The last decade has seen a rapid increase in the use of Thermally Sprayed Coatings for Oil and Gas production applications. In particular, since 1982 the Offshore Oil and Gas Industry has considered Thermally Sprayed Aluminum (TSA) for protection of steel structures in the splash zone and other areas in the marine environment. Experience to date has indicated that when TSA is properly applied with a specific sealer system a service life in excess of 30 years with zero maintenance is possible. This produces a corresponding reduction in life cycle costs. Other coating systems such as nickel-based alloys, ceramics and thermoplastics are also finding useful applications. This paper discusses recent advances in thermal spraying technology and current and future applications in the Oil and Gas Industry. This is illustrated with reference to several projects and details on life cycle costs. In particular, thermal spraying of pressure vessels, risers, pipelines and structural components are detailed.

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