Castolin_TPDS_OTW_16XS_hardbanding_oil_gas_industry

Hardbanding ED & TEST VED O APPR

For Oil and Gas drilling

Technical Performance DataSheet (TPDS)

12Ti 13CF 16XS Optimized Performance

10SS

• Crack Free Design • Casing Friendly • Optimized Tool Wear Resistance • Flexible Rebuild Design

Description: OTW 16XS Extreme Service is a product ideally suited for drilling in the most demanding ERD and Ultra ERD wells.

The unique nature of these wells puts severe stress on the drill string, prompting the industry to respond with High performance Tool Joint Connections (XT™, VX™, TT™). These connections produce higher torque values with lower drag and wall thickness. This requires increased reinforcement through optimized hardbanding solutions, resulting in heightened structural integrity and minimal dilution, while still providing effective overall durability.

OTW 16XS was specifically designed for use in Ultra Deepwater applications, where most wells are highly deviated and extremely deep. As these wells require the highest level of strength and prolonged performance, OTW 16XS not only contains superior casing friendly properties, but also demonstrates a unique ability to offer the best wear-resistant materials in both open hole and cased hole environments.

Providing the highest casing & open hole wear resistance, OTW 16XS contains a uniquely weighted mix of multicarbides (Cr, Ti, Mo, and W), which is dispersed uniformly throughout a tempered martensitic micro-structure.

This creates superior thickness and anti-wear properties, which maximize wear resistance, strength and longevity.

OTW 16XS is also able to be cost-effectively reapplied over itself and most standard, non-cracking wires for drill pipe refurbishment and reinstatement.

Overview: • Advanced coating chemistry and microstructure • Very Casing friendly • Acknowledged hardbanding alloy in Ultra deep water drilling • Excelent open hole resistance • Ideal for multiple layer applications

12Ti 13CF 16XS

Adhesion Test Conclusion for OTW 16XS After compression and close examination of test pieces, it noted that there was a sound bond between OTW 16XS hardband overlay onto base material and OTW 16XS onto OTW 16XS.

Hardness Investigation Hardness Survey Hardbanding Base material

Castolin OTW 16XS AISI 4137M

Readings:

Rockwell "C"

Hardness readings Hardband Heat affected zone (HAZ) Base metal

A 59.6 37.5 33.7

B 61.1 33.4 32.1

C 60.7 35.2 29.7

Average 60.5 35.4 31.8

Hardness is an important mechanical property in hardbanding, as it is needed to give wear resistance in harsh open hole environments, however if hardness is too great, crack formation and even spalling can occur, as is usually the case in severe drilling environments. In addition, cracking or a too high hardness hardbanding can lead to accelerated casing wear and an unsmooth surface.

Hardness must be evenly distributed throughout the hardbanding microstructure, in order to ensure stable properties, consistency and smooth transition.

Hardness was measured using a Vickers Indentor (HV) on the polished cross section and also a Rockwell Indentor, type C (HRC) on the ground surface. The hardbanding was welded as a single weave bead on AISI 4137M.

Hardness Conclusion for OTW 16XS OTW 16XS has an average hardness of 60,5 HRC, which gives it excellent open hole wear resistance. However, OTW 16XS achieves much great casing wear performance, as its high hardness scale is insulated with a Crack Free Design microstructure. With hardness properties consistent throughout, there is a smooth-hardness gradual transition into the tool joint material through the Heat Affected Zone (HAZ). The hardness is consistent through the microstructure and there is a smooth hardness transition into the tool joint material through the Heat Affected Zone (HAZ).

12Ti

13CF 16XS

Microstructure Conclusion OTW 16XS has been designed to produce a unique microstructure which is super hard for open hole performance, yet fine, smooth and tough to stay extremely casing friendly. Consequently, the structure contains very fine, ultra-hard Titanium-cermet phases dispersed in a tough, tempered martensitic matrix. This is seen 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 16XS and the tool joint is smooth and contains no flaws, inclusions or secondary, harmfull phases.

Cross section of OTW 16XS 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 the hardbanding wire can be successfully Rewelded (Re applied) over an existing handbanding overlay. This reduces significantly the cost and time of the refurbishment, and also ensures the highest security if the hardbanding is not to be completely removed before refurbishment.

Ideally, a well designed hardbanding wire should be able to be rewelded over itself, and also other members of its hardbanding family. It is even better when it can also be rewelded over competitive products.

Carbide/matrix structure of OTW 16XS

Carbide/matrix structure of OTW16 XS in high resolution

This requires Flexible Application Design (FAD), as used in the development of 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.

12Ti

To test for compatibility, OTW 16XS 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.

13CF

16XS

Compatibility Conclusions: OTW 16XS Old Hardbanding

New Hardbanding

10SS

10SS

12Ti

12Ti

13CF

13CF

16XS

12Ti 16XS 13CF

Product A Product B Product C Product D

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 spalling issues Product B – Leading Ti containing product Product C – Leading overall non-cracking Product D – Suspected to crack After rewelding with OTW 16XS over the 7 welded hardbanding alloys, all 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 micrograph transition zones between different alloys and OTW 16XS are recorded and studied.

OTW 16XS has been shown not only to be fully compatible (interchangeable) with itself, but also with the other products in the OTW range, OTW12 Ti, OTW10 SS and OTW13 CF as well as most commonly used hardbanding alloys available in

12Ti Fusion line of OTW 16XS on top of OTW12 Ti.

Fusion line of OTW12 Ti on top of OTW 16XS. 13CF

16XS

Casing Wear Testing Casing wear testing was done on 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 16XS Product A

Product B

Product C

Product D

Tool Joint Wear Testing Tool Joint wear testing is done on 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 16XS Product A Product B Product C Product D

*

Product A - Cracking type alloy,

*

Product B & C - designed to be crack free,

Product D - suspected to crack (Compatibility unknown)

Performance Data Overview Hardness HRC 57-62 G65 Test data 1 layer, loss (g) 0,312

Casing Wear Trio Test N-80(g/hrs/22ftROP) Casing Wear loss (2006)

TJ Wear in O/H Trio (g/hrs/22Ft ROP) Mohr (in loss)

6,5 0,0403

TJ Wear in Casing Mohr T-95 Inch loss

0,0000”

T-95 Casing Mohr Test (2012) Casing Wear % 5,72 0,96 CW Factor 12Ti Friction factor 0,33 Est. revs. To 87% nom. wall Infinite

13CF 16XS

2,25

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 13CF 16XS

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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.