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Downhole Tools

Downhole Tools


Corrosion & Abrasion Solutions Ltd. (CASL) has a variety of services to offer the downhole tools sector to protect against the damaging effects of corrosion and wear. Some of the downhole components we service are rotors, stators, mandrels, bearing housings, bearing mandrels, wash pipes, and more.

SOME OF CASL’S FEATURED SERVICES FOR DOWNHOLE TOOLS INCLUDE:

  • Hard Chrome Plating – HEEF 25 and HEEF KR
  • Sulfamate Nickel Chrome Plating
  • Thermal Spray including High Velocity Oxygen-Fueled (HVOF), Twin Wire Electric-Arc (TWA), Atmospheric Plasma, and Combustion Powder systems
  • Plasma Transferred Arc Welding (PTAW)
  • Production Honing for heavy stock removal
  • CNC Rotor Polishing
  • Shot peening – glass bead and 110
  • Phosphating – zinc phosphate
  • Grinding – OD, ID and surface grinding
  • General machine shop services

CASL has created processes and set up our facility to ensure you experience minimal downtime, reduced corrosion and wear on products, and cost-effective solutions. We want you to achieve extended use on your major downhole tool parts and components.

FACILITY SPECIFICATIONS:

PTAW – ID, OD, and flat plate applications

  • ID – 2.5” to 4” in diameter, up to 48” in length
  • ID – 4” up to 12”, up to 96” in length
  • ID – 12” and larger up to 12’ in length
  • OD – 3” to 48” diameter, up to 36’ in length
  • Table-top units for large, flat applications

THERMAL SPRAY

  • HVOF Systems
  • DJ Hybrids
  • JP5000
  • Air Plasma and Twin Wire Arc Systems
  • Can handle OD up to 28” and lengths up to 25’

CHROME & ELECTROPLATING

  • Electroplating division can handle pieces up to a weight of 20,000 lb
  • We have the capacity to chrome pieces up to 40’ in length with a diameter of up to 34”

Thermal Spray

CASL provides quality in-house application of thermally sprayed coatings for various downhole tools equipment. CASL uses thermal spray systems and alloys designed to produce superior coatings for longest tool life. CASL uses high-energy powder combustion, twin wire arc systems, atmospheric plasma or high velocity oxygen fuel (HVOF) processes to provide customers with dense, high strength, low porosity coatings, that protects and extends the life of your assets.

With in-house technical support, CASL provides its customers with the coating systems and material options for their individual applications. CASL’s various thermal spray systems give us the ability to apply a wide range of coating materials – from aluminum to zinc and all of the alloys in-between.

TYPICAL THERMAL SPRAY ALLOYS ARE AS FOLLOWS:

  • Tungsten Carbide/Cobalt for severe abrasion and erosion resistance
  • Stainless steels for moderate corrosion and dimensional restoration
  • Modified Hastelloy® C type alloys for severe corrosion and pitting
  • Monel for corrosion resistance in downhole applications
  • Hastelloy® materials for chloride environments and exceptional corrosion and erosion resistance
  • Hastelloy® and stainless steels for hydrogen blistering control
  • Ceramic materials for high temperature erosion and corrosion resistance, and electrical insulation
  • Amorphous nickel based materials for high temperature wear resistance and moderate impact abrasion applications
  • Custom alloys, which can be manufactured for special needs upon request

HIGH VELOCITY OXYGEN FUEL (HVOF)

HVOF is our most commonly used thermal spray process. The HVOF process uses high kinetic energy and controlled thermal output to produce dense, low porosity coatings.

A wide variety of alloys can be used in the HVOF process such as metals, cermets, and some ceramics. The HVOF process provides an extremely dense coating with bond strengths of greater than 10,000 PSI, and porosity levels less than 1%.

Common HVOF applications include:

  • Centrifuge Bowls
  • Bearing Mandrels
  • Upper Distributors
  • Mud Rotors
  • Wear Sleeves
  • Drive Shafts
  • Suspension Rods
  • Washpipes

PLASMA SPRAY

Our atmospheric plasma spray system is used to apply ceramic coatings for non-conductive, thermal insulation, corrosion and wear resistance applications. Ceramic coating applications include titanium oxide and chromium oxide.

Common plasma applications include:

  • Pump Components
  • Drive shafts

TWIN WIRE ARC SPRAY

The Twin Wire Arc Spray process starts with an arc struck between two continuously fed alloy wires. The droplet of molten material is then blasted with an air jet that blows the molten particles toward the substrate. This process provides high adhesive strength and low porosity.

Most metal alloys can be used in the Twin Wire Arc Spray process. Twin wire arc coatings have a deposit efficiency of 60-70%, coating bond strength between 5,000 and 7,000 PSI, and porosity levels of 1-5%.

Common Twin Wire Arc Spray applications include:

  • Rebuild of heavily worn components
  • Aluminum Bronze Metering Valve and anti-galling applications
  • Undercoat for ceramic applications

COMBUSTION POWDER

Our high-energy combustion powder systems are used for a variety of specialty applications, using a select group of highly corrosion resistant alloys. Ideally suited to applications where our other processes cannot reach, where we have severe corrosion and erosion occurring and/or a mirror finish is not required.

Common Combustion Powder applications include:

  • Downhole pumps and motors
  • Dimensional restoration of bearing surfaces

WHY CHOOSE CASL?

  • We provide a full service (one stop shop) that offers customized solutions from start to finish
  • We are one of the only providers in North America that offer sulfamate nickel chrome plating services
  • We complete various outsourced testing, and we have our own small lab for testing our own products
  • ISO 9001:2008 certified since 2003
  • Services are not limited to downhole tools and can be applied to related equipment requiring protection from corrosion and wear

Plasma Transferred Arc Welding (PTAW)

CASL offers Plasma Transferred Arc Welding (PTAW) services for your downhole tools.

PTAW is a high energy density, low heat input, inert gas welding process that provides minimal dilution and high resistance to chipping because of its dense metallurgical structure. Coatings are fused to the base material, free of voids, oxide films, and discontinuities. PTAW overlays are used to extend the life of components subject to extreme abrasion and/or impact.

PTAW HARDFACING CREATES A METALLURGICAL BOND WITH THE BASE MATERIAL AND IS USED ON PARTS SUBJECT TO:

  • Severe abrasion
  • Extreme impact
  • Thermal shock
  • Corrosion

WE CAN OFFER MULTIPLE OVERLAYS WITH DIFFERENT TYPES OF TUNGSTEN CARBIDE (WC) PARTICLES:

  • Macrocrystalline
  • Spherical
  • Cast and Crushed

CASL can offer non-magnetic, stainless steel and Inconel PTAW overlays for specialty applications.

SOME TYPICAL PTAW TUNGSTEN CARBIDE (WC) OVERLAY APPLICATIONS INCLUDE:

  • Stabilizers
  • Bearings
  • Kick Pads
  • Collars
  • Bent Housings

WHY CHOOSE CASL?

  • We provide a full service (one stop shop) that offers customized solutions from start to finish
  • We are one of the only providers in North America that offer sulfamate nickel chrome plating services
  • We complete various outsourced testing, and we have our own small lab for testing our own products
  • ISO 9001:2008 certified since 2003
  • Services are not limited to downhole tools and can be applied to related equipment requiring protection from corrosion and wear

Electroplating

Electroplating has covered the oil & gas, oil sands, pulp & paper, power generation, hydraulics, and heavy equipment industries for many years and is a cost effective process to enhance wear component life, corrosion resistance, and anti-galling properties.

Using electroplating to protect your parts and components from wear, erosion and corrosion will minimize equipment downtime, keep you productive, efficient and profitable. We are one of the two facilities in North America approved to apply nickel-chrome coatings in downhole tool applications.

WE HAVE THE CAPABILITY OF PROVIDING THE FOLLOWING PLATING APPLICATIONS:

  • Chrome HEEF 25 and HEEF KR
  • Sulfamate Nickel & Chrome

The cost-effectiveness of chrome plating allows our customers to recycle many of their products for additional or extended use. We have the capacity to chrome pieces up to 40’ in length with a diameter up to 34”.

Sulfamate nickel is 100% pure nickel and is plated in a very low stress condition from sulfamate rich concentrated bath and plates as an amorphous grain. It is primarily used as a barrier underneath chrome to protect from corrosion and extend the life of chrome plating. Our two step nickel chrome process provides an additional barrier for corrosive environments – to work with the durability of the chrome application.

Phosphate also provides anti-galling protection for downhole components by a thin film chemical dip.

BENEFITS OF HARD CHROME PLATING INCLUDE:

  • Low coefficient of friction
  • Wear resistant
  • Corrosion resistant
  • Excellent surface finish
  • Excellent bond strength
  • Chemical bond

CASL IS A RECOGNIZED ELECTROPLATING LEADER IN:

  • Industrial Hard Chrome Plating
  • Nickel-Chrome Plating

WHY CHOOSE CASL?

  • We provide a full service (one stop shop) that offers customized solutions from start to finish
  • We are one of the only providers in North America that offer sulfamate nickel chrome plating services
  • We complete various outsourced testing, and we have our own small lab for testing our own products
  • ISO 9001:2008 certified since 2003
  • Services are not limited to downhole tools and can be applied to related equipment requiring protection from corrosion and wear

Finishing

ALONG WITH THE VARIETY OF PLATING APPLICATIONS CASL HAS TO OFFER, WE HAVE EXTENSIVE CAPACITY FOR THE FOLLOWING SUPPORTING PROCESSES:

  • Honing
  • Grinding
  • Polishing
  • Machining

CASL has the ability to finish any coatings we apply that require honing, grinding, polishing or machining in house.

Our cylindrical grinding equipment allows us to perform outside and inside diameter work (OD and ID) as we have a large selection of ID cylindrical and surface grinders, so we can deliver on short turn-around times.

We currently have 10 honing machines in our honing division servicing both horizontal and vertical requirements. Our capacity allows us to provide the honing and complete reconditioning of control valves to the honing of downhole tools and hydraulic cylinders.

CASL also provides shot peening as an additional process to relieve stress and add durability to your downhole components.

OUR CAPACITIES SHOULD ACCOMMODATE MOST JOB REQUIREMENTS:

  • Polishing – up to 50’ length, 50” diameter
    • CNC Rotor Polishing Equipment
  • Honing – Up to 50ft (25ft stroke) length on most sizes, from 3/8” to 36” diameter
  • Grinding – Up to 192” length on most sizes, 40” diameter

WHY CHOOSE CASL?

  • We provide a full service (one stop shop) that offers customized solutions from start to finish
  • We are one of the only providers in North America that offer sulfamate nickel chrome plating services
  • We complete various outsourced testing, and we have our own small lab for testing our own products
  • ISO 9001:2008 certified since 2003
  • Services are not limited to downhole tools and can be applied to related equipment requiring protection from corrosion and wear

Protecting Global Infrastructure. Corrosion and Wear Solutions Providers With Over 25 Years of Experience.

Head Office
4212-97 Street, Edmonton, AB T6E 5Z9
Main: 780-461-8333
Toll Free: 1-888-377-0427
Fax: 780-440-3129
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© 2017 Corrosion & Abrasion Solutions Ltd.