Well Tubular, Coating System and Method for Oilfield Applications

Abstract

A technique facilitates the use of polymer materials in a downhole environment via utilization of a coating that can be applied to the polymer material. The methodology enables formation of a coating that sufficiently bonds with an underlying base structure of polymer material to withstand the harsh environment encountered in a downhole application. Additionally, the coating may utilize reactive chemistries to further protect the polymer material against the ingress of deleterious fluids while located in the downhole environment. Well tubulars formed of coated polymer are also described.

What is claimed is: 
     
         1 . A coated downhole component, wherein the coated downhole component is formed of a fiber reinforced polymer material comprising bismaleimide resin, and wherein the coating comprises:
 a plurality of layers in which at least one layer is formed of a material having a reactive chemistry selected to react in the presence of downhole well fluids that are deleterious to the polymer material, wherein the material having a reactive chemistry comprises aluminium nitride; and   a layer covalently bonded with the bismaleimide resin in the polymer material, wherein such layer comprises imide-extended bismaleimide.   
     
     
         2 . The coated downhole component as recited in  claim 1 , wherein the coating further comprises an impermeable, compliant layer, wherein the impermeable, compliant layer is formed from a material selected from the group comprising flexible glass in sheet form, mica in sheet form, silicon oxide applied by vapor deposition, and silicon carbide applied by vapor deposition. 
     
     
         3 . The coated downhole component as recited in  claim 1 , wherein the coating is modulated. 
     
     
         4 . The coated downhole component as recited in  claim 1 , wherein the coating comprises a sheet of flexible glass. 
     
     
         5 . The coated downhole component as recited in  claim 1 , wherein the coating comprises a sheet of mica. 
     
     
         6 . The coated downhole component as recited in  claim 5 , wherein the sheet of mica is corrugated. 
     
     
         7 . The coated downhole component as recited in  claim 1 , wherein the coating comprises silicon oxide. 
     
     
         8 . The coated downhole component as recited in  claim 7 , wherein the silicon oxide is applied by vapor deposition. 
     
     
         9 . The coated downhole component as recited in  claim 1 , wherein the coating comprises silicon carbide. 
     
     
         10 . The coated downhole component as recited in  claim 9 , wherein the silicon carbide is applied by vapor deposition. 
     
     
         11 . The coated downhole component as recited in  claim 1 , wherein the layer having a reactive chemistry is disposed between an inner modulated resin layer and an outer impermeable, compliant layer. 
     
     
         12 . The coated downhole component as recited in  claim 11 , wherein the reactive chemistry comprises a reagent that is reactive to a potentially permeating well fluid. 
     
     
         13 . The coated downhole component as recited in  claim 11 , wherein the reactive chemistry comprises a plurality of reagent layers, each reagent layer having a specific reactive reagent. 
     
     
         14 . The coated downhole component as recited in  claim 11 , wherein the reactive chemistry comprises particles creating a mixture of reactive reagents that are reactive to specific substances potentially located in a downhole environment. 
     
     
         15 . The coated downhole component as recited in  claim 11 , wherein the reactive chemistry comprises a braided structure of reactive reagents that are reactive to specific substances potentially located in a downhole environment. 
     
     
         16 . The coated downhole component as recited in  claim 1 , wherein the coating comprises a veil. 
     
     
         17 . The coated downhole component as recited in  claim 1 , wherein the reinforcing fibers are carbon fibers. 
     
     
         18 . The coated downhole component as recited in  claim 1 , wherein the coating further comprises a filler material. 
     
     
         19 . The coated downhole component as recited in  claim 18 , wherein the filler material contains a material selected from the group consisting of calcium oxide, carbon, silica, silica gel, glass flakes, kaolinite, montmorillonite, mica, organic material, metakaolin, and a silane based gel with vinyl, amino, or maleimido functionality.