Why Corrosion Is a Major Challenge in Oil and Gas
Corrosion is one of the biggest maintenance concerns within the oil and gas sector. Pipelines, valves, pumps, structural steel, pressure vessels and offshore platforms are all exposed to conditions that naturally break down metal over time.
Saltwater exposure is particularly aggressive in offshore environments, while chemicals and gases used during extraction and processing can accelerate corrosion even further.
When corrosion is left untreated, the impact can be significant. Components may weaken, production can slow down and safety risks can increase. In many cases, replacing damaged parts is far more expensive than applying protective coatings from the start.
A Dual Approach
Applications fall into two categories – corrosion protection coatings and engineering coatings.
Corrosion Protection
Corrosion protection coatings are typically applied using either flame spray or arc spray, also known as the twin wire arc spray process.
Common coating materials include thermal spray aluminium (TSA), thermal spray zinc/aluminium (TSZA) and thermal spray zinc (TSZ). The choice depends on the operating environment and the expected service life before maintenance is required.
TSA coatings have been widely used to help combat Corrosion Under Insulation (CUI) for more than 30 years and continue to be specified across major coating projects today.
Engineering Coatings
Engineering coatings can be applied using a range of thermal spray and cladding processes to change the surface properties of a component.
In the oil and gas industry, these coatings are commonly used to improve wear and chemical resistance. Popular examples include HVOF applied tungsten carbide coatings and arc sprayed Inconel 625.
The choice of coating material and application process depends entirely on the operating conditions and performance requirements. Metallisation works closely with customers to recommend the most suitable solution for each application.
Common Uses in Oil and Gas Applications
Offshore Structures
Platforms, walkways, risers, helidecks and support steelwork all require protection from constant exposure to saltwater, moisture and harsh weather conditions.
Pipelines and Pipe Spools
Pipelines and pipe spools often operate in aggressive environments where corrosion and surface degradation can lead to costly issues.
Storage Tanks and Pressure Vessels
Storage tanks and pressure vessels are regularly exposed to chemicals, temperature changes and environmental conditions that can accelerate corrosion over time.
How Does the Coating Process Work?
The process involves spraying molten or heated coating material onto a prepared metal surface at high speed. Once applied, the coating forms a protective layer that shields the underlying material from corrosion, wear and environmental damage.
For many oil and gas applications, aluminium and zinc based coatings are commonly used due to their excellent corrosion resistance. These coatings act as sacrificial protection, meaning they corrode in place of the underlying steel. This helps preserve the integrity of the component for much longer.
The video shows a common application for corrosion protection. The operators are applying Thermal Spray Aluminium (TSA) by the flame spray process.
Working With Us
At Metallisation Ltd, we work closely with oil and gas operators, engineering companies and contractors to deliver coating solutions that meet real world demands.
Our experience covers a wide range of thermal spray technologies and coating materials, allowing us to support both new build projects and refurbishment work.
We’re able to handle both one-off jobs and large-scale runs, and we always focus on getting the details right. And if you have your own production line? We can support you with advice, training or supply of thermal spray equipment – depending on what you need.
