Amorphous nickel phosphorus alloys for oil and gas

Abstract

There is disclosed a system and method for applying an amorphous NiP alloy coating on pipes and rods, particularly for use in the oil and gas industries to inhibit corrosion. In an embodiment, the method comprises applying an amorphous nickel phosphorus or NiP alloy coating to pipes and rods for use in oil and gas industries, comprising: preparing a Watt's type nickel phosphorus (NiP) plating bath solution utilizing a Watt's type nickel electrolyte containing hypophosphorous acid; maintaining the plating bath solution temperature at between 120° F. and 170° F. adjusted to regulate phosphorus content over 11%; regulating a pH level of the plating bath solution between 1.0 and 3.0 utilizing sulphuric acid; and controlling the cathode current density in the range of 10-100 amps/sq/ft. Significant cost savings may be realized by using an electroplated nickel-phosphorus alloy over regular carbon steel alloy components at sufficient thickness to be pore free replacing the use of more expensive components made of stainless steels or nickel base alloys.

1 . A method of applying an amorphous nickel phosphorus (NiP) alloy coating to oil and gas equipment used in downhole applications, comprising:
 preparing a Watt's type NiP plating bath solution utilizing a Watt's type electrolyte containing phosphorous acid;   maintaining the plating bath solution temperature at between about 120° F. and 170° F. adjusted to regulate phosphorus content over 11%;   regulating a pH level of the plating bath solution at between about 1.0 and 3.0 utilizing sulphuric acid; and   controlling the cathode current density in the range of about 10-100 amps/sq/ft.   
     
     
         2 . The method of  claim 1 , wherein the plating bath solution temperature is between about 150° F. and 170° F. 
     
     
         3 . The method of  claim 2 , wherein the plating bath solution controls the pH level of the plating bath solution using nickel carbonate. 
     
     
         4 . The method of any one of  claims 3 , wherein the cathode current density in the range of about 50-100 amps/sq.ft. 
     
     
         5 . The method of any one of  claims 5 , wherein the plating bath solution comprises about 1.1M nickel sulphate hexahydrate, 0.2-0.4M nickel chloride hexahydrate, 0.65M boric acid, and 0.25 to 6.0 M of phosphorous acid. 
     
     
         6 . The method of any one of  claims 5 , wherein the nickel chloride level has a preferred range of 10-45 g/L, and a more preferred range of 15-20 g/L. 
     
     
         7 . The method of any one of  claims 6 , wherein the boric acid has a preferred range of 30-45 g/L, and a more preferred range of 40-45 g/L. 
     
     
         8 . The method of any one of  claims 7  where in the bath phosphorous acid has a preferred range 10-40 g/L, and a more preferred range of 20-30 g/L. 
     
     
         9 . The method of  claim 1 , wherein the nickel chloride based nickel phosphorus plating bath comprises a solution containing 0.75-1.2M of nickel chloride hexahydrate, 1.5-3.0M of phosphorous acid, 0.1-0.6M of phosphoric acid, and a pH level maintained by using nickel carbonate. 
     
     
         10 . The method of  claim 1 , wherein, the plating bath solution includes about 0.50-2.0 M of hypophosphorous acid; about 0.25-1.0 M of phosphorous acid. 
     
     
         11 . The method of  claim 1 , wherein the plating bath solution includes about 0.25-0.50 hypophosphorous acid and 0.25-0.50 of phosphorous acid.