Application of Thermal Spray Coating to mitigate corrosion issues for Oil and Gas Refineries

Application of Thermal Spray Coating to mitigate corrosion issues for Oil and Gas Refineries | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Application of Thermal Spray Coating to mitigate corrosion issues for Oil and Gas Refineries Urvesh Vala, I B Dave This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6223818/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract In the present scenario the Thermal Spray Coating is highly durable prestigious alternative coating solution to replace traditional Hot Dipped Galvanizing Coating as an alternative solution for new and existing structures in industries and offering a range of benefits for long durability and maintenance free solution for more than 25 years in service. There is no weld life for site application in case of Hot Dip Galvanized Structure and may customers have issue with coating performance and applicability of liquid coating or cold spray application on Hot Dip Galvanizing for repair application. Thermal Spray Coating can apply very safely, maintenance can be possible at site, easy application as compared to Hot Dip Galvanizing and accepted by many Customers Specifications as an alternative solution to the traditional Hot Dip Galvanizing Coating. Thermal Spray Coating is an anti-corrosive protection used for very long life of the coating for onshore and offshore structures, equipment and piping. Thermal Spray Coating is the only coating system recognized by international code and standards having desired service life of more than 25 years to its first maintenance cycle time in very aggressive environment like offshore platform where aggressive corrosive environment is the great challenge to the end users. This paper covers the comparison of Thermal Spray Metallic Coating with traditionally used Hot Dipped Galvanized Coating and summarizes the merits of using a more advanced coating system. Thermal Spray Coating can be applied by anyone of the following coating methods, Arc Spray, Flame Spray and High Velocity Oxygen Fuel, High Velocity Air Fuel, Atmospheric Plasma Spray, Vacuum Plasma Spray, Cold Spray, etc. Many more thermal coating methods can be considered to optimize the cost of Coating Application for Oil & Gas Refineries, Petrochemical Complex, Marine, Shipping Industries, Power Sector including Nuclear Plant. Thermal Spray Coating can be applied with the help of filler material starting from pure metals, alloys, ceramic, composite, etc. in the form of wire and powders. Thermal Spray Coating can be applied to any metal and non-metal surface with, or little surface preparation based on the type of coating thickness to be applied. Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6223818","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":451363195,"identity":"fec73f5e-9908-4420-bce6-761bd936a067","order_by":0,"name":"Urvesh Vala","email":"","orcid":"","institution":"Gujarat Technical University","correspondingAuthor":false,"prefix":"","firstName":"Urvesh","middleName":"","lastName":"Vala","suffix":""},{"id":451363196,"identity":"cefaa3ed-addf-4c83-af57-f941628c35d8","order_by":1,"name":"I B Dave","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA5klEQVRIiWNgGAWjYBACNgkGAyBlA2IzPvgAopiJ05IGVms4gxgtDBAth8HapXmIcRifdPPGzzwV5+362Y9fkJzBYCfPwM57AL/DZI4VS/OcuZ08syenwOADQ7JhAzNfAgG/5BhIzmy7nWxwgychcQYDcwIDM48BIS3GP2f+O5dsD9RymIehnigtZhIfGw7YGUiwH2zmYThMhBaZY2UWH44lJ0icyWFmnGFw3LCNkBb52c2bbyTU2Nnztx9//uNDRbU8P/8Z/FpgILGBAWQ4ELERpR4I7BkY2B8Qq3gUjIJRMApGGAAAPF4+i4RU9DwAAAAASUVORK5CYII=","orcid":"","institution":"Gujarat Technical University","correspondingAuthor":true,"prefix":"","firstName":"I","middleName":"B","lastName":"Dave","suffix":""}],"badges":[],"createdAt":"2025-03-14 05:53:14","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6223818/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6223818/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":83555853,"identity":"36d07385-33b7-4e97-ad15-0981a951e7da","added_by":"auto","created_at":"2025-05-28 11:39:04","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":662106,"visible":true,"origin":"","legend":"","description":"","filename":"ApplicationofThermalSprayCoatingtomitigatecorrosionissuesforOilandGasRefineries.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6223818/v1_covered_dc562ccb-71bb-47dd-b270-64e74d9e403e.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Application of Thermal Spray Coating to mitigate corrosion issues for Oil and Gas Refineries","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"","lastPublishedDoi":"10.21203/rs.3.rs-6223818/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6223818/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eIn the present scenario the Thermal Spray Coating is highly durable prestigious alternative coating solution to replace traditional Hot Dipped Galvanizing Coating as an alternative solution for new and existing structures in industries and offering a range of benefits for long durability and maintenance free solution for more than 25 years in service. There is no weld life for site application in case of Hot Dip Galvanized Structure and may customers have issue with coating performance and applicability of liquid coating or cold spray application on Hot Dip Galvanizing for repair application. Thermal Spray Coating can apply very safely, maintenance can be possible at site, easy application as compared to Hot Dip Galvanizing and accepted by many Customers Specifications as an alternative solution to the traditional Hot Dip Galvanizing Coating. Thermal Spray Coating is an anti-corrosive protection used for very long life of the coating for onshore and offshore structures, equipment and piping. Thermal Spray Coating is the only coating system recognized by international code and standards having desired service life of more than 25 years to its first maintenance cycle time in very aggressive environment like offshore platform where aggressive corrosive environment is the great challenge to the end users. This paper covers the comparison of Thermal Spray Metallic Coating with traditionally used Hot Dipped Galvanized Coating and summarizes the merits of using a more advanced coating system. Thermal Spray Coating can be applied by anyone of the following coating methods, Arc Spray, Flame Spray and High Velocity Oxygen Fuel, High Velocity Air Fuel, Atmospheric Plasma Spray, Vacuum Plasma Spray, Cold Spray, etc. Many more thermal coating methods can be considered to optimize the cost of Coating Application for Oil \u0026amp; Gas Refineries, Petrochemical Complex, Marine, Shipping Industries, Power Sector including Nuclear Plant. Thermal Spray Coating can be applied with the help of filler material starting from pure metals, alloys, ceramic, composite, etc. in the form of wire and powders. 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