Hardbanding ED & TEST VED O APPR
For Oil and Gas drilling
Technical Performance DataSheet (TPDS)
12Ti Optimized Performance
13CF
• Crack Free Design • Casing Friendly • Optimized Tool Wear Resistance • Flexible Rebuild Design
Description: OTW 12Ti actively prolongs against wear in the most extreme drilling conditions, as demonstrated by its performance in highly deviated well & open hole applications. Maximum drill pipe life is achieved through superior wear-resistant properties, coupled with the ultra-smooth, casing friendly features preferred by most oil companies. OTW 12Ti Titanium-Carbide chemical composition creates a martensitic matrix, which infuses ultra-smooth / ultrafine compounds into an abrasion resistant, ultra-hard microstructure, ensuring optimal strength and metallurgical integrity. OTW 12Ti hardness scale of 61.5 HRC, combined with our Non-Cracking (NCD) and Flexible Application Designs (FAD), enables high load, open hole performance while simultaneously meeting all casing friendly requirements. End-users yield a higher return on investment and long-term savings through OTW 12Ti’s life-extending drill pipe technology. OTW 12Ti can be reapplied over itself and most other hardbanding materials, ensuring quick and easy repair in even the most remote locations. OTW 12Ti is a flux-cored wire alloy, designed & manufactured by Castolin Eutectic in our own state-of-the-art facilities, ensuring the highest degree in quality control. Furthermore, OTW is certified by NS-1 for application and reapplication of tool joints.
Overview: • Casing friendly • Combination of open hole & casing wear performance • Highest open hole resistance in its class • Ideal for application over existing hardbanding material • Fully compatible with all “non-cracking” hardbanding products • Ideal for all-purpose hardbanding applications • Flexible Application Design (FAD) & Non-Cracking Alloy Design (NCD)
CERTIFICATE OF APPROVAL This is to certify that the following product has been reviewed and approved by Fearnley Procter FZE and an NS1™ Technical Review Committee. Date of Approval: 16/8/2011
Cert/NS-1™ Approval Number: 0052/11-2
Valid Until: 15/8/2013
Reviewed Against: AA.03.30.00.1110 Rev. 09
Review Number: FP FZE 454
NS-1™ Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment, Edition 2 – January 2006
CERTIFICATE OF APPROVAL This is to certify that the following procedure has been reviewed and approved by Fearnley Procter FZW and an NS-1™ Technical Review Committee. Date of Approval: 16/8/2011
Cert/NS-1™ Approval Number: 0053/11-2
Valid Until: 15/8/2013
Reviewed Against: AA.03.30.00.1110 Rev. 09
Review Number: FP FZE 455
NS-1™ Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment, Edition 2 – January 2006 Procedure: OTW-12 Hardbanding applied over OTW-12
Product: OTW-12 Hardbanding Candidate: Castolin Eutectic – Hardbanding Division, PO Box 178, Hammaren 13, 4056, Tanager, Norway
Candidate: Castolin Eutectic – Hardbanding Division, PO Box 178, Hammaren 13, 4056, Tanager, Norway
FEARNLEY PROCTER NS-1™ LEVEL 2 PRODUCT APPROVAL (OTW-12 Alloy Hardbanding - New Application for Tool Joints Only )
FEARNLEY PROCTER NS-1™ LEVEL 2 PROCEDURE APPROVAL (OTW-12 Alloy Hardbanding – Re-Application for Tool Joints Only )
Scope: The procedure followed has been to compare the specific requirements of the relevant Fearnley Procter NS-1™ documentation with the submitted information, and to perform certain testing on the product.
Scope: The procedure followed has been to compare the specific requirements of the relevant Fearnley Procter NS-1™ documentation with the submitted information, and to perform certain testing on the product.
The evaluation of the application procedures for OTW-12 Alloy Hardbanding on drill pipe has been performed in compliance with the general requirements and recommendations as stipulated in NS-1™ Supplementary Requirements, AA.03.30.00.1110 (Rev. 09) Section 5.0, and Sub-Specification 90.1, 90.3 and 160.
The evaluation of the application procedures for OTW-12 Alloy Hardbanding on drill pipe has been performed in compliance with the general requirements and recommendations as stipulated in NS-1™ Supplementary Requirements, AA.03.30.00.1110 (Rev. 09) Section 5.0, and Sub-Specification 90.1, 90.3 and 160.
The following data was supplied and tests performed by Castolin Eutectic to Fearnley Procter, for this approval.
The following data was supplied and tests performed by Castolin Eutectic to Fearnley Procter Norway, for this approval.
1. Casing Wear Analysis Data, 2. Hard-banding Adhesion Test Results, 3. Welding Procedures/Guidelines, 4. Inspection Guidelines, 5. Acceptance/Rejection Criteria, 6. Hardness Test Results, 7. Field Data on use Reference Documents: Castolin Eutectic Hardbanding Manual Version 1.2 June 2010 – MOHR Engineering Wear Test Report, Project No. 1701021.
1.Hard-banding Adhesion Test Results, 2. Welding Procedures/Guidelines, 3. Inspection Guidelines, 4. Acceptance/Rejection Criteria, 5. Hardness Test Results, 6. Field use data Re-application was performed by applying OTW-12 and then grinding down to 1/32 and applying a further banding of OTW-12.
As a result of the review Castolin Eutectic OTW-12 Alloy Hardbanding has been granted approval and is listed as an NS-1™ Level 2 approved product and deemed suitable for service when applied as per the processes and procedures reviewed and the requirements of NS-1™.
Reference Documents: Castolin Eutectic Hardbanding Manual Version 1.2 June 2010
Approved By:
As a result of the review Castolin Eutectic OTW-12 Alloy Hardbanding has been granted approval and is listed as an NS-1™ Level 2 approved product and deemed suitable for service when applied as per the processes and procedures reviewed and the requirements of NS-1™.
Kevin Fearnley (Chairman NS-1™ Technical Review Committee) Fearnley Procter FZE (A Fearnley Procter Group Company) www.fearnleyproctergroup.com
Approved By:
Kevin Fearnley (Chairman NS-1™ Technical Review Committee) Fearnley Procter FZE (A Fearnley Procter Group Company) www.fearnleyproctergroup.com
Fearnley Procter NS1 approval for hardbanding products is one of the current certifications available, Castolin OTW 12Ti has been certified according to this standard over some years and continuous to perform accordingly. During the NS1 approvals following are surveyed; recommended procedures manuals, Wear performances (Mohr wear testing), application of the product by a hardbanding company following the procedures, Mechanical testing of the welded hardbanding layer integrity.
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Bond Strength Evaluation By NS1 Standards The hard banding adhesion test is designed to evaluate the interfacial bonding strength between hardbanding and the tool joint material. This is accomplished by compressing a ring section of the tool joint with hard banding on the outer circumference. This compression produces high tensile stresses in and around the fusion line and attempts to separate the hardbanding overlay from the base tool joint material. The most severe and controlled hardbanding adhesion test was supervised by Feanley Proctor engineers using the Fearnley Procter Work Instruction 3.13 Hardbanding Adhesion Test Rev. 000.
Figure 1: Compression test set-up is mounted in the 10K tensile test machine
Figure 2: Visual exam
A visual examination following the Adhesion Test is made with an optical microscope (Figures 2,3) which looks for any signs of delamination or cracking in:
1. The hardband overlay 2. Between OTW hardbanding and tool joint material 3. Between OTW hardbanding and OTW hardbanding when reapplying
Figure 3: Micrograph Exam
Bond Strength Results for OTW 12Ti Ring section samples were cut from hardbanding samples of OTW 12Ti on typical tool joint material, AISI 4137 steel. In addition, worn OTW 12Ti was rewelded with OTW 12Ti and a ring section was also produced. A close inspection of all adhesion test rings showed no cracking or delamination in the hardbanding overlay. The same crack-free results were observed between OTW 12Ti and tool joint material as well as OTW 12Ti when applied onto itself. The more detailed metallographic examination showed solid fusion between the OTW 12Ti hardbanding overlay and the base material, as well as OTW 12Ti fused onto itself. No Separation cracks were found running parallel between the hardbanding and the base metal fusion line, or in the Heat Affected Zone (HAZ).
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Adhesion Test Conclusion for OTW 12Ti After compression and close examination of the test pieces, it was noted that there was a solid bond between the OTW 12Ti overlay and base material, as well as OTW 12Ti on OTW 12Ti.
Hardness Investigation Hardness Survey Hardbanding Base material
Castolin OTW 12Ti AISI 4140
Readings:
Rockwell "C"
Hardness readings Hardband Heat affected zone (HAZ) Base metal
A 62 38 29
B 61.5 39 31
C 61.1 38.5 30
Average 61.5 38.5 30.0
Hardness is an important mechanical property in hardbanding, and is needed to provide wear resistance in harsh open hole environments. However, if hardness properties are too great, crack formation and even spalling will occur, such as in severe drilling conditions. In addition, cracking or a too high hardness hardbanding can lead to accelerated casing wear and an unsmooth surface. Additionally, the hardness must be uniform throughout the hardbanding, ensuring stable properties and a smooth transition. Hardness was measured using a Vickers indentor (HV) on the polished cross section and also Rockwell indentor, type C (HRC) on the ground surface. The hardbanding was welded as a single weave bead on AISI 4140 steel.
Hardness Conclusion for OTW 12Ti OTW 12Ti has an average hardness of 61,5 HRC, which not only offers good open hole wear resistance, but a unique high hardness that encompasses a Crack-Free Design microstructure, which also means outstanding casing wear performance. The hardness is consistent through the microstructure with a smooth hardness transition into the tool joint material via the Heat Affected Zone (HAZ).
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Microstructure Conclusion OTW 12Ti has been designed to produce a unique microstructure which is super hard for open hole performance, yet fine, smooth and tough fine, smooth and touch, keeping it extremely casing friendly. Consequently, the structure contains very fine, ultra-hard Titanium-cermet phases dispersed in a tough, tempered martensitic matrix. This is shown in the optical microscopy images. The dilution is optimized in terms of keeping it low enough to have minimal influence on the hardbanding chemistry and properties, but high enough to ensure good bonding. The interface between the OTW 12Ti and the tool joint is smooth and contains no flaws, inclusions or secondary, harmfull phases.
Cross section of OTW 12Ti showing low heat input, optimized dilution and uniform hardbanding thickness.
Compatibility and Flexible Application Design (FAD) In the tool joint repair and refurbishment business, a key requirement today is that hardbanding wire can be successfully Rewelded (Re applied) over existing handbanding overlay. This reduces significantly the cost and time of refurbishment, also ensuring the highest security in the event that old hardbanding material is not completely removed before reinstatement.
Carbide/matrix structure of OTW 12Ti
Tool joint OTW 12Ti transition interface
Ideally, a well designed hardbanding wire should be able to be rewelded over itself, and also other members of its hardbanding family. Even better is when it can be rewelded over competitive products. This requires Flexible Application Design (FAD), used by all OTW hardbanding wires. FAD then allows COMPATIBILITY not just with itself, but all OTW alloys and all key hardbanding products on the market during refurbishment of worn drill pipes after the drilling operations. FAD means cost effectively repair and refurbishment, with full flexibility over what is rewelded over, with the assurance that bonding will be good, and the OTW hardbanding will function as designed. To test for compatibility, OTW 12Ti was rewelded over the full range of OTW hardbanding wires in the first series. It was then rewelded over 3 of the 4 most common, commercially available products in the market.
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Compatibility Conclusions: OTW 12Ti Old Hardbanding
New Hardbanding
10SS
10SS
12Ti
12Ti
13CF
13CF
16XS
16XS
Product A Product B Product C
12Ti 13CF 16XS 10SS
Original Hardbanding worn arrow
New Hardbanding
Worn Hardbanding BOX
Previous coating or rebuilded surface
BOX
Product A – This product is non compatible and has cracking and galling issues Product B – Leading Ti containing repair product Product C – Leading Non Cracking all rounder After rewelding with OTW 12Ti over the 7 welded hardbanding alloys, all the hardbanding overlay is examined visually for cracks and then cut and polished to study the interface between the new and old hardbanding products. There should be a smooth transition with no crack formation and the micrographs of transition zone between different alloys and OTW 12Ti are recorded and studied. OTW 12Ti has been shown to be not only fully compatible (interchangeable) with itself, but also with the other products in the OTW range, OTW16 XS, OTW10 SS and OTW13 CF plus the most commonly used hardbanding alloys available in the market today.
Fusion line between competitor alloy B and OTW 12Ti on top
Fusion line of OTW 12Ti on top of OTW16 XS.
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Non-Cracking Design (NCD) Most hardbanding products have a higher hardness and different thermal expansion coefficient than the tool joint materials they’re welded to. These mechanical differences, plus the thermal stress created during welding, result in high tensile stress within the hardbanding layer, which can usually be relieved through “controlled cracking” of the hardbanding. The OTW ranges are all Non-Cracking Designed (NCD) alloys, a feature that not only reduces casing wear, but also saves up to 75% of re-application costs, in contrast to using commercial products that crack. The table below shows a reduced number of steps needed, reflecting significant savings and cost reduction. OTW 12Ti is designed to be crack free on tool-joints. This has been done for over 6 years with continual success, provided that the welding procedure in the OTW Hardbanding Application Manual is followed. Operation
Traditional Cracking alloy
Castolin OTW 12Ti
Removal of previous hardbanding layer
Heavy grinding / Machining / Plasma gouging
No*
Mild steel build up layer
Yes
No
Mild steel layer machining / grind
Yes
No
Apply new hardbanding
Yes
Yes * Only cleaning or slight grinding
Dye Pen. Exam as welded
NCD OTW 12Ti in as welded condition
Wear Testing Understanding this difference is critical to our success in the Hardbanding business, and strongly suggests that actually 3 “coating” properties are required: • High wear resistance of the Tool’s hardbanding coating in open hole • Low wear of the casing from the tool hardbanding coating • Low coefficient of friction of hardbanding coating Castolin Eutectic and Trio constructed the world’s only Hardbanding test machine owned by a consumable developer. The machine measures all 3 properties for a range of typical muds. Moreover, the «coating structure» contains the properties which are determined by the alloy, welding machine parameters and final hardbanding procedure. All 3 need optimization before product commercialization. All 3 need also to be optimised before commercialising the product. Our efforts have been recognised by the Fearnley Procter’s NS1 testing with early approval of OTW 12Ti.
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Casing Wear Testing Casing wear testing was done by the Mohr test machine following latest (API) protocol. This uses T95 casing material for all new wear tests.
Mohr T95 Casing Wear (%)
(%)
14 12 10 8 6 4 2 0
S-135 TJ-steel
OTW 12Ti
Product A
Product B
Product C
Tool Joint Wear Testing Tool joint wear testing is carried out by the ASTM G65 wear test machine, which is widely used in the industry.
(gram loss)
ASTM G65 Abrasion Wear Test Procedure “A”
0.45 0.4 0.35 0.3 0.25
*
0.2 0.15 0.1 0.05 0
OTW 12Ti
Product A
Product B
Product C
*
Product A - Cracking type alloy, Product B & C - designed to be crack free
12Ti
Performance Data Overview Hardness HRC 59-64 G65 Test Data 1 layer, loss (g)
0,279
Mohr T-95 Casing Wear Test (2012) Casing Wear %, Mohr TJ Wear in casing (in. loss) TJ wear in open hole(in. loss) CW Factor Friction factor Est. revs. To 87% nom. wall
7,33 0,0000� 0,0497 1,39 0,32 Infinite
Mohr N-80 Casing Wear Test (2010) Casing Wear %, Mohr CW Factor Friction factor Independent Tests (2006) TJ wear in O/H (g/hrs/22Ft ROP) Casing Wear Loss N80 (g/hrs/22Ft ROP)
Production and Quality Control
12Ti
14,42 2,89 0,39 4,4 3,0
12Ti
12Ti
The all-round, TiC-alloyed hardbanding. Best in class combined open hole and casing wear performance.
13CF
13CF
16XS
16XS 12Ti
10SS "Extreme Service" grade alloy for advanced drilling 10SS 13CF operations like ERD, TTRD etc. Very low friction and casing wear
16XS
10SS A robust, sour service grade, universal hardbanding alloy, with good weldability and easy to apply.
12Ti
13CF A NbC-alloyed, casing friendly alloy for intermediate to advanced hardbanding applications.
16XS
10SS
12Ti
Approval & Customer Performance
Internal & external Testing
Own quality production
12Ti
www.castolin.com
Contacts OilTec & Hardbanding
Global Division Director Doug Yono +971 56 759 4708 doug.yono@mec-holding.de
NAFTA & Brazil Ted Thames +1 713 826 6031 ted.thames@eutecticusa.com
Europe & Russia Hans Erik Elven +47 911 35167 hans.erik.elven@castolin.com
Business & Technical Support Manager Bengt Larsson +47 958 76500 bengt.larsson@castolin.com
Asia & China Antonio Fu 傅爱军 +86 21 5046 1405 ext 115 +86 1381 7361 629 antonio.fu@castolin.com
Middle East & Africa Bill McDougall +971 506 449 243 billmcdougall@ castolin.com
Stronger, with Castolin Eutectic
www.castolin.com
www.otw-hardbanding.com
Ask for a demonstration from our Application Specialists.