Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Visual Inspection of Rotary Shouldered Connections:
Tutorial / Overview.
Rev 0 Page 1 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Visual Inspection of Rotary Shouldered Connections
Objective: Identification and assessment of the attributes specified by the appropriate
Inspection Standard(s). For this exercise the appropriate standards are:
API Recommended Practice 7G
TH Hill DS-1, 3rd Edition
Fearnley Procter NS-2 Rev. 0 November 1999
The assessment of the individual attributes as described in the following pages uses the Visual
Connection Inspection procedure in DS-1 as a model.
Where there are variations between the DS-1 model and the other relevant standards, these differences
are noted in the pages relating to the specific attributes where the variations occur.
Equipment Required:
Steel rule graduated in 1/64”
Metal straight-edge
Hardened and ground profile gauge
OD callipers
Lead gauge and setting standard
(Lead gauge and setting standard shall show evidence of calibration
in the last 6 months traceable to National Standards)
Rev 0 Page 2 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 1.0: Weight/Grade Stencils.
Note 01: Weight/grade stencil examination only applies to drill pipe tool joints
The sketches and tables that follow show the locations and meanings of the weight/grade
stencils (hard stamps) which should be present on all drill pipe tool joints.
The tool joint may be marked in either the milled slot on the O.D of the pin tool joint or on the
pin neck.
Where both locations are stencilled, the markings must agree.
If neither marking is present, the pipe shall be rejected unless traceability to the weight and
grade of the pipe can be achieved through the manufacturer’s joint serial number.
Note 02: When pin connections are re-machined, the repairer is supposed to note the pin neck
details before machining and to re-stencil the details onto the re-machined
connection. In practice this does not always happen.
Note 03: NS-2 does not require a specific check for weight/grade stencils. However, there is a
general requirement in NS-2 that all material being inspected shall be assigned a
unique identification number and that number shall be stencilled into the component
at a suitable location.
Rev 0 Page 3 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Figure No. 01,
Weight / Grade Stencil Identification Marks & Locations
Rev 0 Page 4 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 2.0: Hardbanding
Figure No. 02,
Example of Well Applied Alloy Hardbanding
Hardbanding (AKA Hardfacing) is commonly applied to box tool joints to reduce O.D. wear.
Several types of hardbanding are available, but for drill pipe, wear resistant alloy overlays have become
increasingly common. This is mainly due to the fact that they cause less casing damage than
hardbanding which uses tungsten carbide particles.
There are several different types of materials, and methods of application leading to a wide variety of
finished product.
Most users of hardbanded drill pipe (and hardbanded BHA components) have their own specific
requirements and acceptance criteria.
It is quite probable that these “in house” criteria will not match either DS-1 or NS-2
Inspectors are encouraged to ensure they have the relevant information from the customer prior to
commencing the assessment.
Rev 0 Page 5 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
2.1: Assessment of hardbanding condition may be subdivided into the following:
2.1.1 Dimensional Checks:
Location. At the inboard end of the tool joint ending very near the 18 degree tool joint
taper. Some styles of hardbanding incorporate 3 “fingers” of hardband
running down the taper.
Width. Normally a minimum of 3 inches. Typically, hardbanding is applied in 1
inch wide bands with a slight overlap between the bands. Remember that
the hardbanded area reduces the available tong space on the tool joint, so
wider hard bands, as well as costing more to apply, can also reduce the life
of the tool joint by limiting the number of re-cuts available before the tong
space becomes too short.
Height. Hardbanding is normally applied either flush with or proud of the tool joint
O.D. When applied proud, an upper limit on the O.D. of the hardbanded
area is normally specified.
2.1.2 Surface Condition
.
Smoothness. Sharp edges and protrusions on the surface of the hardband can cause severe
casing wear and are therefore not permitted.
Cracks. Due to the high residual stresses resulting from welding, cracks often occur
across the weld bead. Cracks in the hardbanding may not rejectable unless
they extend into the base metal of the tool joint.
Broken or
missing areas. Cracks from different areas of the hardbanding may join up to form areas
which are essentially separated from the main body of the hardbanding.
These areas can then break up or fall out of the main body of the
hardbanding. This process is known as “Spalling”
Rev 0 Page 6 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
2.2: Standards References
DS-1 has relatively simple acceptance criteria which may be summarised as follows:
Type of material and method – No comment
Location - No comment
Width – No comment
Height – No more than 3/16” above the surface of the tool joint O.D.
Smoothness – No protruding chips or weld beads unless permitted by the end user
Cracks – Hairline cracks are permissible unless they extend into the base metal of the tool
joint
Broken or missing areas – No broken or missing areas bigger than ½” across the major
dimension
NS-2 has a somewhat more complex acceptance criteria which may be summarised as
follows:
Type and method – Wear resistant alloy applied flush and smooth or proud and smooth
Location – No comment
Width – Minimum 3 inches
Height – No maximum specified, but diameter shall be constant over the entire hardbanded
area
Smoothness – Hardband shall be ground or machined concentric and have a surface finish of
not more than 125 micro inch CLA (Calculated Linear Average) This surface finish to be
verified with surface roughness standard.
Cracks – Cracks transverse to the weld bead are acceptable if less than 1/16” wide and spaced
more than ½” apart.
“Branch off” cracks less than 1/16” wide and intersecting no more than 2 other transverse
cracks are acceptable.
Circumferential cracks (i.e. parallel to the weld bead) are not acceptable.
Broken or missing areas – None accepted.
Rev 0 Page 7 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Figure No. 03,
Cracked Hardbanding
Figure No. 04,
Spalled Hardbanding
Rev 0 Page 8 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 3.0: Cracks
Threaded connections and tool joint bodies are visually examined for the presence of cracks.
Cracks which may be detected visually during this inspection fall into the following categories:
1. Fatigue cracks in the roots of the connection threads.
On the box connection, these will normally only be visible if they extend through the
full thickness of the material and can be seen on the outer surface
of the box tool joint.
2. Split boxes
Normally associated with box swell and easily seen. However, the combination of
high hoop stress in the box combined with longitudinal stress concentrators (e.g. deep
tong cuts) can cause the box to split without any other visible deformation.
3. Heat checking
Heat checking occurs when the tool joint is rotated whilst pressed hard against the
formation wall resulting in rapid heating and cooling. Heat check cracks are
normally fine longitudinal cracks which can enlarge with time resulting in a split box.
4. Cracks in hardbanded areas
As discussed in the previous section, cracks in hardbanded areas are not necessarily
cause for rejection unless they run into the base metal of the tool joint.
Note 04: Grinding to remove cracks is not permitted.
The presence of fatigue cracks, heat check cracks, split boxes or cracks in hardbanded areas extending
into the base metal of the tool joint is cause for rejection in API RP7G, DS-1 and NS-2
Figure No. 05,
Heat Check Cracks illustrated on the right hand photograph leading to a
Split Box illustrated in the left hand photo.
Rev 0 Page 9 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 4.0: Bevel Width
Bevel width is the distance from the outer edge of the sealing shoulder to the O.D. of the tool joint.
If no bevel is present, there is an increased risk of sealing shoulders failing to seal across their full
width
API RP7G and DS-1 require as a minimum an approximate 45 degree bevel at least 1/32” wide on the
full circumference of both pin and box
NS-2 makes no comment on bevel width.
Bevel Width
Figure No. 06,
Example of Bevel Width
450
Minimum
1/32”
Figure No. 07,
Detail of Bevel Width.
Rev 0 Page 10 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 5.0: Thread surfaces
Assessment of thread surface condition is always a potentially controversial area for inspectors since,
even with the acceptance criteria laid down in DS-1 and NS-2, there is still significant room for
individual interpretation of these criteria.
The primary purpose of the threads is to pull the sealing shoulders together with enough force to
prevent drilling mud at high pressure inside the pipe from leaking out through the connection.
The torque applied when making up a rotary connection should largely be expended in compressing the
sealing shoulders, not in overcoming thread interference.
With this in mind, it is important that thread damage does not result in additional thread interference as
this will have the effect of reducing the torque available to compress the sealing shoulders.
The threads themselves act as stress concentrators and, in an effort to minimise their effect, API Spec 7
requires virtually all rotary connections to have threads with full root radii (V0.038R, V0.040 and
V0.050).
Anything which interrupts the root radius (e.g. pitting) will increase the stress concentration and could
lead to premature fatigue cracking
Both DS-1 and NS-2 attempt to formalise the visual inspection of thread surfaces and introduce
acceptance criteria.
5.1: Acceptance Criteria.
The Acceptance Criteria is described as follows:
DS-1
1. Pits or other imperfections which appear to exceed 1/16” in depth or 1/8” in
diameter which penetrate below the thread root are cause for rejection
2. Pits or other imperfections which appear to exceed 1/16” in depth or 1/8” in
diameter which occupy more than 1 ½” along any thread helix are cause for
rejection
3. Raised protrusions shall be removed with a hand file or soft (non metallic)
buffing wheel. Thread profile shall be checked after any filing or buffing is
carried out
NS-2
1. Pits which appear to be more than 1/16” deep or 1/8” in diameter located in
the thread roots shall be cause for rejection
2. Pits which appear to be more than 1/16” deep or 1/8” in diameter which
occupy more than 1 ½” along any thread helix are cause for rejection
3. Any galling which cannot be repaired using a hand file is cause for
rejection. Thread profile shall be checked after any repair is carried out
Rev 0 Page 11 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
It is likely that strict application of the acceptance criteria in either of theses standards will lead to
many serviceable connections being rejected.
In particular, since neither standard differentiates between the highly loaded threads (i.e. near the neck
of the pin) and the lightly loaded or un-engaged threads (i.e. nose of the pin), many connections could
be rejected for damage exceeding the acceptance criteria in an area of the connection which is not
subject to fatigue and which is not affecting make up torque.
Figure 08, Above
Galled Threads
Figure 09, Right
Broken Threads
Rev 0 Page 12 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 6.0: Box Swell
Box swell (AKA box expansion or “belled” box) is checked to determine if the connection has been
subjected to excessive torsional stress.
Excess torsional stress can occur because the make up torque was too high or because excess rotary
torque was applied to the drillstring in response to some specific downhole condition.
Depending on the relative strengths of the box and pin (factors which are controlled primarily by the
box O.D. and the pin I.D), when excess torsional stress is applied, either the pin will stretch or the box
will swell.
Box swell can be detected by one of three methods.
1. DS-1 and NS-2 using the following method:
Place a straight edge along the longitudinal axis of the tool joint and looking for any gaps between
the straight edge and the tool joint. If any gaps are present, the O.D. is measured next to the bevel
and again at 2 inches from the bevel. If the O.D at the bevel is increased by 1/32” or more, then
the connection is rejected.
2. NS-2 also states that “taper rock” as indicated by placing a straight edge across the threads is
cause for rejection
3. API RP7G uses the following method:
Measure the counterbore diameter and compare the measured value with the counterbore diameter
found in API Spec 7, table 25 for new connections.
If the measured value exceeds the maximum value permitted by API 7 by more than 1/32”, the
connection shall be rejected
Note 05: Using the DS-1/NS-2 method boxes which have been swollen and subsequently
subjected to OD wear may not be detectable.
Measuring counterbore diameter is a more reliable method of detecting box swell.
In DS-1 inspections, measurement of the counterbore diameter becomes a requirement for Category 4
and 5 inspections on drill pipe and category 3-5 inspections on BHA components.
This means that in inspection categories below these, a possibility exists that box swell could go
undetected.
In NS-2 measurement of the counterbore diameter is always required for all Drillstem components.
Rev 0 Page 13 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Figures 10 & 11,
Examples of Box Swell
Rev 0 Page 14 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 7.0: Seal Surfaces
When a pin and box are made up correctly, it is the quality of the contact between the sealing shoulders
which determines whether or not the connection will leak under pressure. The threads do not form a
seal in a rotary shouldered connection.
With this in mind, it is clear that assessment of the condition of sealing surfaces is an extremely
important part of the visual inspection of rotary shouldered connections
API RP7G requires sealing shoulders to be checked for the presence of galls, nicks, washes, fins or any
other condition which could affect the pressure holding capacity of the joint. However, this document
does not specify any accept/reject criteria to apply when damage is detected
7.1: Reference Standards
DS-1: No raised metal or corrosion products on the seal surface
Pitting or interruptions of the seal surface estimated to exceed 1/32” deep at any given
location are cause for rejection.
Pitting or interruptions of the seal surface estimated to occupy more than 20% of the seal
width at any given location are cause for rejection
No filing of the seal surfaces is permitted
NS-2: Any galling or pitting of the seal surface which exceeds 1/32” in depth at any given
location shall be cause for rejection.
Any galling or pitting of the seal surface which occupies more than 25% of the seal width at
any given location are cause for rejection
Rev 0 Page 15 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Figures 12,13,14 & 15,
Examples of Seal Surface Damage.
Rev 0 Page 16 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 08: Re-facing
Refacing of damaged sealing shoulders is common practice. Typically, the inspection company
performs this service whilst the inspection job is in progress.
Equipment and procedures for field re-facing of rotary connections are not discussed during this
training course.
However, during visual inspection process, inspectors have to make 2 decisions relating to re-facing.
These are:
1. If the sealing shoulder does not meet the acceptance criteria for visual inspection, will
field Refacing the connection result in the connection satisfying the acceptance criteria?
2. If field Refacing is performed, will the amount of material removed exceed the
cumulative limit for the connection?
API RP7G, DS-1 and NS-2 all state that that when Refacing is performed, only the minimum amount
of material should be removed & that the maximum amount of material removed at any one Refacing
operation should not exceed 1/32” and that the cumulative limit for Refacing a connection shall not
exceed 1/16”
The normal problem for inspectors is ascertaining how much, if any, Refacing has been performed on
the connection prior to the current inspection.
New or re-machined connections may have “Benchmarks” marked on the flat of the pin and the
counterbore to give a simple visual indication of how much, if any, Refacing can be performed.
None of the standards provide specific guidance for determining if Refacing can be performed on
connections without benchmarks, however, reference to the acceptance criteria for pin neck length and
box counterbore depth can be used to determine if Refacing is possible.
The acceptance criteria for pin neck length and counterbore depth quoted in DS-1 and NS-2 are the
new dimensions for these attributes as Specified in API Spec 7 with a 1/16” allowance applied for
Refacing
Therefore, if no benchmarks are visible, the inspector must determine if Refacing will result in either
the pin neck length or counterbore depth failing to meet the acceptance criteria
Figure No. 16:
Style and Location of Benchmarks on Pin & Box Connections.
Rev 0 Page 17 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 09: Pin Thread Profile
Pin thread profile is checked mainly to determine if the pin has been subjected to excessive torsional
stress.
Pin stretch is detected using a profile gauge.
Pin stretch is measured with a lead gauge. (Measurement of pin lead is discussed in the next section)
In addition to pin stretch, the profile gauge can help in assessing the condition of thread flanks, roots
and crests
The thread profile inspection requirements for DS-1 and NS-2 are as follows:
DS-1
• A hardened and ground thread profile gauge shall be used.
• The profile gauge shall mesh with the thread flanks so that no light is visible at any of
the flanks or thread roots
• Visible gaps at not more than 2 thread crests estimated to be no more than 1/16” are
acceptable
• Uniform flank wear estimated to be less than 0.010 inch is permissible
• Any gaps visible at the thread flanks requires lead measurements to be performed
• 2 thread profile checks shall be performed at 90° +/- 10° apart
NS-2
• The gauge shall conform to the thread profile so that no light is visible
• Visible gaps at no more than 2 threads crests estimated to be no more than 1/16” are
acceptable
• Pin lead measurement is required when visible gaps are evident on the thread flanks
• 2 thread profile checks shall be performed at 90° apart
• Pin stretch shall be checked in at least 3 positions around the circumference near the
last engaged threads. Suspect connections shall be verified using a lead gauge
Thread stretch only occurs in the highly loaded threads near the neck of the pin, so that is where the
profile gauge should be used.
Note No. 06: DS-1 fails to address this important point.
Pin stretch causes the profile to “rock” in the threads. Worn or damage flanks typically cause the
gauge to move linearly.
Rev 0 Page 18 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Figure No. 17:
Correct Location of Profile Gauge Using
Hardened & Ground Profile Gauge.
Figure No. 18:
In-correct Location of Profile Gauge.
Pressed Steel Profile Gauge
Rev 0 Page 19 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 10: Pin Lead
Pin Lead is measured when stretch has been detected.
Pin lead can only be measured accurately using a lead gauge fitted with the correct ball points and the
correct lead setting standard.
Thread lead is defined as the distance from a point on one thread to the same point on the next thread.
Lead is normally measured over a fixed distance – usually 2 inches.
The dial indicator on the lead gauge is adjusted to read zero when the gauge is placed on the setting
standard.
When the lead gauge is placed on the connection being inspected, any difference in the lead between
the setting standard and the connection can be read directly from the dial indicator.
Figure No 19:
Use of Pin Lead Gauge.
Ball point selection
API Spec 7 table H-1, column 7 lists the required ball points for all API and specific non-API rotary
connections. The commonly used API rotary connections all require 0.144 inch diameter ball points
Setting standard selection
The setting standard used must have the same number of threads per inch and the same taper per foot as
the connection being inspected. API Spec 7 Table 25 lists this information for all API rotary
connections.
For example, an NC50 pin has 4 threads per inch and a 2 inch taper per foot. The required setting
standard should be clearly marked with the same information.
Rev 0 Page 20 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Equipment calibration:
DS-1 requires the gauge and the setting standard to be calibrated with traceability to National standards
every 6 months.
This is an impractical requirement for most inspection companies, particularly when operating in
remote field locations.
NS-2 requires the lead gauge to be calibrated using the setting standard prior to use, after every 25
measurements and on completion of each days work.
If out of calibration, parts inspected since the last good calibration shall be re-inspected.
This is much more practical, since it recognises that the setting standard is unlikely to go out of
calibration
Procedure:
DS-1 requires pin lead to be measured over a 2 inch interval beginning at the first full depth thread
nearest the shoulder. 2 measurements shall be made at 90° +/- 10° apart
API RP7G and NS-2 do not have detailed procedures for performing the measurement
Acceptance criteria:
API RP7G, DS-1 and NS-2 all have the same acceptance criteria.
Pin stretch shall not exceed 0.006 inches over a 2 inch interval
Rev 0 Page 21 of 22 December 2005.
Rotary Tool Inspector
Training Course
Visual Inspection of Rotary
Shouldered Connections.
Section 1: Stress Relief Surfaces
The surfaces of any stress relief features on the connection being inspected are examined for the
presence of corrosion or other conditions which could cause stress concentrators.
Stress relief features work by removing the highly stressed threads at the neck of the pin and the
unengaged threads at the back of the box and replacing them with smooth machined areas which have a
lower cross sectional area than equivalent area on connections without stress relief features.
The benefits in terms of improved resistance to fatigue cracking resulting from the removal of the
stress areas from the pin and box, greatly exceeds the slight loss of strength resulting from the smaller
cross section of the relief features.
However, for maximum benefit, the stress relief features should not contain any corrosion or damage
which could act as a stress concentrator
Specification and acceptance criteria:
DS-1
Built up corrosion shall be removed from stress relief feature surfaces with emery paper or a
flapper wheel to determine the surface condition.
Pitting that is measured or visually determined to be more than 1/32” deep shall be cause for
rejection
NS-2
Pitting greater than 1/32” deep shall be cause for rejection
Hard stamping in the stress relief groove is cause for rejection
The surface finish on the pin relief groove shall be better than 32 micro inch CLA
The surface finish on the boreback shall be better than 125 micro inch CLA
NS-2 does not specify how the surface finish measurements are to be made. In practice a surface
roughness comparator block could be used to estimate the surface finish.
Rev 0 Page 22 of 22 December 2005.