Arnco 100XT Manual

RECOMMENDED PROCEDURES MANUAL

FOR THE PREPARATION, APPLICATION and INSPECTION

OF

ARNCO 100XT

HARDBANDING

VERSION 1.2August 25, 2001

CONFIDENTIAL

Version 1.2, August 25, 2001 CONFIDENTIAL 2

TABLE OF CONTENTS

FOREWORD

POLICY STATEMENT

WARRANTY PROVISIONS AND LIMITATIONS

Section I. TYPES OF ARNCO HARDBANDING

1.1 Raised Hardbanding1.2 Flush Hardbanding

Section II. PREPARATION GUIDELINES

2.1 General 100XT™ Application Information2.2 Welding Equipment2.3 Material Preparation2.4 Recommended Welding Parameters2.5 100XT Usage Chart2.6 Temperature Conversion Chart

Section III. APPLICATION GUIDELINES

3.1 100XT Applied onto AISI 4137 Steel Tool Joints3.2 100XT™Applied onto AISI 4145-HT or AISI 1340-HT Steel

Heavy Weight Drill Pipe, Drill Collars and Other DrillingEquipment

Section IV. INSPECTION GUIDELINES

4.1 Arnco 100XT™ Inspection Criteria

CLOSING REMARKS

ATTACHMENTS

Attachment 1: Hardband Equipment Set-Up WorksheetAttachment 2: Temperature Conversion Chart


FOREWORD

While Arnco 100XT is a ferrous based wear resistant alloyhardbanding, it is a completely different metallurgical design which is almost50% more effective against casing wear than Arnco 200XT. Arnco100XT also has approximately the same open hole wear properties as fineparticle Tungsten Carbide hardbanding. There is also a key cosmeticdifference in that Arnco 100XT does not exhibit stress cracking in thedeposited metal provided the recommended procedures in this manual arefollowed.

As with the Arnco 200XT manual, this is a manual of generalrecommended procedures for various possible applications of Arnco100XT. This information is provided for general guidance purposes onlyas it is impossible to anticipate all the different applications where Arnco100XT might be used. It is therefore the sole responsibility of users ofArnco 100XT to ensure that a.) an acceptable welding practice isadopted alongside these guidance notes as an aid to defining a detailedwelding procedure for a particular set of circumstances and b.) that such aprocedure is followed in practice. If in doubt, please contact an Arncorepresentative for further assistance.

As with the previous manuals, Arnco Technology hopes that thispublication will facilitate a better understanding of drilling equipmenthardbanding technology. Arnco Technology is constantly researching anddeveloping new products and new applications which will be introducedwhen they have been proven to work successfully in the field. Any questionsabout this manual or Arnco 100XT™ may be addressed to:

ARNCO TECHNOLOGY TRUST, LIMITED5915 BRITTMOORE ROAD

HOUSTON, TEXAS 77041-5619Telephone: (713) 466-9535

Fax: (281) 552-3555Email: [email protected]

Website: www.arncotech.com


ARNCO TECHNOLOGY POLICY STATEMENTJuly 1, 2001

Arnco Technology Trust Limited (Arnco) is pleased to announce anindustry leading warranty for its current range of hardbanding

products.

Arnco is the world leader in drill string hardbanding products. The Arnco 100XT™ has beenan extremely effective and trouble free product. However, as with any welding process, theadherence to the recommended application parameters is critical to the integrity andperformance of the finished product.

Customers and end users have long sought a better way to assure that once the products areapplied, they will work without failure.

Arnco has developed a new program to better assure such a result, while giving ourcustomers 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 independentmonitor.

This procedure will give our customers a verification that the Arnco specified parametershave been properly adhered to by monitoring the application to assure compliance with thosespecifications. Once verified and approved, the warranty provides that, in the unlikely eventof any specific defect occurring in the Arnco hardbanding as a direct result of the technicalperformance of the Arnco product used, then Arnco will replace, in full, the faulty hardbandingat Arnco’s expense. Please see the following page for the specific provisions of the warrantyand its limitations.

* The “Arnco Recommended Procedures Manual” is available at no cost direct fromArnco. For a copy, please contact:

Arnco Technology Trust Limited5915 Brittmoore Road, Houston, Texas 77041-5619, USA

Telephone: (01) 713-466-9535 Fax: (01) 281-552-3555E-Mail: [email protected] Website: www.arncotech.com


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 “ArncoRecommended Procedures Manual”

4. An independent failure analysis will be performed to determine the cause ofthe failure. If the failure is caused by the product or application, then Arncowill be responsible for the repair as stated. If it is caused by the drillingconditions, etc. then the cost of the repair will be the responsibility of thecustomer.

Limitations

1. Limited to the cost of removal of defective hardbanding, application of abutter pass and reapplication of the new hardbanding only, includingnecessary inspections involved in the hardbanding application.

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

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


SECTION I. TYPES OF ARNCO 100XT™ HARDBANDING

1.1 RAISED HARDBANDING

RAISED HARDBANDING IS STRONGLY RECOMMENDED ON ALL TOOL JOINTS FOR MAXIMUM CASING AND TOOL JOINT PROTECTION

1.1.1 A recess groove is machined into the 18° elevator shoulder and filled flushwith Arnco 100XT . One layer is then applied raised on the tool joint O.D. for aspecified length. Normally, 3” of hardbanding is applied on the Box O.D. and, as arecommended option, 2” is applied on the Pin O.D. Instead of the full length of thetool joint contacting the inner surface of the casing or the open hole wall, the Arncohardband 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 minimalcontact with the inside surface of the casing or open hole wall. This is of concernwhen drilling or tripping in and out of the well bore.

1.1.3 Arnco 100XT hardbanding applied in this manner also reduces thepossibility of heat checking occurring on the tool joint surface. Instead of the tooljoint 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 andrequire removal and re-application. The drill string would then be salvaged andcontinue to be utilized.

1.1.4 When 100XT hardbanding makes contact with the inside of the casing, thelow coefficient of friction reduces the torque and drag experienced in extendedreach or high-angle wells. As a result, this reduction in torque and drag shouldreduce fuel cost.

1.1.5 When application is performed on new or used tool joints in a non-millapplication (as performed with portable field equipment), it may not be necessary toapply or re-apply hardbanding to the 18° elevator shoulder. The shoulder areashould be visually inspected to determine if it is in serviceable condition. This typeof raised application for new or used tool joints in a non-mill application is illustratedin Figure 1.2.

NOTE: Refer to Section II. of this manual for detailed information concerningapplication on used material.


ARNCO 100XT™

RAISED APPLICATION

2" LP LB 3"

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

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

Figure 1.1


ARNCO 100XT™

RAISED NON-MILL APPLICATION

2" LP LB 3"

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

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

Figure 1.2


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 maximumresults because the tool joint O.D. begins to wear simultaneously with thehardbanding.

1.2.2 For a Flush Hardband application, a recess groove is machined into theentire hardband area of the tool joint and filled with Arnco 100XT™ flush with theO.D. of the tool joint. The hardband area normally includes the 18° elevatorshoulder. This type of application for new, used or rebuilt tool joints is illustrated inFigure 1.3.

NOTE: Refer to Section II of this manual for detailed information concerningapplication on used material.

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


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" HFlush with OD,

+ 1/32", -0"

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

Figure 1.3


SECTION II. PREPARATION GUIDELINES

2.1 GENERAL 100XT™ APPLICATION INFORMATION

2.1.1 Hardband Width: It has become a common practice to order drill pipe withextra long tool joints. With the advent of the high torque type tool joints, the total length of thecombined tool joints may be as much as 36” in length. To increase the bearing effect of theselong tool joints, Arnco recommends applying 2” on the pin tool joint in addition to a 3” or widerband on the box tool joint.

2.1.2 Weld Bead Width: Arnco recommends that a finished weld bead be 1” inwidth. This results in a smoother, more uniform bead. The unit operator should determinehow well the equipment can produce the highest degree of workmanship to attain a flat orslightly convex weld bead profile. Oscillation width and adequate overlap can be adjusted toachieve the desired effect.

2.1.3 Pre-Heat: Preheating of the tool joint or drill collar must be performedregardless of the O.D. or ambient temperature of the steel. Inadequate preheating of theparent steel may cause undesirable cracking in the parent metal. Applicators should refer tothe preheat temperature parameters listed in Section III of this manual.

2.1.4 Slow-Cooling: The hardband unit operator must control the cooling rate of thehardbanded tool joints. In order to ensure the required slow cooling, the tool joints need to bewrapped immediately in thermally insulated blankets or canisters. This wrapping operationand subsequent slow cooling must take place in “still air”. The use of shop ventilation fansshall 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 cooleddown to less than 150ºF (66ºC).

2.1.5 Grinding: Repair grinding to contour overlap areas of the weld bead or toremove spatter or minor protrusions shall be performed as necessary. Heavy, continuousgrinding with stationary grinding wheels is not necessary and should not be performed.

2.1.6 Elevator Shoulder: When welding is required on the 18° elevator shoulder,the unit operator and inspector must pay close attention to the weld profile of the finishedweld bead. If the weld bead height on the 18° elevator shoulder exceeds that of the tool jointshoulder itself, it is necessary to remove that excess height to make it flush with the tool jointshoulder. Any raised weld metal on the 18° elevator shoulder may result in interference withthe elevator’s operation.

2.1.7 Fingers: When “fingers” are required on the 18° elevator shoulder, they alsomust be flush. They may be applied with the hardbanding unit or with hand-held weldingequipment (i.e. MIG gun). If the tool joint has been previously hardbanded and has cooled toless than the required preheat temperature, the tool joint must be preheated again to therequired temperature prior to application of the fingers. Arnco has no opinion on the use offingers, but it has become more accepted that fingers with casing friendly hardbanding arenot applied.


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 thewire Positive (DCEP). Reverse polarity (DCEP) is to be utilized at all times regardless of thetype of steel that the hardband is being applied onto.

2.2.2 The welding equipment should have a clean grounding system that will notresist the flow of electric current. The resistance can be seen as heat build-up in the weldinglead 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 thewelding torch concentric to within .030” ( ,762mm) and at a constant uniform speed ofbetween 60 and 200 seconds per revolution. The tool joint O.D. determines the speed atwhich to rotate the tool joint.

2.2.4 The equipment must have the ability to move the welding torch from verticalcenter so that welding takes place on the uphill side of the tool joint as it is being rotated. Forthis “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, inthe direction of the rotation, to between 17-19 degrees as measured from vertical center ofthe tool joint. For this “Torch Angle”, refer to the Recommended Welding Parametersillustrated 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 slightlyconvex, weld bead profile. Not having both of these adjustments available becomesa 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 standoffdistance of 5/8” (15,9mm) to 1” (25,4mm), from the welding surface and at approximately 50to 90 oscillations per minute.

2.2.7 The equipment must be able to move the torch, parallel to the tool joint axis, fora minimum distance of 4” (102mm). A longer distance, of 6” to 12” (153mm-305mm) ispreferred, especially when hardbanding drill collars or extra long tool joints.

2.2.8 Welding equipment should include a wire feed system capable of feeding thewire through the torch at a variable, uniform speed without damaging the surface or theshape of the wire. Special wire-feed rollers designed for feeding soft-skinned, flux-coredwire should be utilized.


2.2.9 A 100%, pure CO2 shielding gas must be utilized when welding100XT™. The regulated flow must be controlled to deliver 30 to 35 CFH (14-16.5 LPM) tothe arc area.

2.2.10 When welding is performed on the 18° elevator shoulder, the equipment mustbe 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 uniformtemperature from 150°F to 700°F (66°C to 371° C). Refer to Section III of this manual forpreheat 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 thetemperature 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 isonly a surface heat and not a soak heat.

f. If it is determined that it is a surface heat, continue preheating until thetemperature drop is within the tolerances of a soak heat.

2.2.13 The hardband unit operator must control the cooling rate of the hardbandedtool joints. In order to ensure the required slow cooling, the tool joints need to be wrappedimmediately in thermally insulated blankets or canisters. This wrapping operation andsubsequent slow cooling must take place in “still air”. The use of shop ventilation fansshall 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 cooleddown to less than 150ºF (66ºC).

2.2.14 When hardbanding drill pipe tool joints, the ends of the drill pipe should beclosed to prevent a draft, or “chimney effect”, through the drill pipe. This becomes extremelycritical when hardbanding during windy or cold-air conditions, especially where portableequipment is utilized. The use of closed-end protectors, or applying tape over the wrench-hole openings on steel protectors, should be sufficient to prevent the drafting of air throughthe inside of the drill pipe.


2.3 MATERIAL PREPARATION

NOTE: Preparation of the hardband area must be performed to minimize, if noteliminate, foreign matter becoming an impurity in the molten weld puddle and toensure a good fusion bond with the parent metal. Preparation must be performedwhen 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 andfree 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 cleanweld surface for hardbanding new tool joints. Perform a visual inspection of the tooljoint O.D. surface after buffing. “Buffing” the tool joint surface does not alwaysproduce 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 storagecompounds. This will ensure a much cleaner welding process and eliminate theprobability of the lubricant or compound igniting during the preheat.

d. When Raised hardbanding is required on new or used unhardbanded tooljoints, it is sometimes necessary to machine a shallow, .015"(,38mm), recess grooveinto 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 beexamined for eccentric wear caused by downhole drilling conditions. The concentricityof the tool joint should be within .030” (,76mm) of the center axis in order to apply aneven 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 weldbead.

f. Determine the integrity of the existing hardbanding. If any cracking, spalling,chipping or void areas on the existing hardbanding are apparent, the hardbandingmust be removed. The tool joint should then be inspected to ensure that no crackshave propagated into the parent metal. In addition, if cracking from a chromehardbanding is evident, the hardbanding must be removed prior to application ofArnco 100XT .


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 pointthat reapplication is necessary, first ensure that the items listed in previous paragraph 2.3.1are reviewed prior to re-application. For Existing 100XT™, cracks should not be present. Ifthe existing layer contains cracks, then the layer must be removed. Inspect for cracks in theparent 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 jointrebuilt, prior to re-application of any hardbanding.

b. To maintain a crack-free weld bead, 100XT™ must not be applied over anyother chrome hardbanding, including ARNCO 200XT™!

NOTE: If you have any questions concerning application of100XT™ over any hardbanding, contact your Arnco representativeprior to proceeding.

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

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

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


ARNCO 100XTRECOMMENDED WELDING PARAMETERS

"TORCH SETTINGS"

"X" Distance ranges between ½" (12,7mm) and 1-1/2" (38,1mm) T.I.R. +/- .015" ( ,38mm)

PROCESS FCAW (AUTOMATIC)SHIELDING GAS 100% CO2 @ 30-35CFH (14-16.5LPM)FILLER METAL Mild Steel WireELECTRODE SIZE 1/16" (1,6mm)PREHEAT 150°F (66°C) to 700°F (371°C)CURRENT TYPE / POLARITY DCEP (REVERSE)AMPERAGE 240 – 320 ampsVOLTAGE 24 – 30 VDCOSCILLATION SPEED 60 – 120 Oscillations per minuteOSCILLATION WIDTH .750" (19,0 mm) to 1.0" (25,4 mm)WELD BEAD OVERLAP .125" (3,2 mm) to .250" (6,4 mm)POST WELD TEMPERING NOT REQUIREDPOST WELD COOL DOWN COVERED, IN STILL AIRINTERPASS TEMPERATURE 850°F (454°C) MAXIMUM

Figure 2.1


ESTIMATED USAGE OF 100XT™ HARDBANDING WIRE

Tool Joint Pounds Per Pounds Per Tool Joint Width of Hardbanding Diameter Linear Inch .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

7" .586 .440 .586 1.172 1.758 2.198 2.344

7-1/4" .607 .455 .607 1.214 1.821 2.276 2.428

8" .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

NOTE: These figures are theoretical based on deposition rates for 1/16" diameter wire and3/32" thickness. If you deposit 4/32”” thickness, you will consume 33% more wire. It isadvisable to perform your own tests to determine actual usage rates for your operation.

Table 2.1 100XT™ USAGE CHART


SECTION III. APPLICATION GUIDELINES

SPECIAL NOTATION FOR WELDING PROCEDURES

The following specific welding procedures are to be used as guidelines fordeveloping your own particular written welding procedure. They list the vitalprocedures for applying Arnco 100XT™ onto AISI 4137, 4145-HT and 1340 steels. Itwould be very difficult to write a recommended procedure for every conceivableapplication, 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 representativePRIOR TO WELDING. They will assist you in developing one to meet your specificrequirement. The procedures on the following pages consist of those specificallyfor:

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 withTungsten Carbide, and the limitations for application over ALL ChromeHardbanding

AISI 4145-HT STEEL AND AISI 1340-HT STEEL

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

• 100XT™ applied onto used heavy weight drill pipe (Hevi-Wate or Spiral-Wate), drill collars and various other drilling equipment previouslyhardbanded with Tungsten Carbide and the limitations for application overALL Chrome Hardbanding


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, ensurethat the necessary equipment and material preparation has been performed asrecommended in Section II of this manual.

3.1.2 Applicators are strongly advised to use a “test piece” or ‘practice joint” of thesame diameter, thickness and steel type to fine tune the welding equipment prior to startingproduction. Operators can utilize the Hardband Setup Worksheet (Attachment I) includedwith this manual to document the equipment settings necessary to hardband each size tooljoint. 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 utilizeReverse Polarity (DCEP). This will ensure the proper weld fusion, penetration and depositionof the 100XT™ onto the parent metal.

3.1.4 When welding with 100XT™, a 100%, pure CO2 shielding gas must beutilized. The regulated flow should be adjusted to deliver 30-35 CFH (14-16.5 LPM) to thewelding arc.

3.1.5 For a particular O.D. of tool joint, select the proper Preheat TemperatureRange listed below:

Tool Joint O.D. Preheat Temperature ___3-1/8” to 4-3/8" 150°F to 200°F (66°C to 93°C)4-3/4” to 5-1/4” 200°F to 250°F (93°C to 121°C)5-1/2” to 6-1/4” 400°F to 500°F (204°C to 260°C)6-3/8” to 6-7/8” 400°F to 600°F (204°C to 316°C) 7” to 7-7/8” 500°F to 600°F (260°C to 316°C)8” to 8-1/2”(nom.) 600°F to 700°F (316°C to 371°C)8” to 8-1/2”(w/5"id.)* 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; onefor each of the minimum and maximum temperatures of the range. The unit operator mustensure that the desired, preheat temperature range is controlled. Experience has taught usthat excessive preheat can distort the weld bead profile and insufficient preheat cannegatively affect the metallurgy of the weld as well as the parent metal.

NOTE: Arnco does not recommend the use of tempstiks, as they are notaccurate. When tempstiks are used on the prepared hardband surface, the residuemust be removed prior to welding. If not, the residue becomes an impurity that mayaffect the fusion bond of the 100XT to the prepared surface.


3.1.6 The Maximum Interpass Temperature for all 100XT™ hardbanding proceduresis 850°F (454°C).

3.1.7 The unit operator should adjust the hardband equipment to attain a flat orslightly convex weld profile as illustrated in Figure 4.3.1, contained in the Post-Weld MaterialInspection 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. Inaddition, each weld bead should meet the required hardband height (dimension H) as shownin 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 theweld bead is consistently tied into the side of the recess groove in the tool joint shoulder. Inaddition, the weld bead shall not exceed the surface of the adjacent elevator shoulder asexplained in paragraph 2.1.4, of this manual.

3.1.9 The hardband unit operator must control the cooling rate of the hardbandedtool joints. In order to ensure the required slow cooling, the tool joints need to be wrappedimmediately in thermally insulated blankets or canisters. This wrapping operation andsubsequent slow cooling must take place in “still air”. The use of shop ventilation fansshall 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 cooleddown to less than 150ºF (66ºC).

3.1.10 When the 100XT™ is applied over a layer of Tungsten hardbanding, it ispossible that micro-cracks may appear in the new layer. These micro-cracks rarely occur andhave not been found to be detrimental to the integrity of the 100XT™. The few instanceswhere 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” inlength. When this micro-cracking is seen, it must be investigated by utilizing a probe grinderto determine the depth of the crack and, if necessary, remove it. The hardband area that isremoved can be repaired by preheating the tool joint to the specified temperature andperforming a patch-weld repair.

3.1.11 To maintain a crack-free weld bead, the 100XT™ can be applied over itselfbut 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.


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 orused, ensure that the necessary equipment and material preparation has been performed asrecommended in Section II of this manual.

3.2.2 As with AISI 4137 Steel, applicators are urged to use a “test piece” or “practicejoint” of the same size and steel type to fine tune the welding equipment prior to startingproduction. 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 CO2 shielding gas must beutilized. The regulated flow should be adjusted to deliver 30-35 CFH (14-16.5 LPM) to thewelding arc.

3.2.5 For AISI 4145-HT or AISI 1340-HT Steel of a particular O.D., select the properPreheat Temperature Range listed below:

Tool Joint/Drill Collar O.D. Preheat Temperature __Less than 4-3/4” 200°F to 300°F (93°C to 149°C)4-3/4” to 5-1/4” 300°F to 400°F (149°C to 204°C)5-1/2” to 6-1/4” 400°F to 500°F (204°C to 260°C)6-3/8” to 6-7/8” 400ºF to 600ºF (204ºC to 316ºC) 7” to 7-7/8” 500ºF to 600ºF (260ºC to 316ºC)8" to 8-1/2"(nom.) 600°F to 700°F (316°C to 371°C)8" to 8-1/2"(w/5"id.)* 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; onefor each of the minimum and maximum temperatures of the range, The unit operator mustensure that the desired, preheat temperature range is controlled. Experience has taught usthat excessive preheat can distort the weld bead profile and insufficient preheat cannegatively affect the metallurgy of the weld as well as the parent metal.

NOTE: Arnco does not recommend the use of tempstiks, as they are notaccurate. When tempstiks are used on the prepared hardband surface, the residuemust be removed prior to welding. If not, the residue becomes an impurity that mayaffect the fusion bond of the 100XT to the prepared surface.


3.2.6 The Maximum Interpass Temperature for all 100XT™ hardbanding procedures is850°F (454°C).

3.2.7 The unit operator should adjust the hardband equipment to attain a flat orslightly convex weld profile as illustrated in Figure 4.3.1, contained in the Post-Weld MaterialInspection 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. Inaddition, each weld bead should meet the required hardband height (dimension H) as shownin 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 theweld bead is consistently tied into the side of the recess groove in the tool joint shoulder. Inaddition, the weld bead shall not exceed the surface of the adjacent elevator shoulder asexplained in paragraph 2.1.4, of this manual.

3.2.9 With AISI 4145-HT Steel, a slow cool-down, after hardbanding is extremelycritical. These types of material are used in a transition zone between pieces of drillingequipment that have widely varied wall thickness’ and areas of high stress concentration. Theresult of rapid cool-down is usually catastrophic. For this reason, the hardband unit operatormust control the cooling rate of the hardbanded tool joints. In order to ensure the requiredslow cooling, the tool joints need to be wrapped immediately in thermally insulated blanketsor canisters. This wrapping operation and subsequent slow cooling must take place in “stillair”. The use of shop ventilation fans shall have the airflow directed away from thehardbanded tool joints during handling, wrapping and slow cool storage. The ends ofthe pipe must be closed off to prevent a drafting effect through the inside of the pipe. Anygrinding 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 mostcritical areas for application of any hardbanding. Great care and special attentionmust be given to this area to ensure that the welding and post-weld procedures arestrictly 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 ispossible that micro-cracks may appear in the new layer. These micro-cracks rarely occur andhave not been found to be detrimental to the integrity of the 100XT™. The few instanceswhere 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” inlength. When this micro-cracking is seen, it must be investigated by utilizing a probe grinderto determine the depth of the crack and, if necessary, remove it. The hardband area that isremoved can be repaired by preheating the tool joint to the specified temperature andperforming a patch-weld repair.

3.2.11 To maintain a crack-free weld bead, the 100XT™ can be applied over itselfbut not over any other chrome hardbanding, including Arnco 200XT™.

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


SECTION IV. INSPECTION GUIDELINES

4.1 Pre-Weld Equipment Inspection

4.1.1 Ensure that the proper wire feed assembly (for soft-skinned cored wire) and torch tipare 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 rollersto 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 weldbead 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 oscillationparameters are set per your welding procedures. These adjustments are based on thehardbanding 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 accuratelyregulated.

4.2 Pre-weld Material Inspection

4.2.1 Ensure that the material to be hardbanded is clean and free of all foreign matter suchas 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 sothat 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 thatthe 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 anycracks. Suggested inspections may include bi-directional wet or dry magnetic particleinspection of that surface area. This eliminates the possibility of welding over pre-existingcracks or defects. Experience has taught us that many times when existing hardbanding,especially tungsten carbide, is removed, it creates heat checking (small surface cracks) inthe body of the steel. Heat checking can also be caused by high axial loading against the tooljoints during drilling operations and has nothing to do with existing hardbanding. With eithersituation, when cracks are welded over during the hardband application, it most likely willcause these cracks to propagate into the parent metal. Therefore, it is very important that acritical tool joint inspection be performed after removal of existing hardbanding and prior tohardbanding or re-hardbanding a tool joint.


4.3 Post-Weld Material Inspection

NOTE: It is important to remember that hardbanding is a simple process andthe inspection of hardbanding is equally simple. It is also very easy to beoverly critical with acceptance and rejection criteria. A hardband is consideredacceptable if the general appearance and the dimensional measurements arewithin the product guidelines.

4.3.1 Visual Inspection of the 100XT™ hardband area consists of all of the followingcriteria.

4.3.1.1 Any weld bead with a crack visible to the naked eye is suspect for furtherinvestigation. Application of 100XT™ onto new tool joints, usedunhardbanded tool joints or over existing 100XT™ should not producecracks. 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 stresscracking 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 andminor protrusions are considered rejectable unless removed by grinding. Overlap areasshould be ground to conform to the overall hardband profile. Spalling of the weld bead is notacceptable.

4.3.1.3 The weld bead profile shall be flat to slightly convex and consistent throughoutthe entire hardband area. If the weld profile is “humped” in the middle of the weld bead, it issometimes possible to repair with grinding. If it is apparent that lengthy grinding isnecessary to remove the hump, the hardband area should be removed and the tool jointrebuilt before reapplying 100XT™. This hump is normally caused by improper torch angle oroffset 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 isconsidered reject. A concave profile may be caused by improper torch angle or offset andcan usually be corrected. In addition, this concave profile can also be the result of excessivepreheat 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. Itis sometimes possible to repair, by spot-welding, those void areas that do not tie-in properlywith the adjacent parent metal. However, this repair welding should not include welding asingle, narrow bead around the entire circumference of the tool joint. Proper overlap andoscillation width of a weld bead shall be adjusted to attain the proper tie-in.


4.3.1.6 Tie-ins with adjacent weld beads should be consistent to prevent deep furrowsor voids between weld beads. Again, repair welding should not include the welding of asingle, narrow bead around the entire circumference to correct a void area. Proper overlapand oscillation width of a weld bead to another shall be adjusted to attain an overall, flat orslightly convex hardband area. The acceptable weld bead profiles are illustrated below inFigure 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 toremain on the weld surface. In addition, welding slag is normally generated during thewelding process and, if allowed to accumulate in the torch nozzle, will fall out and contaminatethe weld puddle. The unit operator should keep the torch assembly clean. At a minimum, thetorch 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 theweld 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 areashall conform to the diagrams illustrated in Section I of this manual or to customerrequirements. The hardband height and overall length can be easily measured with the use ofa 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 weldbeads. Excessively high areas should be repaired by minor grinding if those areas exceedthe tolerance for maximum specified height.


CLOSING REMARKS

Again, we urge all users of this manual to treat it as a guide to creating yourown procedures to meet your particular requirements. If you stay within theserecommended parameters, you can be assured of a quality 100XT™ hardbandapplication.

We express special thanks to all our end users, applicators and inspectors fortheir cooperation and input into the development of Arnco 100XT™.

In closing, let us at Arnco Technology assure all of you that this hardbandingcan be extremely effective in reducing casing wear and tool joint wear if appliedproperly and used to its optimum potential. While we recognize the fact that it iscompletely different to apply than other hardbandings, it is no more difficult if theproper procedures are followed. It is usually when applicators operate outside therecommended parameters that they experience difficulties.

If a situation arises where 100XT™ must be applied outside the Arncorecommended procedures, CALL US FIRST!

Thank you!

ARNCO TECHNOLOGY TRUST, LTD.


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


ATTACHMENT 2

Arnco 100XT Manual

Documents

shop ventilation

thermally

open hole

subsequent

hardband setup

unhardbanded

normal tool

slow cool