Castolin Eutectic has developed a new and innovative range of hardbanding products for the oil and gas industry to greatly increase drilling production with less wear on the drill pipe.
The new hardbanding products address the complex wear phenomena in the oil and gas industry, helping the industry cope with increasing well depths and high cost of failure.
Directional drilling and extended-reach drilling (ERD) exert unprecedented torque and drag force on the drill pipe. Castolin Eutectic’s hardbanding technology has enabled the drilling industry to exceed all previous stress limit levels on both the casing and drilling string.
What is hardbanding?
Hardbanding is the wearfacing welding process used in drilling to protect drilling assets while minimising wear on casing and drilling tool joints to reduce operational costs especially in the oil and gas industry.
Hardbanding involves the application of a wearfacing material on the drill tool joint, and is performed by approved hardbanding applicators for OEM drill pipe producers and drilling companies.
Hardbanding has long been seen as an effective means of preventing tool joint wear. Tungsten carbide-based hardbanding, for instance, which was in widespread use in the 1990s,was determined to be the primary cause of casing wear.
However, the absence of hardbanding, while slowing casing wear to a small degree allowed tool joints to wear at an accelerated rate, reducing the torsional capacity of the drill pipe and increasing risk for drilling operations.
Previous casing-friendly alloys reduced casing wear, but produced unacceptable tool joint wear as a consequence. Crack-prone design flaws were also present, causing catastrophic tool joint failure and in some cases, even the failure of the hardbanding itself due to tool joint spalling.
Castolin Eutectic’s challenge therefore, was to develop a solution that balanced casing wear defence and tool joint protection.
Key requirements for hardbanding:
- Optimised performance
- Crack-free design
- Casing friendly
- Optimised tool wear resistance
- Flexible rebuild design
- Low casing wear determined by Mohr T-95 testing, well within industry limits
- Highly durable and wear resistant, protecting the tool joint
- Crack-resistant, preventing cracking in the material and tool joint
- Spalling-resistant metallurgical compatibility
- Material is easy to reapply without special prep or pre-conditioning
The alloy’s wear resistance performance in open hole situations, qualifies among the best on the market with low casing-wear properties. This alloy may be cost-effectively reapplied over itself to refurbish worn drill pipes after drilling operations.
During development of the OTW range, Castolin Eutectic constructed its own, unique hardbanding C-Wear testing machines. As a result, all Castolin Eutectic OTW products have NS1 certification, which is mandatory for the oil and gas industry.
The OTW range includes:
- 10SS – the new standard for Sour Gas, casing-friendly wire that’s easy to weld
- 16XS – the casing-friendly leader in ‘all-purpose’ non cracking design wires ideal in advanced drilling operations
- 12Ti – best in class with tough all-round hardness, where combined open and case hole wear performance counts
- 13CF – excellent casing wear resistance against current industry standards with exceptional tool performance