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美国安科技术公司 300XT 钻杆接头耐磨带焊接工艺 - 版本 1.2 - 2005-10-01 - 英文版


RECOMMENDED PROCEDURES MANUAL

FOR THE PREPARATION, APPLICATION and INSPECTION

OF

ARNCO 300XT? HARDBANDING
VERSION 1.2 October 1, 2005

CONFIDEN

TIAL

TABLE OF CONTENTS
REVISION HIGHLIGHTS FOR THIS MANUAL FOREWORD POLICY STATEMENT WARRANTY PROVISIONS AND LIMITATIONS Section 1: TYPES OF ARNCO HARDBANDING 1.1 1.2 Section 2: Raised Hardbanding Flush Hardbanding

PREPARATION GUIDELINES 2.1 2.2 2.3 2.4 2.5 2.6 General 300XT? Application Information Welding Equipment Material Preparation Recommended Welding Parameters 300XT? Usage Chart Temperature Conversion Chart

Section 3:

APPLICATION GUIDELINES 3.1 3.2 3.3 300XT? Applied onto AISI 4137 Steel Tool Joints 300XT?Applied onto AISI 4145-HT or AISI 1340-HT Steel Heavy Weight Drill Pipe, Drill Collars and Other Drilling Equipment 300XT? Re-Application Procedure

Section 4:

INSPECTION GUIDELINES 4.1 Arnco 300XT? Inspection Criteria

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

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REVISION HIGHLIGHTS FOR THIS MANUAL Several items have been changed within this Version 1.2 manual. These changes are the result of Arnco Technology’s ongoing effort to provide the best hardbanding products and procedures available to the drilling industry and its technology. ? In Section 3 a 300XT? Re-Application Procedure has been added. This procedure contains various information regarding the inspection of worn 300XT?hardbanding. It includes inspection criteria for “excessive porosity”, as well as information for the removal and re-building of the hardband area. ? In all applicable sections, it is noted that the use of an Argon/CO2 shielding gas mixture can be utilized when welding with 300XT?. The Applicator now has a choice to use a 100% Pure CO2 shielding gas or a specified mixture of Argon/CO2 as referenced in the procedures. ? Over the past three to four years more end-users have wanted Applicators to apply a hardband thickness of between 3/32” to 4/32” (~2,38mm to ~3,17mm). Arnco has thought it best to revise the thickness dimension of the hardband as shown in the diagrams for Raised Applications. The new thickness dimension is 4/32”, +0”, -1/32” (~3,17mm, +0mm,-0,8mm). ? Concerning the Slow-Cooling of the 300XT? after application; In all applicable sections, the use of slow-cooling methods such as thermal blankets or canisters now states that;
“The blankets or canisters shall remain on the tool joint ends until the tool joint has cooled down to less than 150°F (66°C)” and any repair grinding shall be performed “after the tool joint has been cooled down to less than 150°F (66°C)”.

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FOREWORD
While Arnco 300XT? is a Fe (iron) based wear resistant alloy hardbanding, it is a completely different metallurgical design which is significantly more effective against casing wear than Arnco 200XT?. Arnco 300XT? has better open-hole wear properties than spherical Tungsten Carbide hardbanding. There is also a key cosmetic difference in that Arnco 300XT? does exhibit minor micro-cracking, and significantly less than Arnco 200XT? in the deposited metal, provided the recommended procedures in this manual are followed. The micro-cracking in Arnco 300XT? is totally different than the stress cracking in Arnco 200XT?. As with the Arnco 100XT? and 200XT? manuals, this is a manual of general recommended procedures for various possible applications of Arnco 300XT?. This information is provided for general guidance purposes only as it is impossible to anticipate all the different applications where Arnco 300XT? might be used. It is therefore the sole responsibility of users of Arnco 300XT? 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 the best understanding of drilling equipment hardbanding technology. Arnco Technology is constantly researching and developing new products and new applications that will be introduced when they have been proven to work successfully in the field. Any questions about this manual or Arnco 300XT? may be addressed to: ARNCO TECHNOLOGY TRUST, LIMITED 3657 BRIARPARK DRIVE HOUSTON, TEXAS 77042-5205, USA Telephone: (832) 214-5200 Fax: (832) 214-5205 Email: Arnco@arncotech.com Website: www.arncotech.com

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ARNCO TECHNOLOGY POLICY STATEMENT
Arnco Technology Trust Limited (Arnco) maintains this industry leading warranty for its current range of hardbanding products.
Arnco Technology is the world leader in drill string hardbanding products. 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 continued to seek better ways to ensure that once the products are applied, they will work without failure. Arnco Technology has developed this program to better ensure such a result, while giving our customers a warranty with great clarity. This warranty applies only to Arnco 300XT? and Arnco 100XT hardbanding when applied in full conformance with the applicable Arnco Recommended Procedures Manual*, as witnessed and verified 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 Technology. For a copy, please contact: Arnco Technology Trust Limited 3657 Briarpark Drive, Houston, Texas 77042-5205, USA Telephone: (01) 832-214-5200 Fax: (01) 832-214-5205 E-Mail: Arnco@arncotech.com Website: www.arncotech.com

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PROVISIONS AND LIMITATIONS
Provisions
1. 2. 3. 4. Hardbanding must be applied by an Arnco Certified Applicator. 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. Hardbanding must be applied strictly in conformance with the current Arnco Recommended Procedures Manual. 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. Not included is the potential loss of time or revenue of the customer in the event of defective hardbanding. 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.

2. 3.

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SECTION 1: TYPES OF ARNCO 300XT? HARDBANDING 1.1 RAISED HARDBANDING RAISED HARDBANDING IS STRONGLY RECOMMENDED ON ALL TOOL JOINTS FOR MAXIMUM CASING AND TOOL JOINT PROTECTION 1.1.1 When specified by the customer, an optional recess groove is machined into the 18° elevator shoulder and filled flush with Arnco 300XT?. One layer is then applied raised on the tool joint O.D. for a specified length. Normally 3” (~76mm) of hardbanding is applied on the Box O.D. and, as a recommended option, 2” (~50mm) 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 300XT? 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 subsequently require its removal and re-application. The drill string could then be salvaged and continue to be utilized. 1.1.4 When 300XT? 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 2 and 3 of this manual for detailed information concerning application onto used material.

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ARNCO 300XT? RAISED APPLICATION

2" (~50mm) 4/32", +0”, - 1/32"
(3,17mm, +0mm, -0,80mm)

LP H

LB

3" (~76mm) 4/32", +0”, - 1/32"
(3,17mm, +0mm,-0,80mm)

** Apply 300XT? flush on 18° shoulder, +0, - 1/32" (+0, -0,80mm); When specified, the Taper Weld Bead width shall be a minimum of 3/4” (19mm)

Figure 1.1

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ARNCO 300XT? RAISED NON-MILL APPLICATION

2" (~50mm) 4/32", +0”, - 1/32"
(3,17mm, +0mm, -0,80mm)

LP H

LB

3" (~76mm) 4/32", +0”, - 1/32"
(3,17mm, +0mm, -0,80mm)

On Box End, apply 300XT? approximately 3/8", +/- 1/8" from the 18° shoulder (9,52mm, +/- 3,17mm)

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 300XT?, applied in this manner will not yield maximum results because the tool joint OD 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 300XT? 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. 1.2.3 Application of 300XT?on the Pin O.D. is a recommended option. NOTE: Refer to Section 2 and 3 of this manual for detailed information concerning application on used material.

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ARNCO 300XT? FLUSH APPLICATION

2" 3/32" ,+0, - 1/32" (2,38mm +/- 0,80mm)
Flush with O.D., + 1/32", -0" (+0,80mm,-0)

LP D H

LB

3" 3/32", +0, - 1/32" (2,38mm +/- 0,80mm)
Flush with OD, + 1/32", -0" (+0,80mm,-0)

** Apply 300XT? flush with 18° shoulder, +0, - 1/32" (+0mm, -0,80mm) When specified, the Taper Weld Bead width shall be a minimum of 3/4” (19mm)

Figure 1.3

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SECTION 2: GENERAL GUIDELINES 2.1 GENERAL 300XT? APPLICATION INFORMATION

2.1.1 Hardband Width: It has become a common practice to order drill pipe with 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” (914mm) in length. To increase the bearing effect of these long tool joints, Arnco recommends applying 2” (50mm) on the pin tool joint in addition to a 3” (76mm) or wider band on the box tool joint. 2.1.2 Weld Bead Width: Arnco recommends that the finished weld bead be 1-1/8” (~28,6mm) in 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, of 1/8” (3,17mm) 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 shall refer to Section 3 of this manual for the specific preheat temperature ranges for the type of steel and OD size of the parent metal and ensure that the pre-heat is a “soak” heat and not a surface heat. 2.1.4 Slow-Cooling: The Applicator must “slow-cool” the hardbanded tool joints. To ensure the required slow cooling, the tool joints need to be wrapped immediately in thermally insulated blankets or canisters. 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 wrapping and subsequent slow cooling must take place in “still air”. The blankets or canisters shall remain on the tool joint ends until the tool joint has cooled down to less than 150°F (66°C). 2.1.5 Grinding: Repair grinding to contour overlap areas of the weld bead or to remove spatter or minor protrusions shall be performed as necessary after the tool joint has been cooled down to less than 150°F (66°C). Heavy, continuous grinding 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 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. 2.1.7 Fingers: When “fingers” are required on the 18° elevator shoulder, they also 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.

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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” (0,76mm) 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 configured 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” (~120mm) 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. 2.2.9 A shielding gas must be supplied to the arc when welding Arnco 300XT?. Arnco has learned from experience that either a Pure 100% Carbon Dioxide or a mixture of Argon and Carbon Dioxide gases can be utilized when welding. The specified Argon/CO2 gas mixtures are; a) 82%Ar/18%CO2 or b) 80%Ar/20%CO2 or c) 75%Ar/25%CO2. No other gas mixtures of Argon and Carbon Dioxide shall be utilized as they may negatively affect the weld. The regulated flow for all gases 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.

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2.2.11 The pre-heat 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 3 of this manual for the specific preheat temperature ranges for the type of steel and OD size of the parent metal. The heat applied should be a soak heat rather than a surface heat. 2.2.12 To determine if a soak heat is being applied, 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 Applicator must “slow-cool” 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. 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 wrapping and subsequent slow cooling must take place in “still air”. The blankets or canisters shall remain on the tool joint ends until the tool joint has cooled down to less than 150°F (66°C). Any grinding shall be done after the tool joint has cooled down to less than 150?F (66?C). 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 wrench-hole openings on steel protectors, should be sufficient to prevent the drafting of air through the inside of the 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 Material Preparation Information:

2.3.1.1 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. 2.3.1.2 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” of the tool joint surface does not always produce a clean weld surface, consequently, further cleaning may be necessary. Applicators are to determine the best method available to prepare the weld surface. 2.3.1.3 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 pre-heat. 2.3.1.4 When Raised hardbanding is required on new or used unhardbanded tool joints, it is sometimes necessary to machine a shallow, .015" (0,38mm), recess groove into the tool joint O.D. to give a clean, smooth and concentric weld surface. 2.3.1.5 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” (0,76mm) of the center axis in order to apply an even layer of hardbanding. If the eccentricity of the tool joint is greater than .030” (0,76mm) it may cause the welding arc to be erratic and produce an unacceptable weld bead. 2.3.2 Application of 300XT? onto Used hardbanded drill pipe: Refer to Sub-Section 3.3 for detailed application procedure of 300XT? onto used pipe.

NOTE: If you have any questions concerning application of 300XT? over any hardbanding, contact your Arnco representative prior to proceeding. 2.4 RECOMMENDED 300XT? WELDING PARAMETERS: The welding parameters for 300XT? hardbanding wire are the same as for 100XT? as 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 300XT? 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 300XT RECOMMENDED WELDING PARAMETERS "TORCH SETTINGS"

"X" Distance ranges between ?" (12,7mm) and 1-1/2" (38,1mm) “T.I.R.” +/- .015" (+/- 0,38mm) 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) See Specific Procedure in Section 3 DCEP (REVERSE) 240 – 320 amps 24 – 30 VDC Approx. 50-90 Oscillations/minute .750" (19,0 mm) to 1.0" (25,4 mm) .125" (3,17 mm) to .250" (6,35 mm) OPTIONAL COVERED, IN STILL AIR 850°F (454°C) MAXIMUM

Figure 2.1

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ESTIMATED USAGE OF 300XT? HARDBANDING WIRE
Tool Joint Diameter 4-1/2" 4-3/4" 5" 5-1/4" 5-1/2" 5-3/4" 6" 6-1/8" 6-1/4" 6-1/2" 6-5/8" 6-3/4" 7" 7-1/4" 8" 8-1/4" 8-1/2" Pounds Per Linear Inch .378 .398 .419 .440 .460 .481 .502 .513 .524 .546 .555 .565 .586 .607 .671 .697 .723 Pounds Per Tool Joint Width of Hardbanding .750" 1.00" 2.00" 3.00" 3.750" 4.00" .284 .299 .314 .330 .345 .361 .377 .385 .393 .410 .416 .424 .440 .455 .503 .523 .542 .378 .398 .419 .440 .460 .481 .502 .513 .524 .546 .555 .565 .586 .607 .671 .697 .723 .756 .796 .838 .880 .920 .962 1.004 1.026 1.048 1.092 1.110 1.130 1.172 1.214 1.342 1.394 1.446 1.134 1.194 1.257 1.320 1.380 1.443 1.506 1.539 1.572 1.638 1.665 1.695 1.758 1.821 2.013 2.091 2.169 1.418 1.493 1.571 1.650 1.725 1.804 1.883 1.924 1.965 2.048 2.081 2.119 2.198 2.276 2.516 2.614 2.711 1.512 1.592 1.676 1.760 1.840 1.924 2.008 2.052 2.096 2.184 2.220 2.260 2.344 2.428 2.684 2.788 2.892

NOTE: These figures are theoretical based on deposition rates for 1/16" (1,6mm) diameter wire and 3/32" (2,38mm) thickness. If you deposit 4/32” (3,17mm) 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 300XT? USAGE CHART

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SECTION 3:

APPLICATION GUIDELINES SPECIAL NOTATION FOR WELDING PROCEDURES

The following specific welding procedures can be used as a guideline for developing your own particular written welding procedure. These procedures provide vital information for application of Arnco 300XT? 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 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 ? ? 300XT? applied onto New or Used tool joints for OD sizes 3-1/8” to 8-1/2” (79,37mm to 215,90mm) 300XT? applied onto Used tool joints and the limitations for application over Other Hardbandings

AISI 4145-HT STEEL AND AISI 1340-HT STEEL ? ? 300XT? applied onto New or Used heavy weight drill pipe (Hevi-Wate or Spiral-Wate), drill collars and various other drilling equipment 300XT? applied onto Used heavy weight drill pipe (Hevi-Wate or SpiralWate), drill collars and various other drilling equipment and the limitations for application over Other Hardbandings

AISI 4137, AISI 4145-HT STEEL AND AISI 1340-HT STEEL ? 300XT? Re-Applied onto Used drill pipe tool joints, heavy weight drill pipe (Hevi-Wate or Spiral-Wate), drill collars and various other drilling equipment and the limitations for application over Other Hardbandings

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3.1

300XT?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 2 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 300XT? onto the parent metal. 3.1.4 When welding with 300XT?, a shielding gas must be supplied to the arc. Arnco has learned from experience that either a Pure 100% Carbon Dioxide or a mixture of Argon and Carbon Dioxide gases can be utilized when welding. These gas mixtures are; a) 82%Ar/18%CO2 or b) 80%Ar/20%CO2 or c) 75%Ar/25%CO2. Other gas mixtures of Argon and CO2 shall not be utilized as they may negatively affect the weld. The regulated flow for all gases must be controlled to deliver 30 to 35 CFH (14-16.5 LPM) to the arc area. 3.1.5 listed below: For a particular O.D. of tool joint, select the proper Preheat Temperature Range 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 always utilized correctly. However, if tempstiks are used on the prepared hardband surface, the residue must be removed prior to welding. If not, the residue can become an impurity that may affect the fusion bond of the 300XT? to the prepared surface.

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3.1.6 The Maximum Interpass Temperature for all 300XT? 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 ~1/8" (~3,17mm) and consistently “tie-in” with the edge of the 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 1 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 Applicator 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. 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 wrapping and subsequent slow cooling must take place in “still air”. The blankets or canisters shall remain on the tool joint ends until the tool joint has cooled down to less than 150°F (66°C). Any grinding shall be done after the tool joint has cooled down to less than 150?F (66?C). 3.1.10 When the 300XT? is applied, micro cracking will appear in the new layer. This micro cracking has been found not to be detrimental to the integrity of the 300XT?. 3.1.11 To maintain the preferred amount of micro cracking, the 300XT? can be applied over itself but not over some other hardbandings, including Arnco 200XT?. 3.1.12 optional. Post-Weld Tempering of the 300XT? on AISI 4137 tool joints is not required but

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3.2

300XT? 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 2 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, always utilize Reverse Polarity (DCEP). This will ensure the proper weld fusion, penetration and deposition of the 300XT? onto the parent metal. 3.2.4 When welding with 300XT?, a shielding gas must be supplied to the arc. Arnco has learned from experience that either a Pure 100% Carbon Dioxide or a mixture of Argon and Carbon Dioxide gases can be utilized when welding. These gas mixtures are; a) 82%Ar/18%CO2 or b) 80%Ar/20%CO2 or c) 75%Ar/25%CO2. Other gas mixtures of Argon and CO2 shall not be utilized as they may negatively affect the weld. The regulated flow for all gases must be controlled to deliver 30 to 35 CFH (14-16.5 LPM) to the arc area. 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) 500?F to 600?F (260?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 3.2.6 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 always utilized correctly. However, if tempstiks are used on the prepared hardband surface, the residue must be removed prior to welding. If not, the residue can become an impurity that may affect the fusion bond of the 300XT? to the prepared surface.

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3.2.7 The Maximum Interpass Temperature for all 300XT? hardbanding procedures is 850°F (454°C). 3.2.8 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 ~1/8" (~3,17mm) and consistently “tie-in” with the edge of the 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 1 of this manual. 3.2.9 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. 3.2.10 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 cooldown is usually catastrophic. For this reason the Applicator 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. 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 wrapping and subsequent slow cooling must take place in “still air”. The blankets or canisters shall remain on the tool joint ends until the tool joint has cooled down to less than 150°F (66°C). Any grinding shall be done after the tool joint 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. 3.2.11 When the 300XT? is applied, micro cracking will appear in the new layer. This micro cracking has not been found to be detrimental to the integrity of the 300XT?. 3.2.12 To maintain the preferred amount of micro cracking, the 300XT? can be applied over itself but not over some other chrome hardbandings, including Arnco 200XT?. 3.2.13 Post-Weld Tempering of the hardband area is optional, but not required. If tempering of the hardband area is desired, the following parameters are recommended: a) b) Post weld heat treat to 1075?F (580?C), +/- 50?F (10?C) for a maximum of 2 hours. Slow cool down to ambient temperature following PWHT process.

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3.3 3.3.1

300XT RE-APPLICATION PROCEDURE General Information

3.3.1.1 When used drill pipe, previously hardbanded with 300XT? has been worn to the point that reapplication is necessary, the existing 300XT? layer must first be cleaned and inspected. This is necessary to determine if the existing layer is intact and serviceable prior to the application of a new layer of 300XT?. Acceptable 300XT? hardband areas can then have a new layer of 300XT? applied per the application procedures for 4137, 4145HT and 1340HT steels as contained within this manual. 3.3.1.2 Arnco has determined, from previous testing and experience, that 300XT? can be applied over itself and over some, but not all, of the other types of hardbanding. The hardbanding wires that have been found to be metallurgically compatible with 300XT? are Arnco 100XT, Armacor-M, Tuboscope TCS-8000 and TCS-Ti. Those that are definitely not compatible with 300XT? are Arnco 200XT? and Pinnchrome. 3.3.1.3 Compatibility of the 300XT? with the various Tungsten applications can vary because of the amount of Tungsten particle content and quality of application. Specifically, if the particle content is too concentrated at or near the fusion line of the Tungsten application, subsequent spalling of the Tungsten layer from the parent metal can occur after the 300XT? is applied over the existing Tungsten layer. If the application of the previous Tungsten layer is suspect, then the layer should be removed and the hardband area rebuilt before a layer of 300XT ? is applied. 3.3.1.4 The owner of the drill pipe, as well as the applicator, should also note then when different hardbanding wires are applied one over another, the latest application, even if applied correctly, is only as good as the previous applied layer. If the previous layer was not applied per the manufacturer’s procedures (with respect to preheat, application or slow-cooling) spalling of the newly applied layer from the previous layer, as well as spalling at the fusion line from the parent metal, can occur. 3.3.1.5 Owners of drill pipe and Arnco Certified Applicators should consult Arnco before applying 300XT? over other types of hardbanding. 3.3.2 Cleaning of the Existing Hardband Area

3.3.2.1 Cleaning of the hardband area must be performed to remove all drilling mud, dirt, rust, oil, grease, thread compound, paint, etc. Utilizing a side-grinder & cup brush will usually produce a sufficiently clean surface for inspection and welding. 3.3.2.2 Washing of the hardband area with a soap or solvent solution may be necessary to ensure a clean surface, especially when an oil based mud was utilized during drilling operations.

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3.3.3

General Inspection of the Existing Hardband Area

3.3.3.1 The hardband area shall be visually inspected for existing crack widths, spalling, chipping, flaking and porosity and to identify the existing hardband. 3.3.3.2 As best as possible, the existing hardband needs to be identified to ensure compatibility with 300XT?. If the existing layer’s identity is unknown or found not to be compatible with 300XT?, then all the hardbanding must be removed and the hardband area rebuilt before application of a new layer of 300XT?. Traceability records provided by the owner and/or the applicator can help provide information regarding previous hardbanding. 3.3.3.3 Magnetic Particle Inspection (MPI-wet or dry) or Liquid-Penetrant Inspection (LPI) of the hardband area is usually performed during the inspection of the pipe ends to check for cracks that may have propagated from the edges of the hardband into the parent metal. Care should be taken when a “dry” MPI is performed so to not “mask” any cracks that may have propagated into the parent metal. Cracks in the hardband area not visible to the naked eye, yet seen by MPI or LPI, are not relevant for rejection, unless they extend from the hardband into the parent metal. 3.3.4 Specific Acceptance and Rejection Criteria for Used/Worn 300XT?

3.3.4.1 Crack widths within the existing 300XT? hardband area are acceptable if less than .010” (0,25mm) in width. 3.3.4.2 The number of, and spacing between, cracks can vary from joint to joint. There is no definite crack pattern that can be expected. A crack pattern with numerous cracks shall not be a cause for rejection. Usually the cracks that were visible at the hardband surface, after application, are not always visible after the 300XT? has worn flush to the tool joint OD. 3.3.4.3 Cracks can be oriented in any direction; longitudinal, oblique or circumferential. Usually any circumferential cracks that may be seen are less than 2.0” (50mm) in length. However, a single circumferential crack, not intersected by a longitudinal or oblique crack and centered in the middle of the weld bead shall be rejected; as this indicates rapid-cooling of the hardband when previously applied. A typical acceptable 300XT? crack pattern is shown in the photograph below;

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3.3.4.4 Spalling within the existing 300XT? hardband area, at the fusion line, shall be rejected. Some examples of spalling are shown in the photographs below. The photo on the right also has porosity which contributed to the spalling in small areas.

Spalling at the Fusion Line

Spalling from Porosity

Note: Do not confuse spalling with flaking or chipping. Spalling occurs when the hardband layer separates at the fusion line with the parent metal. Flaking or chipping occurs only within the thickness of the hardband layer. 3.3.4.5 Chipping or Flaking: Minor chipping or flaking of the existing 300XT? layer is acceptable only if the affected area is less than one square inch (1.0 in2 or 25.4mm2). Chipped or flaked areas can be ground smooth by hand-grinding to remove any sharp edges. If desired, a patch repair application of 300XT? over the ground area is acceptable if applied per the established procedures contained within this manual. The photograph shown below is an example of reject flaking that has areas that are larger than one square inch.

Flaking Within the Thickness of the Hardband Layer

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3.3.4.6 Porosity: The inspection of porosity to determine if acceptable, or reject, must include a decision based on the overall quality and workmanship of the previous application. Therefore, the inspector needs to have some basic knowledge of the hardband application process and what specifically causes porosity during welding. There are various interpretations of what is considered to be “excessive” porosity. Further, experience has proven that even when porosity was found “acceptable”, and when a new layer of hardbanding was applied, that more porosity then became visible. That is, it is possible that porosity can be contained within an existing layer and is not all visible at the surface. A common rejection criteria of some manufacturers and end-users is if the hole is “greater than 1/8” (3,17mm) in width and 1/16” (1,6mm) in depth”, it is reject. Or, if more than 5 holes are visible within a single 120° view of the hardband area, the hardband is reject. Some end-users have more strict reject/accept criteria established. Applicators should take note of any specific criteria established by their customer, as well as establish their own reject/accept criteria. In addition, experience has also proven that hardband areas that had excessive porosity do not always cause the hardband to chip, flake or spall. There has been hardbanding found that was inspected in the past that excessive porosity was not detected after application and/or was sometimes ignored during inspection. Such hardbanding remained intact and continued to wear flush to the OD of the tool joint. The criteria that follows is Arnco’ interpretation of reject vs. acceptable porosity. In all cases, the root cause of the porosity should be investigated and an attempt be made to eliminate it. a) Excessive porosity, that is continuous and contained in all of the hardbanding, is usually caused by the total absence or interruption of gas flow at the arc during welding. This type of porosity shall be rejected. b) Sporadic or intermittent porosity that is “clustered”, and/or appears intermittently in clusters, around the hardband circumference, is usually caused by interrupted or insufficient gas flow during welding. This type of porosity shall be rejected. c) Porosity that is found to be continuous or in multiple clusters around the circumference of the weld bead, and is shallow in depth with holes less than 1/32” (0,79mm) deep, is also usually caused by interrupted or insufficient gas flow during welding. However, the porosity did not propagate as deep. Trying to repair it by patch welding is virtually impossible. This type of porosity shall be rejected. d) A single clustered porous area that appears only once or twice within the hardband area may be caused by an interruption of gas flow for a short period of time. If the area is less than one square inch (1.0 in2 or 25,4mm2) it should not necessarily be rejected. It has been known to be possible, but not always, to remove a clustered area by hand-grinding and then make a patch repair of over that area. e) The specific cause of isolated (single-hole) porosity is not definitely known. It may be caused by an instantaneous interruption of gas flow. It may occur at random, sometimes only one to three times or so, within the circumference of a weld bead but is not clustered or continuous. This type of porosity should not necessarily be rejected.

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Note: If either single-cluster or isolated porosity is accepted, and as stated previously, if during the reapplication of a new layer of 300XT?, the hardband Operator sees more porosity that has formed at the surface of the new layer, the new hardband layer shall be rejected. The hardband area shall then be removed and the area rebuilt with a mild steel wire before application of a new layer of 300XT?. The photographs shown below are some examples of reject excessive, sporadic and isolated porosity found in existing hardbanding layers as well as new applied layers of 300XT?.

Excessive Porosity Worn But Intact

Excessive Porosity Worn But Intact

Clustered and Isolated PorosityContinuous But Intact

Excessive Porosity in New Applied LayerDefinitely Confirmed Reject

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3.3.4.7 Blow-holes and Voids: Sometimes “Blow-Holes” and Voids in the weld bead are sometimes associated with porosity. This is not always the case. Even with sufficient gas flow, blow-holes can be the result of the welding arc being “blown back” when the arc passes over an area that may not have been sufficiently cleaned or may have had a high amount of residual magnetism contained in the tool joint. Voids are areas where no welding had occurred, such as at the end of a weld bead tie-in. Both will show an absence of weld metal as parent metal can be easily seen. They are rarely seen on used or worn hardbanding because the hard-metal area surrounding the blow-hole or void has been worn during use. They can be seen after application of the new applied layer. Blow-holes and voids are usually confined to one blow-hole or void area and shall be rejected, regardless of size, unless they are repaired with a spot or patch weld while the tool joint remains hot at sufficient temperature. Therefore, the hardband Operator should inspect the entire 360° circumference of the 300XT? weld beads for any blow-holes or voids immediately after application while the tool joint is still placed in the chuck assembly and is at sufficient temperature. The photographs shown below are some examples of Blow-Holes and Voids found in new applied layers of 300XT?. The photo on the left is hardband found reject due to numerous blow-holes. The hardband was removed and the area rebuilt prior to a new layer being applied. The photo on the right was patch welded and made acceptable.

Numerous Blow-Holes-Hardband Rejected

Void Area Made Acceptable After Repair

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3.3.5

Removal and Rebuild of the Hardband Area

3.3.5.1 The following methods shall be utilized when it is found that the existing layer of used hardbanding needs to be removed when found to be reject or not compatible with 300XT?. The Applicator can utilize any removal method listed below. The methods listed are in order from the most to the least preferred by Arnco. They are; a) By machining with a composite or ceramic type of tooling on a conventional lathe or CNC equipment. b) By grinding with stationary grinding equipment. c) By plasma-arc gouging equipment. d) By carbon-arc gouging equipment. 3.3.5.2 The Applicator should consult the manufacturer of the material (if known) for any required dimensions that may be affected during repair. As an example, one most important dimension is the Minimum Hardband Area Diameter after the removal of hardbanding. That is, the wall thickness of the remaining material in the hardband area should be sufficient so that the Heat Affected Zone (HAZ) of the mild steel application does not penetrate to the ID of the area being rebuilt. Experience has taught us that usually the HAZ will penetrate to .375” (9,52mm) into the parent metal. A minimum wall thickness of .750” (19mm) is usually required so to allow for the HAZ to be no closer than .375” (9,52mm) to the ID of the material after welding. If a remaining wall thickness of less than .750” (19mm) may be realized, then careful consideration should be made when removing the reject hardbanding and applying the mild steel layer. Specifically, only remove the hardbanding to just below the surface of the parent metal; Do not remove any excess parent metal than is needed. 3.3.5.3 The Applicator must utilize a mild steel wire for rebuild that is compatible with the parent metal steel. Some suggested commonly used wires are Lincoln L-70 or ESAB ER70-S6. The rebuilt surface shall be welded up to the existing tool joint OD and be clean and free of slag. 3.3.5.4 The Applicator shall have a Magnetic Particle or Liquid Penetrant Inspection performed after application of the mild steel wire and weld surface preparation to ensure the layer is free of cracks. 3.3.6 Application of New 300XT? Layer

3.3.6.1 Application of the new layer of 300XT? shall be per the applicable procedures stated in this Section 3 of this manual for 4137, 4145HT and 1340HT Steels. 3.3.6.2 As stated previously, the hardband Operator should inspect the entire 360° hardband area after application of the 300XT? for blow-holes or voids that can be repair welded while the tool joint is still hot, as well as for any porosity that may be visible. 3.3.7 Final Inspection of the New 300XT? Layer

3.3.7.1 Final Inspection of the new applied layer of 300XT? shall be per the criteria stated in Section 4 of this manual.

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SECTION 4: 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 300XT? 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 shielding gas is of good quality and, if a mixture, is the correct mixture for use with 300XT?. Ensure that 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” (0,76mm). 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 300XT? Hardband Area

NOTE: CRACKING IS DEFINED AS “VISIBLE TO THE NAKED EYE” ONLY. ANY CRACKS DETECTED BY MAGNETIC PARTICLE OR LIQUID PENETRANT INSPECTION, AND/OR NOT VISIBLE TO THE NAKED EYE, ARE NOT RELEVANT OR REJECTABLE UNLESS THEY EXTEND INTO THE PARENT METAL. 4.3.1.1 Once the 300XT? is applied, micro-cracking of the hardband area will occur. This cracking is not like that of 200XT?. The following criteria applies to this type of cracking: a) The micro-cracks may be oriented longitudinal, oblique and transverse to the tool joint axis, including circumferential. b) The spacing between the cracks can vary at intervals around the circumference.

c) A single crack that is oriented transverse to the tool joint axis and is located in the middle of the single weld bead indicates that rapid cooling probably has occurred and is therefore reject. d) No crack, regardless of orientation, shall not be wider than .010” (0,25mm).

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 300XT?. 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.

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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 usually 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. 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 Figure 4.3.1

ACCEPTABLE

4.3.1.7 Excessive porosity (pin-holes) is not acceptable. Usually, during the hardband application of 300XT?, porosity is caused by improper, interrupted or restricted flow of the shielding gas or from 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” (3,17mm) diameter and greater than 1/16” (1,59mm) in depth, as well as gaps between the weld beads, which are not repaired by welding, are reject. 4.3.1.9 Applicators shall refer to Section 3.3 for more information concerning inspection of porosity, blow-holes and voids when welding onto used/worn hardbanding. 4.3.2 Dimensional Inspection of the Hardband Area

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 As before, we urge all users of this manual to continue 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 300XT? hardband application. We express special thanks to all our end users, applicators and inspectors for their cooperation and input into the development of Arnco 300XT?. 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 300XT? must be applied outside the Arnco recommended procedures, CALL US FIRST!

Thank you!
ARNCO TECHNOLOGY TRUST, LTD.

3657 Briarpark Drive, Houston, Texas 77042-5205, USA Telephone: (01) 832-214-5200 Fax: (01) 832-214-5205 E-Mail: Arnco@arncotech.com Website: www.arncotech.com

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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 Version 1.2, October 1, 2005 CONFIDENTIAL 35


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