Arnco 100XT Manual

RECOMMENDED PROCEDURES MANUAL

FOR THE PREPARATION, APPLICATION and INSPECTION

OF

ARNCO 100XT  HARDBANDING

VERSION 1.2 August 25, 2001

CONFIDENTIAL

TABLE OF CONTENTS FOREWORD POLICY STATEMENT WARRANTY PROVISIONS AND LIMITATIONS LIMITATIONS Sec Section ion I. I.

TYPE TYPES S OF OF ARN ARNCO CO HA HARD RDBA BAND NDIN ING G 1.1 1.2

Section Section II.

PREPARATION GUIDELINES 2.1 2.2 2.3 2.4 2.5 2.6

Section III.

Raised Hardbanding Flush Ha Hardbanding

Gene Genera rall 100X 100XT™ T™ Appl Applic icat atio ion n Inf Infor orma mati tion on Welding Eq Equipment Material Pr Preparation Reco Re comm mmen ende ded d Weld Weldin ing g Para Parame mete ters rs 100XT Usage Chart Temp Temper erat atur ure e Conv Conver ersi sio on Cha Chart

APPLICATION APPLICA TION GUIDELINES GUIDELI NES 3.1 3.2

100XT Applied onto AISI 4137 Steel Tool Joints 100XT™Applied onto AISI 4145-HT or AISI 1340-HT Steel Heavy Weight Drill Pipe, Drill Collars and Other Drilling Equipment

Section IV. INSPECTION GUIDELINES 4.1

Arnc Ar nco o 100 100XT XT™ ™ Ins Inspe pect ctio ion n Cri Crite teri ria a

CLOSING REMARKS ATTACHMENTS Attachment 1: Hardband Equipment Set-Up Worksheet Attachment 2: Temperature Conversion Chart

Version 1.2, August 25, 2001

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FOREWORD While Arnco 100XT  is a ferrous based wear resistant alloy hardbanding, it is a completely different metallurgical design which is almost 50% more effective against casing wear than Arnco 200XT . Arnco 100XT also has approximately the same open hole wear properties as fine particle Tungsten Carbide hardbanding. There is also a key cosmetic difference in that Arnco 100XT  does not exhibit stress cracking in the deposited metal provided the recommended procedures in this manual are followed. As with the Arnco 200XT  manual, this is a manual of general recommended procedures for various possible applications of Arnco 100XT . This information is provided for general guidance purposes only as it is impossible to anticipate all the different applications where Arnco 100XT  might be used. It is therefore the sole responsibility of users of Arnco 100XT  to ensure that a.) an acceptable welding practice is adopted alongside these guidance notes as an aid to defining a detailed welding procedure for a particular set of circumstances and b.) that such a procedure is followed in practice. If in doubt, please contact an Arnco representative for further assistance. As with the previous manuals, Arnco Technology hopes that this publication will facilitate a better understanding of drilling equipment hardbanding technology. Arnco Technology is constantly researching and developing new products and new applications which will be introduced when they have been proven to work successfully in the field. Any questions about this manual or Arnco 100XT™ may be addressed to:

ARNCO TECHNOLOGY TRUST, LIMITED 5915 BRITTMOORE ROAD HOUSTON, TEXAS 77041-5619 Telephone: (713) 466-9535 Fax: (281) 552-3555 Email: [email protected] Website: www.arncotech.com Version 1.2, August 25, 2001

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ARNCO TECHNOLOGY POLICY STATEMENT July 1, 2001

Arnco Technology Trust Limited (Arnco) is pleased to announce an industry leading warranty for its current range of hardbanding products. Arnco is the world leader in drill string hardbanding products. The Arnco 100XT™ has been an extremely effective and trouble free product. However, as with any welding process, the adherence to the recommended application parameters is critical to the integrity and performance of the finished product. Customers and end users have long sought a better way to assure that once the products are applied, they will work without failure. Arnco has developed a new program to better assure such a result, while giving our customers a warranty with greater clarity. This warranty applies only to Arnco 100XT™ hardbanding applied in full conformance with the “Arnco Recommended Procedures Manual” *, as witnessed and verified either by Arnco personnel or an Arnco approved independent monitor. This procedure will give our customers a verification that the Arnco specified parameters have been properly adhered to by monitoring the application to assure compliance with those specifications. Once verified and approved, the warranty provides that, in the unlikely event of any specific defect occurring in the Arnco hardbanding as a direct result of the technical performance of the Arnco product used, then Arnco will replace, in full, the faulty hardbanding at Arnco’s expense. Please see the following page for the specific provisions of the warranty and its limitations. * The “Arnco Recommended Procedures Manual” is available at no cost direct from Arnco. For a copy, please contact:

Arnco Technology Trust Limited 5915 Brittmoore Road, Houston, Texas 77041-5619, USA Telephone: (01) 713-466-9535 Fax: (01) 281-552-3555 E-Mail: [email protected] Website: www.arncotech.com


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PROVISIONS AND LIMITATIONS Provisions 1.

Hardbanding must be applied by an Arnco Certified Applicator

2.

Arnco personnel or an Arnco approved monitor must witness the application. The cost of this service is to be negotiated between Arnco and the customer.

3.

Hardbanding must be applied strictly in conformance with the current “Arnco Recommended Procedures Manual”

4.

An independent failure analysis will be performed to determine the cause of the failure. If the failure is caused by the product or application, then Arnco will be responsible for the repair as stated. If it is caused by the drilling conditions, etc. then the cost of the repair will be the responsibility of the customer.

Limitations 1.

Limited to the cost of removal of defective hardbanding, application of a butter pass and reapplication of the new hardbanding only, including necessary inspections involved in the hardbanding application.

2.

Not included is the potential loss of time or revenue of the customer in the event of defective hardbanding.

3.

Not included is the cost of a third party monitor that might be required by the customer or end user. If they wish to have a monitor present during repair, it will be at their expense, not Arnco’s. Arnco will provide their own monitoring service as required.


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SECTION I. TYPES OF ARNCO 100XT™ HARDBANDING 1.1

RAISED HARDBANDING

RAISED HARDBANDING IS STRONGLY RECOMMENDE D ON ALL TOOL JOINTS FOR MAXIMUM CASING AND TOOL J OINT PROTECTION

1.1.1 A recess groove is machined into the 18 ° elevator shoulder and filled flush with Arnco 100XT  . One layer is then applied raised on the tool joint O.D. for a specified length. Normally, 3” of hardbanding is applied on the Box O.D. and, as a recommended option, 2” is applied on the Pin O.D. Instead of the full length of the tool joint contacting the inner surface of the casing or the open hole wall, the Arnco hardband makes the contact, thereby reducing casing wear AND tool joint wear. This raised application for tool joints is illustrated in Figure 1.1. 1.1.2 Application on the Pin O.D. is strongly recommended for extra-long tool joints. This will further ensure the entire tool joint area (Box and Pin) will have minimal contact with the inside surface of the casing or open hole wall. This is of concern when drilling or tripping in and out of the well bore. 1.1.3 Arnco 100XT hardbanding applied in this manner also reduces the possibility of heat checking occurring on the tool joint surface. Instead of the tool joint being damaged by heat checking, the hardband surface will absorb the load. The worst thing that could happen is that the hardband would be damaged and require removal and re-application. The drill string would then be salvaged and continue to be utilized. 1.1.4 When 100XT  hardbanding makes contact with the inside of the casing, the low coefficient of friction reduces the torque and drag experienced in extended reach or high-angle wells. As a result, this reduction in torque and drag should reduce fuel cost. 1.1.5 When application is performed on new or used tool joints in a non-mill application (as performed with portable field equipment), it may not be necessary to apply or re-apply hardbanding to the 18 ° elevator shoulder. The shoulder area should be visually inspected to determine if it is in serviceable condition. This type of raised application for new or used tool joints in a non-mill application is illustrated in Figure 1.2. NOTE: Refer to Section II. of this manual for detailed information concerning application on used material.


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ARNCO 100XT™ RAISED APPLICATION

2"

LP

3/32" +/- 1/32"

LB H

3" 3/32" +/- 1/32"

** Apply 100XT™ flush on 18 ° shoulder, +0, - 1/32"

Figure 1.1


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ARNCO 100XT™ RAISED NON-MILL APPLICATION

2" 3/32" +/- 1/32"

LP

LB H

3" 3/32" +/- 1/32"

On Box End, apply 100XT™ approximately 3/8" (+/- 1/8") from 18 ° shoulder.

Figure 1.2


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1.2

FLUSH HARDBANDING

1.2.1 Flush Hardbanding is recommended only if the maximum tool joint O.D. must be restricted so as not to cause interference with the casing inside diameter. Any hardbanding, including 100XT™, applied in this manner will not yield maximum results because the tool joint O.D. begins to wear simultaneously with the hardbanding. 1.2.2 For a Flush Hardband application, a recess groove is machined into the entire hardband area of the tool joint and filled with Arnco 100XT™ flush with the O.D. of the tool joint. The hardband area normally includes the 18 ° elevator shoulder. This type of application for new, used or rebuilt tool joints is illustrated in Figure 1.3. NOTE: Refer to Section II of this manual for detailed information concerning application on used material.

1.2.3

Application of 100XT™on the Pin O.D. is a recommended option.


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ARNCO 100XT™ FLUSH APPLICATION

2"

LP

LB

3"

3/32" ,+0, - 1/32"

D

3/32", +0, - 1/32"

Flush with O.D., + 1/32", -0"

H

Flush with OD, + 1/32", -0"

** Apply 100XT™ flush with 18 ° shoulder, +0, - 1/32"

Figure 1.3


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SECTION II. 2.1

PREPARATION GUIDELINES GENERAL 100XT™ APPLICATION INFORMATION

Hardband Width: It has become a common practice to order drill pipe with 2.1.1 extra long tool joints. With the advent of the high torque type tool joints, the total length of the combined tool joints may be as much as 36” in length. To increase the bearing effect of these long tool joints, Arnco recommends applying 2” on the pin tool joint in addition to a 3” or wider band on the box tool joint. Weld Bead Width: Arnco recommends that a finished weld bead be 1” in 2.1.2 width. This results in a smoother, more uniform bead. The unit operator should determine how well the equipment can produce the highest degree of workmanship to attain a flat or slightly convex weld bead profile. Oscillation width and adequate overlap can be adjusted to achieve the desired effect.

2.1.3 Pre-Heat: Preheating of the tool joint or drill collar must be performed regardless of the O.D. or ambient temperature of the steel. Inadequate preheating of the parent steel may cause undesirable cracking in the parent metal. Applicators should refer to the preheat temperature parameters listed in Section III of this manual. Slow-Cooling: The hardband unit operator must control the cooling rate of the 2.1.4 hardbanded tool joints. In order to ensure the required slow cooling, the tool joints need to be wrapped immediately in thermally insulated blankets or canisters. This wrapping operation and subsequent slow cooling must take place in “still air”. The use of shop ventilation fans shall have the airflow directed away from the hardbanded tool joints during handling, wrapping and slow cool storage. Any grinding shall be done after the tool joint has cooled down to less than 150ºF (66ºC). Grinding: Repair grinding to contour overlap areas of the weld bead or to 2.1.5 remove spatter or minor protrusions shall be performed as necessary. Heavy, continuous grinding with stationary grinding wheels is not necessary and should not be performed. Elevator Shoulder: When welding is required on the 18 ° elevator shoulder, 2.1.6 the unit operator and inspector must pay close attention to the weld profile of the finished weld bead. If the weld bead height on the 18 ° elevator shoulder exceeds that of the tool joint shoulder itself, it is necessary to remove that excess height to make it flush with the tool joint shoulder. Any raised weld metal on the 18 ° elevator shoulder may result in interference with the elevator’s operation. Fingers: When “fingers” are required on the 18 ° elevator shoulder, they also 2.1.7 must be flush. They may be applied with the hardbanding unit or with hand-held welding equipment (i.e. MIG gun). If the tool joint has been previously hardbanded and has cooled to less than the required preheat temperature, the tool joint must be preheated again to the required temperature prior to application of the fingers. Arnco has no opinion on the use of fingers, but it has become more accepted that fingers with casing friendly hardbanding are not applied. CONFIDENTIAL 11 Version 1.2, August 25, 2001

2.2

WELDING EQUIPMENT REQUIREMENTS

2.2.1 The welding equipment should consist of a Constant, Direct Current (DC) power supply capable of furnishing a current of 240 - 320 amperes and 24 - 30 volts, with the wire Positive (DCEP). Reverse polarity (DCEP) is to be utilized at all times regardless of the type of steel that the hardband is being applied onto. 2.2.2 The welding equipment should have a clean grounding system that will not resist the flow of electric current. The resistance can be seen as heat build-up in the welding lead or in its connection after a short weld time. 2.2.3 The equipment should have the ability to grip and rotate the tool joint under the welding torch concentric to within .030” ( ,762mm) and at a constant uniform speed of between 60 and 200 seconds per revolution. The tool joint O.D. determines the speed at which to rotate the tool joint. 2.2.4 The equipment must have the ability to move the welding torch from vertical center so that welding takes place on the uphill side of the tool joint as it is being rotated. For this “Torch off-set”, refer to the Recommended Welding Parameters as illustrated in Figure 2.2.5 In addition, the equipment must have the ability to angle the welding torch, in the direction of the rotation , to between 17-19 degrees as measured from vertical center of the tool joint. For this “Torch Angle”, refer to the Recommended Welding Parameters illustrated in Figure 2.1. NOTE: Machines that are not able to adjust torch angle or offset, from vertical center, have normally demonstrated difficulty to produce a consistently flat, or slightly convex, weld bead profile. Not having both of these adjustments available becomes a greater disadvantage when welding on a tool joint smaller than 4-3/4” (121mm) O.D.

2.2.6 The equipment must have the ability to oscillate the welding torch at a standoff distance of 5/8” (15,9mm) to 1” (25,4mm), from the welding surface and at approximately 50 to 90 oscillations per minute. 2.2.7 The equipment must be able to move the torch, parallel to the tool joint axis, for a minimum distance of 4” (102mm). A longer distance, of 6” to 12” (153mm-305mm) is preferred, especially when hardbanding drill collars or extra long tool joints. 2.2.8 Welding equipment should include a wire feed system capable of feeding the wire through the torch at a variable, uniform speed without damaging the surface or the shape of the wire. Special wire-feed rollers designed for feeding soft-skinned, flux-cored wire should be utilized.


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A 100%, pure CO2 shielding gas must be utilized when welding 2.2.9 100XT™. The regulated flow must be controlled to deliver 30 to 35 CFH (14-16.5 LPM) to the arc area. 2.2.10 When welding is performed on the 18 ° elevator shoulder, the equipment must be able to tilt the tool joint in order to weld the shoulder on a flat plane. 2.2.11 The equipment must have the ability to pre-heat any tool joint to a uniform temperature from 150 ° F to 700° F (66° C to 371° C). Refer to Section III of this manual for preheat temperatures. The heat applied should be a soak heat rather than a surface heat. 2.2.12

To determine a soak heat, perform this simple procedure: a. Remove the tool joint from the heating device and immediately measure the temperature in the area to be hardbanded. b. Immediately cover the tool joint with a canister or thermal blanket c. Allow the tool joint to stand in still air for 4 minutes. d. Then, again, measure the temperature of the tool joint. e. If the temperature drops more than 50 ° F (10°C), the pre-heat applied is only a surface heat and not a soak heat. f. If it is determined that it is a surface heat, continue preheating until the temperature drop is within the tolerances of a soak heat.

2.2.13 The hardband unit operator must control the cooling rate of the hardbanded tool joints. In order to ensure the required slow cooling, the tool joints need to be wrapped immediately in thermally insulated blankets or canisters. This wrapping operation and subsequent slow cooling must take place in “still air”. The use of shop ventilation fans shall have the airflow directed away from the hardbanded tool joints during handling, wrapping and slow cool storage. Any grinding shall be done after the tool joint has cooled down to less than 150ºF (66ºC). 2.2.14 When hardbanding drill pipe tool joints, the ends of the drill pipe should be closed to prevent a draft, or “chimney effect”, through the drill pipe. This becomes extremely critical when hardbanding during windy or cold-air conditions, especially where portable equipment is utilized. The use of closed-end protectors, or applying tape over the wrenchhole openings on steel protectors, should be sufficient to prevent the drafting of air through the inside of the drill pipe.


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2.3

MATERIAL PREPARATION

NOTE: Preparation of the hardband area must be performed to minimize, if not eliminate, foreign matter becoming an impurity in the molten weld puddle and to ensure a good fusion bond with the parent metal. Preparation must be performed when applying hardbanding onto either new or used material.

2.3.1

General Preparation Information: a. Visually inspect the weld surface of all tool joints to ensure they are clean and free of all foreign matter such as rust, dirt, grease, oil, paint or pipe coating. b. Utilizing a side-grinder & cup-brush will usually produce a sufficiently clean weld surface for hardbanding new tool joints. Perform a visual inspection of the tool joint O.D. surface after buffing. “Buffing” the tool joint surface does not always produce a clean hardband surface, consequently further cleaning may be necessary. Applicators are to determine the best method available to prepare the weld surface. c. The threaded connections should be cleaned of all thread lubricants or storage compounds. This will ensure a much cleaner welding process and eliminate the probability of the lubricant or compound igniting during the preheat. d. When Raised hardbanding is required on new or used unhardbanded tool joints, it is sometimes necessary to machine a shallow, .015"(,38mm), recess groove into the tool joint O.D. to give a clean, smooth and concentric weld surface. e. Prior to hardbanding used unhardbanded drill pipe, the tool joints should be examined for eccentric wear caused by downhole drilling conditions. The concentricity of the tool joint should be within .030” (,76mm) of the center axis in order to apply an even layer of hardbanding. If the eccentricity of the tool joint is greater than .030” (,76mm) it may cause the welding arc to be erratic and produce an unacceptable weld bead. f. Determine the integrity of the existing hardbanding. If any cracking , spalling, chipping or void areas on the existing hardbanding are apparent, the hardbanding must be removed. The tool joint should then be inspected to ensure that no cracks have propagated into the parent metal. In addition, if cracking from a chrome hardbanding is evident, the hardbanding must be removed prior to application of Arnco 100XT .


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2.3.2

For Application of 100XT™ onto Used hardbanded drill pipe:

a. When used drill pipe, previously hardbanded with 100XT™ has been worn to the point that reapplication is necessary, first ensure that the items listed in previous paragraph 2.3.1 are reviewed prior to re-application. For Existing 100XT™, cracks should not be present. If the existing layer contains cracks, then the layer must be removed. Inspect for cracks in the parent metal prior to re-applying another layer of 100XT™. If there are cracks in the parent metal, they must be completely removed and the tool joint rebuilt, prior to re-application of any hardbanding. To maintain a crack-free weld bead, 100XT™ must not be applied over any b. other chrome hardbanding, including ARNCO 200XT™!

NOTE: If you have any questions concerning application of 100XT™ over any hardbanding, contact your Arnco representative prior to proceeding.

2.4 RECOMMENDED 100XT™ WELDING PARAMETERS: The welding parameters for 100XT™ hardbanding wire are illustrated in Figure 2.1. Applicators should refer to this diagram for equipment set-up.

2.5 WIRE USAGE CHARTS: Applicators should use Table 2.1, to determine the amount of 100XT™ hardbanding wire required to weld a particular O.D. tool joint or drill collar.

2.6 TEMPERATURE CONVERSION CHART: Applicators may use the enclosed temperature Conversion Chart (Attachment 2) to convert temperatures, either Fahrenheit to Celsius or vice versa.


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ARNCO 100XT RECOMMENDED WELDING PARAMETERS "TORCH SETTINGS"

"X" Distance ranges between ½" (12,7mm) and 1-1/2" (38,1mm) T.I.R. +/- .015" ( ,38mm) PROCESS SHIELDING GAS FILLER METAL ELECTRODE SIZE PREHEAT CURRENT TYPE / POLARITY AMPERAGE VOLTAGE OSCILLATION SPEED OSCILLATION WIDTH WELD BEAD OVERLAP POST WELD TEMPERING POST WELD COOL DOWN INTERPASS TEMPERATURE

FCAW (AUTOMATIC) 100% CO2 @ 30-35CFH (14-16.5LPM) Mild Steel Wire 1/16" (1,6mm) 150° F (66° C) to 700° F (371° C) DCEP (REVERSE) 240 – 320 amps 24 – 30 VDC 60 – 120 Oscillations per minute .750" (19,0 mm) to 1.0" (25,4 mm) .125" (3,2 mm) to .250" (6,4 mm) NOT REQUIRED COVERED, IN STILL AIR 850° F (454° C) MAXIMUM

Figure 2.1


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ESTIMATED USAGE OF 100XT™ HARDBANDING WIRE Tool Joint Diameter

Pounds Per Linear Inch

Pounds Per Tool Joint Width of Hardbanding .750" 1.00" 2.00" 3.00" 3.750" 4.00"

4-1/2"

.378

.284

.378

.756

1.134

1.418

1.512

4-3/4"

.398

.299

.398

.796

1.194

1.493

1.592

5"

.419

.314

.419

.838

1.257

1.571

1.676

5-1/4"

.440

.330

.440

.880

1.320

1.650

1.760

5-1/2"

.460

.345

.460

.920

1.380

1.725

1.840

5-3/4"

.481

.361

.481

.962

1.443

1.804

1.924

6"

.502

.377

.502

1.004

1.506

1.883

2.008

6-1/8"

.513

.385

.513

1.026

1.539

1.924

2.052

6-1/4"

.524

.393

.524

1.048

1.572

1.965

2.096

6-1/2"

.546

.410

.546

1.092

1.638

2.048

2.184

6-5/8"

.555

.416

.555

1.110

1.665

2.081

2.220

6-3/4"

.565

.424

.565

1.130

1.695

2.119

2.260

.586

.440

.586

1.172

1.758

2.198

2.344

.607

.455

.607

1.214

1.821

2.276

2.428

.671

.503

.671

1.342

2.013

2.516

2.684

8-1/4"

.697

.523

.697

1.394

2.091

2.614

2.788

8-1/2"

.723

.542

.723

1.446

2.169

2.711

2.892

7" 7-1/4" 8"

NOTE: These figures are theoretical based on deposition rates for 1/16" diameter wire and 3/32" thickness. If you deposit 4/32”” thickness, you will consume 33% more wire. It is advisable to perform your own tests to determine actual usage rates for your operation. Table 2.1 100XT™ USAGE CHART


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SECTION III.

APPLICATION GUIDELINES

SPECIAL NOTATION FOR WELDING PROCEDURES The following specific welding procedures are to be used as guidelines for developing your own particular written welding procedure. They list the vital procedures for applying Arnco 100XT™ onto AISI 4137, 4145-HT and 1340 steels. It would be very difficult to write a recommended procedure for every conceivable application, so we have included the known and proven applications in this manual. If you do not find a particular application or a specific requirement for an application, included in this manual, contact your nearest Arnco Technology representative PRIOR TO WELDING. They will assist you in developing one to meet your specific requirement. The procedures on the following pages consist of those specifically for:

AISI 4137 STEEL TOOL JOINTS •

100XT™ applied onto new or used tool joints for sizes 3-1/8” to 8-1/2” OD

•

100XT™ applied onto used tool joints previously hardbanded with Tungsten Carbide, and the limitations for application over ALL Chrome Hardbanding

AISI 4145-HT STEEL AND AISI 1340-HT STEEL •

100XT™ applied onto new or used heavy weight drill pipe (Hevi-Wate or Spiral-Wate), drill collars and various other drilling equipment

•

100XT™ applied onto used heavy weight drill pipe (Hevi-Wate or SpiralWate), drill collars and various other drilling equipment previously hardbanded with Tungsten Carbide and the limitations for application over ALL Chrome Hardbanding


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3.1

100XT™APPLIED TO AISI 4137 STEEL TOOL JOINTS

3.1.1 Before hardbanding tool joints of any size O.D., whether new or used, ensure that the necessary equipment and material preparation has been performed as recommended in Section II of this manual. 3.1.2 Applicators are strongly advised to use a “test piece” or ‘practice joint” of the same diameter, thickness and steel type to fine tune the welding equipment prior to starting production. Operators can utilize the Hardband Setup Worksheet (Attachment I) included with this manual to document the equipment settings necessary to hardband each size tool joint. The worksheets can then be used for future reference. 3.1.3 When welding new or used AISI 4137 Steel drill pipe tool joints, always utilize Reverse Polarity (DCEP). This will ensure the proper weld fusion, penetration and deposition of the 100XT™ onto the parent metal. 3.1.4 When welding with 100XT™, a 100%, pure CO 2 shielding gas must be utilized. The regulated flow should be adjusted to deliver 30-35 CFH (14-16.5 LPM) to the welding arc. 3.1.5 For a particular O.D. of tool joint, select the proper Preheat Temperature Range listed below: Tool Joint O.D. 3-1/8” to 4-3/8" 4-3/4” to 5-1/4” 5-1/2” to 6-1/4” 6-3/8” to 6-7/8” 7” to 7-7/8” 8” to 8-1/2”(nom.) 8” to 8-1/2”(w/5"id.)*

Preheat Temperature ___ 150 °F to 200° F (66°C to 93° C) 200 °F to 250° F (93°C to 121 ° C) 400 °F to 500° F (204° C to 260° C) 400 °F to 600° F (204° C to 316° C) 500 °F to 600° F (260° C to 316° C) 600 °F to 700° F (316° C to 371° C) 500 °F to 600° F (260° C to 316° C)

* The wall thickness of this size tool joint is much less than normal tool joints It is strongly recommended that preheat temperatures be measured with a digital, electronic pyrometer. The minimum acceptable requirement is the use of two tempstiks; one for each of the minimum and maximum temperatures of the range. The unit operator must ensure that the desired, preheat temperature range is controlled. Experience has taught us that excessive preheat can distort the weld bead profile and insufficient preheat can negatively affect the metallurgy of the weld as well as the parent metal. NOTE: Arnco does not recommend the use of tempstiks, as they are not accurate. When tempstiks are used on the prepared hardband surface, the residue must be removed prior to welding. If not, the residue becomes an impurity that may affect the fusion bond of the 100XT ™ to the prepared surface.


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3.1.6 The Maximum Interpass Temperature for all 100XT™ hardbanding procedures is 850° F (454° C). 3.1.7 The unit operator should adjust the hardband equipment to attain a flat or slightly convex weld profile as illustrated in Figure 4.3.1, contained in the Post-Weld Material Inspection section of this manual. Each weld bead should overlap the previous weld bead ~1/4" (6,5mm) and consistently “tie-in” with the edge of each preceding weld bead. In addition, each weld bead should meet the required hardband height (dimension H) as shown in Figures 1.1, 1.2 and 1.3, in Section I of this manual. 3.1.8 When welding the 18 ° elevator shoulder, the unit operator must ensure that the weld bead is consistently tied into the side of the recess groove in the tool joint shoulder. In addition, the weld bead shall not exceed the surface of the adjacent elevator shoulder as explained in paragraph 2.1.4, of this manual. 3.1.9 The hardband unit operator must control the cooling rate of the hardbanded tool joints. In order to ensure the required slow cooling, the tool joints need to be wrapped immediately in thermally insulated blankets or canisters. This wrapping operation and subsequent slow cooling must take place in “still air”. The use of shop ventilation fans shall have the airflow directed away from the hardbanded tool joints during handling, wrapping and slow cool storage. Any grinding shall be done after the tool joint has cooled down to less than 150ºF (66ºC). 3.1.10 When the 100XT™ is applied over a layer of Tungsten hardbanding, it is possible that micro-cracks may appear in the new layer. These micro-cracks rarely occur and have not been found to be detrimental to the integrity of the 100XT™. The few instances where micro-cracks have been seen have not been found to propagate into the parent metal. Instead, they were found to be superficial in depth, negligible in width and not over 1” in length. When this micro-cracking is seen, it must be investigated by utilizing a probe grinder to determine the depth of the crack and, if necessary, remove it. The hardband area that is removed can be repaired by preheating the tool joint to the specified temperature and performing a patch-weld repair. 3.1.11 To maintain a crack-free weld bead, the 100XT™ can be applied over itself but not over any other chrome hardbanding, including Arnco 200XT™. 3.1.12

Post-Weld Tempering of the 100XT™ on AISI 4137 tool joints is not required.


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3.2

100XT™APPLIED TO AISI 4145-HT STEEL OR AISI 1340-HT STEEL

3.2.1 Prior to hardbanding AISI 4145-HT or AISI 1340-HT Steel, whether new or used, ensure that the necessary equipment and material preparation has been performed as recommended in Section II of this manual. 3.2.2 As with AISI 4137 Steel, applicators are urged to use a “test piece” or “practice joint” of the same size and steel type to fine tune the welding equipment prior to starting production. In addition, the unit operator should utilize the Hardband Setup Worksheet (Attachment I) to document the equipment settings for future reference. 3.2.3 When welding new or used AISI 4145-HT Steel, utilize Reverse Polarity (DCEP). This will ensure the proper weld fusion, penetration and deposition of the 100XT™ onto the parent metal. 3.2.4 When welding with 100XT™, a 100%, pure CO 2 shielding gas must be utilized. The regulated flow should be adjusted to deliver 30-35 CFH (14-16.5 LPM) to the welding arc. 3.2.5 For AISI 4145-HT or AISI 1340-HT Steel of a particular O.D., select the proper Preheat Temperature Range listed below: Tool Joint/Drill Collar O.D. Less than 4-3/4” 4-3/4” to 5-1/4” 5-1/2” to 6-1/4” 6-3/8” to 6-7/8” 7” to 7-7/8” 8" to 8-1/2"(nom.) 8" to 8-1/2"(w/5"id.)*

Preheat Temperature __ 200 °F to 300° F (93°C to 149 ° C) 300 °F to 400° F (149° C to 204° C) 400 °F to 500° F (204° C to 260° C) 400ºF to 600ºF (204ºC to 316ºC) 500ºF to 600ºF (260ºC to 316ºC) 600 °F to 700° F (316° C to 371° C) 500 °F to 600° F (260° C to 316° C)

* The wall thickness of this size tool joint is much less than normal tool joints It is strongly recommended that the preheat temperature be measured with a digital, electronic pyrometer. The minimum acceptable requirement is the use of two tempstiks; one for each of the minimum and maximum temperatures of the range, The unit operator must ensure that the desired, preheat temperature range is controlled. Experience has taught us that excessive preheat can distort the weld bead profile and insufficient preheat can negatively affect the metallurgy of the weld as well as the parent metal. NOTE: Arnco does not recommend the use of tempstiks, as they are not accurate. When tempstiks are used on the prepared hardband surface, the residue must be removed prior to welding. If not, the residue becomes an impurity that may affect the fusion bond of the 100XT ™ to the prepared surface.


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3.2.6 The Maximum Interpass Temperature for all 100XT™ hardbanding procedures is 850°F (454°C). 3.2.7 The unit operator should adjust the hardband equipment to attain a flat or slightly convex weld profile as illustrated in Figure 4.3.1, contained in the Post-Weld Material Inspection section of this manual. Each weld bead should overlap the previous weld bead ~1/4" (6,5mm) and consistently “tie-in” with the edge of each preceding weld bead. In addition, each weld bead should meet the required hardband height (dimension H) as shown in Figures 1.1, 1.2 and 1.3 in Section I of this manual. 3.2.8 When welding the 18 ° elevator shoulder, the unit operator must ensure that the weld bead is consistently tied into the side of the recess groove in the tool joint shoulder. In addition, the weld bead shall not exceed the surface of the adjacent elevator shoulder as explained in paragraph 2.1.4, of this manual. 3.2.9 With AISI 4145-HT Steel, a slow cool-down, after hardbanding is extremely critical . These types of material are used in a transition zone between pieces of drilling equipment that have widely varied wall thickness’ and areas of high stress concentration. The result of rapid cool-down is usually catastrophic. For this reason, the hardband unit operator must control the cooling rate of the hardbanded tool joints. In order to ensure the required slow cooling, the tool joints need to be wrapped immediately in thermally insulated blankets or canisters. This wrapping operation and subsequent slow cooling must take place in “still air”. The use of shop ventilation fans shall have the airflow directed away from the hardbanded tool joints during handling, wrapping and slow cool storage. The ends of the pipe must be closed off to prevent a drafting effect through the inside of the pipe. Any grinding should be done after the tool joint or drill collar has cooled down to less than 150 °F (66° C). NOTE: The center wear pad of the heavy weight drill pipe is one of the most critical areas for application of any hardbanding. Great care and special attention must be given to this area to ensure that the welding and post-weld procedures are strictly adhered to. Failure to do so may result in failure of the joint of drill pipe.

3.2.10 When the 100XT™ is applied over a layer of Tungsten hardbanding, it is possible that micro-cracks may appear in the new layer. These micro-cracks rarely occur and have not been found to be detrimental to the integrity of the 100XT™. The few instances where micro-cracks have been seen have not been found to propagate into the parent metal. Instead, they were found to be superficial in depth, negligible in width and not over 1” in length. When this micro-cracking is seen, it must be investigated by utilizing a probe grinder to determine the depth of the crack and, if necessary, remove it. The hardband area that is removed can be repaired by preheating the tool joint to the specified temperature and performing a patch-weld repair. 3.2.11 To maintain a crack-free weld bead, the 100XT™ can be applied over itself but not over any other chrome hardbanding, including Arnco 200XT™. 3.2.12

Post-Weld Tempering of the hardband area is not required.


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SECTION IV. 4.1

INSPECTION GUIDELINES

Pre-Weld Equipment Inspection

4.1.1 Ensure that the proper wire feed assembly (for soft-skinned cored wire) and torch tip are installed, clean and in proper working order. 4.1.2 Ensure that the Arnco 100XT™ wire is properly loaded into the wire feed assembly. In addition, ensure that only an adequate amount of tension is applied to the wire-feed rollers to feed the wire through to the torch assembly. 4.1.3 Ensure that the torch is set at the proper angle and offset to achieve the correct weld bead profile and deposition for the size and type of material being hardbanded. 4.1.4 Ensure that the correct polarity, voltage, amperage, wire feed, rotation and oscillation parameters are set per your welding procedures. These adjustments are based on the hardbanding equipment and operators’ ability to attain the required weld profile, height, thickness and deposition. 4.1.5 Ensure that the CO2 shielding gas is 100% pure and the flow of gas can be accurately regulated. 4.2

Pre-weld Material Inspection

4.2.1 Ensure that the material to be hardbanded is clean and free of all foreign matter such as dirt, rust, oil, grease, paint or thread compound. 4.2.2 Ensure that the part (tool joint or drill pipe) is set properly in the hardband machine so that the weld area is as level and concentric as possible to within .030” (, 76mm). 4.2.3 If existing hardbanding has been removed and rebuilt with mild steel wire, ensure that the weld area is free of all slag and debris. 4.2.4 The surface of the area where a “butter pass” has been applied shall be free of any cracks. Suggested inspections may include bi-directional wet or dry magnetic particle inspection of that surface area. This eliminates the possibility of welding over pre-existing cracks or defects. Experience has taught us that many times when existing hardbanding, especially tungsten carbide, is removed, it creates heat checking (small surface cracks) in the body of the steel. Heat checking can also be caused by high axial loading against the tool joints during drilling operations and has nothing to do with existing hardbanding. With either situation, when cracks are welded over during the hardband application, it most likely will cause these cracks to propagate into the parent metal. Therefore, it is very important that a critical tool joint inspection be performed after removal of existing hardbanding and prior to hardbanding or re-hardbanding a tool joint.


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4.3

Post-Weld Material Inspection NOTE: It is important to remember that hardbanding is a simple process and the inspection of hardbanding is equally simple. It is also very easy to be overly critical with acceptance and rejection criteria. A hardband is considered acceptable if the general appearance and the dimensional measurements are within the product guidelines.

4.3.1 Visual Inspection of the 100XT™ hardband area consists of all of the following criteria. 4.3.1.1

Any weld bead with a crack visible to the naked eye is suspect for further investigation. Application of 100XT™ onto new tool joints, used unhardbanded tool joints or over existing 100XT™ should not produce cracks. If the cracks are visible to the naked eye, the weld bead is reject. However, as previously written in the application procedures 3.1 and 3.2, when the 100XT™ is applied over used Tungsten carbide hardbanding, micro-cracks may occur. The main consideration is to determine if stress cracking has occurred due to rapid cool-down.

4.3.1.2 Overall, workmanship and cleanliness of weld beads is of utmost importance. No slag, spatter, high spots or minor protrusions should remain on weld area. Spatter and minor protrusions are considered rejectable unless removed by grinding. Overlap areas should be ground to conform to the overall hardband profile. Spalling of the weld bead is not acceptable. 4.3.1.3 The weld bead profile shall be flat to slightly convex and consistent throughout the entire hardband area. If the weld profile is “humped” in the middle of the weld bead, it is sometimes possible to repair with grinding. If it is apparent that lengthy grinding is necessary to remove the hump, the hardband area should be removed and the tool joint rebuilt before reapplying 100XT™. This hump is normally caused by improper torch angle or offset and can usually be corrected by readjustment of the torch assembly. 4.3.1.4 If the weld bead profile is concave and/or insufficient in height, the weld area is considered reject. A concave profile may be caused by improper torch angle or offset and can usually be corrected. In addition, this concave profile can also be the result of excessive preheat and/or interpass temperature. 4.3.1.5 For a Flush Application, the “tie-in” with the edges of the parent metal (recessed area) must be consistent throughout the circumference of that hardbanded area. It is sometimes possible to repair, by spot-welding, those void areas that do not tie-in properly with the adjacent parent metal. However, this repair welding should not include welding a single, narrow bead around the entire circumference of the tool joint. Proper overlap and oscillation width of a weld bead shall be adjusted to attain the proper tie-in.


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4.3.1.6 Tie-ins with adjacent weld beads should be consistent to prevent deep furrows or voids between weld beads. Again, repair welding should not include the welding of a single, narrow bead around the entire circumference to correct a void area. Proper overlap and oscillation width of a weld bead to another shall be adjusted to attain an overall, flat or slightly convex hardband area. The acceptable weld bead profiles are illustrated below in Figure 4.3.1.

UNACCEPTABLE

ACCEPTABLE

ACCEPTABLE

Figure 4.3.1

4.3.1.7 Excessive porosity (pin-holes) is not acceptable. Usually, during hardbanding, porosity is caused by impurities such as rust, solvent or thread dope that are allowed to remain on the weld surface. In addition, welding slag is normally generated during the welding process and, if allowed to accumulate in the torch nozzle, will fall out and contaminate the weld puddle. The unit operator should keep the torch assembly clean. At a minimum, the torch nozzle should be cleaned after welding each tool joint. 4.3.1.8 Voids (burn-ins) or Blow-holes larger than 1/8” diameter and gaps between the weld beads, which are not repaired by welding, are considered rejectable. 4.3.2

Dimensional Inspection of the Hardband Area consists of the following criteria.

4.3.2.1 For either Raised or Flush applications, the dimensions of hardbanded area shall conform to the diagrams illustrated in Section I of this manual or to customer requirements. The hardband height and overall length can be easily measured with the use of a carpenter's square with a six or twelve inch scale. 4.3.2.2 Check alignment across the hardband area for high or low areas in weld beads. Excessively high areas should be repaired by minor grinding if those areas exceed the tolerance for maximum specified height.


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CLOSING REMARKS Again, we urge all users of this manual to treat it as a guide to creating your own procedures to meet your particular requirements. If you stay within these recommended parameters, you can be assured of a quality 100XT™ hardband application. We express special thanks to all our end users, applicators and inspectors for their cooperation and input into the development of Arnco 100XT™. In closing, let us at Arnco Technology assure all of you that this hardbanding can be extremely effective in reducing casing wear and tool joint wear if applied properly and used to its optimum potential. While we recognize the fact that it is completely different to apply than other hardbandings, it is no more difficult if the proper procedures are followed. It is usually when applicators operate outside the recommended parameters that they experience difficulties. If a situation arises where 100XT™ must be applied outside the Arnco recommended procedures, CALL US FIRST! Thank you!

ARNCO TECHNOLOGY TRUST, LTD.


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HARDBAND EQUIPMENT SET-UP WORKSHEET UNIT #__________________ LOCATION____________________ DATE__________

TOOL JOINT O.D.___________TYPE OF WIRE__________________SIZE________ TYPE OF STEEL: AISI 4137________ AISI 4145HT________ AISI 1340HT________ APPLICATION TYPE: RAISED_______ FLUSH______ HARDBAND HEIGHT_______

PROCESS: FCAW__________GMAW__________ Type FLUX ________________ CURRENT POLARITY: DCEN (Straight)_________or DCEP (Reverse)__________ AMPERAGE_____________ VOLTS_______________ SHIELDING GAS: Mixture___________________Flow Rate___________________ TORCH SETTINGS: Angle______Offset from TDC_____Distance from Part______ OSCILLATION:

Width___________ Speed__________ Dwell_______________

ROTATION SPEED: _______________________Minutes / Seconds per Revolution PREHEAT TEMPERATURE RANGE_______________________________________ INTERPASS TEMPERATURE: Maximum allowed___________ Actual __________ SPECIFIED COOL-DOWN PROCESS: _____________________________________

NOTES:

Attachment 1


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ATTACHMENT 2


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Arnco 100XT Manual

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