directional drilling inspection manualpage dept type level document # date rev 2 of 28 ddr man 3...

Page Dept Type Level Document # Date Rev 1 of 28 DDR MAN 3 1000-MAN-DDR-ALL-1002 February 27, 2013 1.0

Title Directional Drilling Inspection Manual Applies To All

Internal Once printed this document becomes an uncontrolled revision unless noted otherwise by the Document Control Center.

Directional Drilling Inspection Manual

Approvals The signatures below certify that this document has been reviewed and accepted for use and distribution.

Approver Title Approval Media Date Mark Chustz Drill Motor Ops Manager Hard Signature 02/27/2013

Jon Francis Director of Manufacturing Hard Signature 02/27/2013

Revision History Documents are reviewed annually to ensure relevance to the systems and process that they define.

Rev # Date Originator

Revisor Dept ECN/ DCR# Reason for Change

1.0 10/18/2012 Elizondo, Mario QMS N/A New release

Distribution/Notification List Distribute to all Level 1, Level 2, and Level 3 managers.




Table of Contents

1 About this Document ............................................................................................................... 4

1.1 Introduction & Purpose ..................................................................................................... 4

1.2 Application & Scope ......................................................................................................... 4

1.3 Reference Documents ...................................................................................................... 4

1.4 Terms & Definitions .......................................................................................................... 4

1.5 Symbols............................................................................................................................ 6

2 Personal Protection & Safety .................................................................................................. 7

3 General Inspection Requirements ........................................................................................... 7

3.1 Outside Inspection Personnel ........................................................................................... 7

3.2 Damage & Repair Paint Code ........................................................................................... 7

4 Motor Inspection Procedure .................................................................................................... 8

4.1 Required Documentation .................................................................................................. 8

4.2 Preparation ....................................................................................................................... 8

4.3 Visual Procedure & Acceptance Criteria ........................................................................... 9

4.3.1 Seal Surfaces & Re-facing ......................................................................................... 9

4.3.2 Minimum Bevel Width................................................................................................. 9

4.3.3 Thread Surfaces......................................................................................................... 9

4.3.4 Box Swell ................................................................................................................... 9

4.3.5 Hard Facing ............................................................................................................... 9

4.3.6 Stress Relief Surfaces ...............................................................................................10

4.3.7 Cracks .......................................................................................................................10

4.4 MT Connection ................................................................................................................10

4.4.1 Particle Concentration ...............................................................................................10

4.4.2 Black Light Intensity ..................................................................................................10

4.4.3 Magnetization ............................................................................................................10

4.4.4 Verification of Field Intensity & Direction ...................................................................10

4.4.5 Examination ..............................................................................................................10

4.4.6 Acceptance Criteria ...................................................................................................11

4.5 Demagnetization ..............................................................................................................11

4.5.1 Demagnetization Method ..........................................................................................11


4.6 Magnetic Particle Inspection (MPI) Bodies .......................................................................11

4.6.1 Verification of Field Intensity & Direction ...................................................................11

4.6.2 Examination ..............................................................................................................11





4.7 Additional Rotor Inspection ..............................................................................................12

4.7.1 Acceptable Criteria ....................................................................................................12

4.8 Additional Stator Inspection .............................................................................................12

4.8.1 Acceptable Criteria ....................................................................................................12

4.9 Examples of Non-Conforming Damage ...........................................................................13

5 MWD Nonmagnetic Tubular Products Inspection Procedure ..................................................19

5.1 Preparation ......................................................................................................................19

5.2 Liquid Penetrant Inspection .............................................................................................20

5.2.1 Inspection Apparatus ................................................................................................20

5.2.2 Penetrant Application ................................................................................................20

5.2.3 Penetrant Removal ...................................................................................................20

5.2.4 Developer Application ...............................................................................................20

5.2.5 Examination ..............................................................................................................21

5.3 Visual Inspection .............................................................................................................21

5.3.1 Connection Inspection ...............................................................................................21

5.3.2 Body Inspection ........................................................................................................22

5.4 Dimensional 3 Inspection Method ....................................................................................23

5.5 Post-Inspection ................................................................................................................24

5.6 Examples of Non-Conforming Damage ...........................................................................25

6 Records .................................................................................................................................28

Table of Figures Figure 1: Stator Chunking .........................................................................................................13 Figure 2: Cracked & Worn .........................................................................................................13 Figure 3: Damaged Rotor ..........................................................................................................14 Figure 4: Pitting .........................................................................................................................14 Figure 5: Missing Buttons & Worn Pad ......................................................................................15 Figure 6: Damaged Facing ........................................................................................................15 Figure 7: Washing .....................................................................................................................16 Figure 8: Pitting & Worn ............................................................................................................16 Figure 9: Pitting & Worn ............................................................................................................17 Figure 10: Pitting .......................................................................................................................17 Figure 11: Worn Pad .................................................................................................................18 Figure 12: Inspection Stencil .....................................................................................................24 Figure 13: Damaged Bevel........................................................................................................25 Figure 14: ID Pitting ..................................................................................................................25 Figure 15: OD Pitting.................................................................................................................26 Figure 16: Set Screw Hole Washout .........................................................................................26 Figure 17: Base Metal Cracks by Hard Banding ........................................................................26 Figure 18: Damage Marking ......................................................................................................27 List of Tables Table 1: Paint Code Indicator Key .............................................................................................. 7




1 About this Document

1.1 Introduction & Purpose

This document outlines SDI Drill Motor and Measurement While Drilling (MWD) inspection procedures, as well as motor department calibration procedures. It is to be used in conjunction with current T.H. Hill DS-1 inspection standards, American Petroleum Institute (API) specifications, and National Institute of Standards and Technology (NIST) calibration standards where required.

1.2 Application & Scope This document applies to all MWD manufacturing and motor shops, and district locations within SDI. It also applies to any third-party inspectors working in SDI manufacturing or district shops. All technicians, personnel, and third-party inspectors performing inspection duties must read this manual.

1.3 Reference Documents Document Number Title 1000-FRM-MTR-MTR-1048 Non-Conformance Report

1057-PRC-QMS-ALL-1003 Product Non-Conformance Procedure

1000-FRM-MTR-MTR-1047 Drill Motor 3rd Party Inspection Report

1000-MFR-MTR-MTR-1003 DHV 3rd Party Inspection Report

1000-PRC-MTR-MTR-1008 Motor Quality Control Procedure

1057-PRC-QMS-ALL-1002 HTC Equipment Calibration Procedure

1000-PRC-MTR-MTR-1017 International Stator QC Procedure

1000-FRM-MWD-MWD-1002 MWD Non-Mag Tubulars 3rd Party Inspection Report

1.4 Terms & Definitions Term/Abbreviation/Acronym Definition +/- Plus or Minus

% Percent

x/ft2 Times per Square Foot

° Degrees

AC Alternating Current

API American Petroleum Institute

ASTM American Society for Testing and Materials

BHA Bottomhole Assembly

BP Bad Profile

BR Broken

CP Chipped/Pitted




CR Cracked

d Diameter

D Depth

DF Damaged Face

DS Damaged Shoulder

DT Damaged Thread

ECC Eccentric Wear

FWDC Full-Wave Direct Current

HWDC Half-Wave Direct Current

ID Inside Diameter

in. Inch

L Length

lb Pound

LWD Logging While Drilling

mL Milliliter

MPI Magnetic Particle Inspection

MS Missing

MSDS Material Safety Data Sheet

MT Magnetic Testing

mW/cm2 Milliwatts per Square Centimeter

MWD Measurement While Drilling

N/A Not Applicable

NDT Nondestructive Testing

NIST National Institute of Standards and Technology

OD Outside Diameter

PPE Personal Protective Equipment

PT Pulled Thread

QC Quality Control

QMS Quality Management Systems

RC Re-chrome

RL Reline

RR Re-run

RTS Return to Stock

RW Rework

SCR Scrap

SW Swelling

TD Thread Damage

W Width




WS Wash

VT Visual Testing

1.5 Symbols The following symbols are used in this document.

Symbol Definition

WARNING! Indicates a hazardous situation that, if not avoided, could result in injury or death.

REFERENCE: The Book symbol identifies a reference to an external document.




2 Personal Protection & Safety

All employees must follow Personal Protective Equipment (PPE) guidelines when conducting the work listed in this document.

This manual is to be used only by SDI trained personnel or supervised trainees. Do not attempt to perform the following procedure(s) without proper training. Serious injury can result from untrained personnel performing the procedure(s) without the proper PPE and training.

3 General Inspection Requirements

3.1 Outside Inspection Personnel 1. Personnel performing inspections per this procedure must have the following:

a. ASNT SNT-TC-1A Level I, Level II or Level III certification. Level I inspectors employed in inspection under this standard shall be directly supervised by a Level II or Level III certified person (T H Hill DS-1 Section 7.15 Inspection Personnel).

b. A copy of their certificate on file at SDI, or with them to show upon request.

2. Inspection tools (when required) must have current calibration certification.

3. Inspectors must have material safety data sheets (MSDS) on hand at all times for any hazardous chemicals that they use. If they use a hazardous chemical provided by SDI, they need to know the location of our MSDS sheets.

4. References:

• API Specifications

• NIST Calibrations

5. Additional motor references:

• SDI Motor Shop Quality Control Manual and part drawings

3.2 Damage & Repair Paint Code When a tool is damaged, rejected or repaired, paint the damaged area the following applicable color.

Table 1: Paint Code Indicator Key Color Motor Department Manufacturing Safety red Cracked Severe damage (repair or reject)

Safety yellow Damaged area or thread Minor/moderate damage (repair)

Safety orange Damaged face N/A

White Repaired N/A

Brown Passed QC inspection after repair N/A




4 Motor Inspection Procedure

4.1 Required Documentation Additional procedures required by an outside company must be thoroughly outlined and presented to SDI in a signed, written request. An SDI Quality Management Systems (QMS), QC Manager, or SDI representative from corporate headquarters must approve the request prior to the procedures being implemented.

If any variance from this procedure is requested by an outside company, it must submit a Non-Conformance Report (NCR) regarding the reason for its request. The NCR will be routed to and reviewed by the appropriate SDI personnel. If a response is needed, the NCR will be addressed appropriately.

4.2 Preparation 1. Gather the following recommended tools:

• Magnetizing Coil

• Full-Wave Direct Current (FWDC) or Half-Wave Direct Current (HWDC) Magnetizing Coil [w/ 10 inch (in.) or larger variable amperage adjustment]

• Flashlight

• Hand-Held Grinder

• Inside Diameter (ID) Caliper

• Outside Diameter (OD) Caliper

• Magnifying Mirror

• Rack Mirror

• Black Light

• Black Canvas Cape

• Visible Light Radiometer

• Ultraviolet Radiometer

• UT Instrument (as needed for analysis)

• Pit Depth Gage

• American Society for Testing and Materials (ASTM) 100 milliliter (mL) Centrifuge Tube

• Burma Castrol Strip

• Field Indicator/Gauss Meter (polarity indicator)

• Magnaglo 20-B or equivalent (water-based)

• Paint Marker

• Spray Paint (for paint code indicators)




2. Wash all debris and mud from equipment to be inspected.

3. If applicable, check tools for straightness. Make a note of crooked tools (ex. bent stator tube) on the 3rd Party Inspection Report.

4. Clean all surfaces that will be inspected to the point that shiny metal surfaces are visible and no traces of scale, mud or lubricant can be wiped off with a clean rag. Connection surfaces include the entire machined areas of the pin and box, the pin nose and 1 in. of OD past the shoulder.

4.3 Visual Procedure & Acceptance Criteria

4.3.1 Seal Surfaces & Re-facing

Seal surfaces must be free of raised metal or protruding corrosion deposits that can be seen or felt by rubbing a metal scale or finger nail across the surface. Any pitting or interruptions of the seal surface that are estimated to exceed 1⁄32 in. of depth (D) or occupy more than 20 percent (%) of the seal width (W) at any given location need to be noted on the Drill Motor (or DHV) 3rd Party Inspection Report. No grinding or metal filing of the seal shoulders is permissible.

If re-facing is necessary, only remove enough metal to correct the damage. Re-facing limits are 1⁄32 in. on any one removal and 1⁄16 in. cumulatively. If existing benchmarks indicate that the shoulder has been refaced beyond the maximum, note the connection on the Drill Motor (or DHV) 3rd Party Inspection Report Report.

4.3.2 Minimum Bevel Width Bevels must meet SDI specifications, manufacturer specifications, API specifications (or DS1 standards if applicable) for top subs and bit box on the mandrels.

4.3.3 Thread Surfaces Thread surfaces must be free of pits or other surface imperfections that appear to exceed 1⁄16 in.[D], or 1⁄8 in. of diameter (d) that penetrates below the thread root, or that occupy more than 1 ½ in.[L] along any thread helix. Raised protrusions must be removed with a hand file or "soft" non-metallic buffing wheel. Check the thread profile after buffing or filing threads.

4.3.4 Box Swell

Place a straightedge along the longitudinal axis of the box OD. If a visible gap exists, compare the OD next to the bevel to the OD at the bevel. If the OD at the bevel is larger than 1⁄32 in., note the connection on the Drill Motor (or DHV) 3rd Party Inspection Report.

4.3.5 Hard Facing

Hard facing (when present) must not extend more than 3⁄16 in. above the OD surface, with no broken or missing areas. Hairline cracks are permissible. Make a note of any protruding carbide chips or beads on the Drill Motor (or DHV) 3rd Party Inspection Report.




4.3.6 Stress Relief Surfaces

Built-up corrosion may be removed from these surfaces with emery paper or a wire wheel in order to determine the surface condition. Make a note of pitting that is (or appears to be) deeper than 1⁄32 in. on the Drill Motor (or DHV) 3rd Party Inspection Report.

4.3.7 Cracks All connections and bodies must be free of visible cracks. Grinding to remove cracks is not permissible. Refer to Section 3.4.6 regarding heat checking.

4.4 MT Connection This section covers use of the wet fluorescent magnetic particle (black light) technique to examine ferromagnetic motor parts for transverse flaws.

4.4.1 Particle Concentration Particle concentration must be 0.2-0.4 mL when measured with a 100 mL centrifuge tube, with a minimum settling time of 30 minutes.

4.4.2 Black Light Intensity Using an ultraviolet radiometer, measure black light intensity at the beginning of the inspection process and then after every eight hours of operating time (throughout the inspection process). Wait five minutes after the black light is turned on before using it. At an average inspection difference, the minimum intensity is 1,500 mW/cm2.

4.4.3 Magnetization Magnetize connections longitudinally with the applicable magnetizing coil. Place the magnetizing coil on the connection for reinforcement, not to oppose any field present. The magnetizing field should be greater than 10 on the gauss meter, when the magnetic particle solution is applied. Check the magnetizing field before and after the solution has been distributed. Check field polarity a field indicator. Uniform field intensity is required around the entire circumference. The magnetic particle solution must be agitated before each application. If the part is 36 in.[L] or more, connections must be magnetized with opposite polarity on both ends.

4.4.4 Verification of Field Intensity & Direction Verify proper field magnitude and orientation under the black light with a Burma-Castrol strip on the inspection surface. At least one line must be visible when the current is off.

4.4.5 Examination Examine the inspection surfaces of each connection of applicable parts under black light. Roll each part to allow areas under solution "puddles" to be exposed, re-sprayed with particle and inspected again. Use a mirror to examine box thread roots, paying close attention to the last engaged thread roots of the pin and box.




4.4.6 Acceptance Criteria

Make a note on the Drill Motor (or DHV) 3rd Party Inspection Report regarding any cracks. Grinding to remove cracks is not permitted, but areas with questionable indications may be cleaned again with a "soft" non-metallic buffing wheel and re-inspected. If the indication reappears, note the connection at that time.

Heat checking occurs when small spider web-like cracks appear on the surface of the metal (the cracks may slightly penetrate the metal). The part can be turned down and if still within minimum requirements it may be re-inspected. Indicate heat checking in yellow paint and record it on the Drill Motor (or DHV) 3rd Party Inspection Report.

4.5 Demagnetization This section covers demagnetizing ferromagnetic metal parts after inspection.

4.5.1 Demagnetization Method 1. Determine the polarity and residual field strength in each end of each part.

2. Place the coil on each end to “oppose” the residual field present in the part. If using a box with a polarity switch, verify correct polarity.

3. The initial magnetization current selection will depend on the residual field strength in the part. Put the coil setting at zero and activate the coil. Move the setting up to 50% then turn off the coil.

4. Check the polarity to see if it is at zero.

5. If the part needs to be demagnetized again, repeat steps two and three. Raise the current setting to approximately 20% less than before, until final activation shows polarity is zero (+/- 3).

4.5.2 Acceptance Criteria Ferromagnetic motor parts are acceptable up to a threshold of 10 gauss maximum after demagnetization. Verify the threshold with a calibrated gauss meter.

4.6 Magnetic Particle Inspection (MPI) Bodies This section covers the examination of stabilizer bodies, blades and welds for linear flaws, using the dry magnetic particle with an active alternating current (AC) field.

4.6.1 Verification of Field Intensity & Direction The yoke must demonstrate the ability to lift the 10 pound (lb) lift bar at a 6 in. leg setting.

Proper field magnitude and orientation must be verified with a Burma-Castrol strip on the inspection surface while particles are applied and the current activated. All three lines must be visible.

4.6.2 Examination Examine welds and base metal within 6 in. of welds bi-directionally. Areas with questionable indications must be cleaned again and re-inspected.




4.6.3 Acceptance Criteria

Any crack or linear imperfection must be noted on the Drill Motor (or DHV) 3rd Party Inspection Report. Grinding to remove cracks is not permitted. Linear imperfections are defined as “other than round.”

4.7 Additional Rotor Inspection

Visually inspect the rotor. Look for washing, wear, cracking and pitting. Note any damages on the Drill Motor (or DHV) 3rd Party Inspection Report. Do not paint on any part of the chrome. Indicate damages on the box of the motor.

4.7.1 Acceptable Criteria 1. Minor chrome pitting less than 1⁄16 in.[d] that does not exceed the underlying metal and

does not occur more than 25 x/ft2 on any part of the rotor is acceptable. Smooth pits with a buffing wheel to remove sharp edges and do not remove parent metal.

2. Major pitting between 1⁄16 - 3⁄16 in.[d] that does not exceed the underlying metal and does not occur more than four times on the entire rotor is acceptable. Smooth pits with a buffing wheel to remove sharp edges and do not remove parent metal.

3. Valleys with visible wear are acceptable as long as there is chrome or tungsten coverage.

4.8 Additional Stator Inspection

Visually inspect the stator using a flashlight. Look for washing, wear, pitting, excessive rust and cracks. Identification bands and numbers should be clearly visible. Note any damage(s) found on the Drill Motor (or DHV) 3rd Party Inspection Report.

4.8.1 Acceptable Criteria Hard banding cracks and chips are acceptable as long as they do not exceed the underlying metal and 10% of the hard band area. Metal needs to be ground down to a smooth finish in order to eliminate rough edges.




4.9 Examples of Non-Conforming Damage

Figure 1: Stator Chunking

Figure 2: Cracked & Worn




Figure 3: Damaged Rotor

Figure 4: Pitting




Figure 5: Missing Buttons & Worn Pad

Figure 6: Damaged Facing




Figure 7: Washing

Figure 8: Pitting & Worn




Figure 9: Pitting & Worn

Figure 10: Pitting




Figure 11: Worn Pad




5 MWD Nonmagnetic Tubular Products Inspection Procedure This procedure outlines the shop inspection steps and requirements for MWD and LWD downhole equipment.

5.1 Preparation 1. Gather the following tools:

• Paint marker

• Depth gage

• 12 in. metal rule (graduated in 1⁄64 in. increments)

• Metal straightedge

• Hardened and ground profile gage

• ID and OD calipers

• Lead gage

• Standard lead template

• Manufacturer’s Inspection Procedures

• Light (for illuminating all internal surfaces)

• Metal scale

• Tape measure

• Flat file or disk grinder

• Flue brush

• Borescope

• Ultrasound thickness gage

The lead gage must show evidence of calibration in the past six months. The lead template must show evidence of calibration in the last year. Calibration must be traceable to NIST standards or those of an equivalent body.

2. Record the tool serial number and description on the MWD Non-Mag Tubulars 3rd Party Inspection Form. Return the tool to the machine shop if no serial number can be located, unless the customer waives this requirement.

3. Clean all surfaces that will be inspected to the point that shiny metal surfaces are visible and no traces of scale, mud or lubricant can be wiped off with a clean rag. Surfaces include the entire machined pin and box areas, a minimum of 1 in. beyond the last thread, and the internal surfaces of the pin from tip to shoulder.

4. Use a grinder to buff connections, holes, and hardband until bare material is visible. Grinding or buffing defects or imperfections is strictly prohibited.

5. Clean collar ID with the flue brush.




6. After cleaning, dry the inspection surface so that a dry towel or tissue does not absorb any moisture when rubbed on the surface.

5.2 Liquid Penetrant Inspection Inspect the end connections, mid-body connections, and any unique mid-body features. Any cracks are cause for rejection. Refer to Sec. 3.2.

Visible water washable, solvent removable, fluorescent liquid or visible penetrant techniques may be used.

5.2.1 Inspection Apparatus • Penetrant and developer must be from the same manufacturer. Penetrant material labeling

must specify that the materials meet ASTM E165 sulfur and halogen requirements.

• Dry powder or solvent-based developers may be used for visible techniques.

• Penetrant material and inspection procedure quality must be verified by testing a cracked test piece.

• A magnifying mirror is required for the examination of the box threads and pin ID.

5.2.2 Penetrant Application 1. Spray tools with liquid penetrant in the end connections, mid-body connections and

unique mid-body features on nonmagnetic tools.

2. Using a mirror, check for complete coverage on the box threads.

3. Let penetrant dwell on tools.

• Dwell time must be within 10-60 minutes, unless the penetrant manufacturer’s recommendations state otherwise (in which case, use the recommendations). Penetrant testing must not be performed if the ambient or component temperature is less than 40°F or greater than 125°F.

• The penetrant must not dry. Additional penetrant may be applied to prevent drying—but the part must be re-cleaned if all penetrant dries.

5.2.3 Penetrant Removal 1. For water washable systems: Wash penetrant off with a low-pressure water spray. Air-

dry the part or dry it with lint-free cloths. If using generated warm air, the temperature at the part surface must not be more than 120°F. To prevent over-washing for fluorescent penetrant, use a backlight and terminate spray immediately after the background has been removed.

2. For visible solvent removable systems: Wipe the part surface with a lint-free cloth. Spray solvent on a similar cloth and use it to remove any remaining surface penetrant. Repeat if needed. Wipe the part surface again with a lint-free cloth. Do not spray solvent or apply directly it to the test surface.

3. Use a magnifying mirror to make sure that excess penetrant has been completely removed from the box threads and pin ID.

5.2.4 Developer Application 1. Apply developer to areas that had penetrant on them.




• Developer must be applied within five minutes of completing the post-rinse drying operation (not required for self-developing penetrants).

• The method of developer application must provide visually uniform coverage over the surface being examined (not required for self-developing penetrants).

• Developing time must be half the allowed penetrant dwell time—but not less than 7 minutes or more 30 minutes.

5.2.5 Examination 1. Within one minute of applying developer, examine for gross imperfections or surface

contamination. Use a blacklight with fluorescent penetrant.

2. Conduct a final examination after allowing the full developing time to complete. Check for any penetrant bleed back and for crack indications—particularly the last-engaged thread roots of pins and boxes (use a mirror to inspect box surfaces).

3. Remove penetrant and developer with water or solvent spray after inspection. Use a blacklight with fluorescent penetrant to check for complete removal.

4. Parts with possible defects or imperfections must be re-cleaned and re-inspected. Grinding or buffing defects or imperfections is strictly prohibited.

5.3 Visual Inspection 1. Visually examine the outside surface of the tool from shoulder to shoulder for

mechanical damage.

2. Re-clean and re-inspect parts with potential defects or imperfections. Any cut, gouge or similar imperfection deeper than 10% of the tool’s nominal surface thickness (OD-ID/2 when measured with calipers and a pit gauge, or measured ultrasonically) is cause for rejection (unless SDI waives this requirement). Grinding or buffing defects or imperfections is strictly prohibited.

3. Spray paint tools that have damage, are rejected, or repaired. Refer to Sec. 3.2

5.3.1 Connection Inspection If the tool contains mid-body connections or other sealing mechanisms the following shall apply:

A. Seal Surface

• If a mid-body connection or unique geometrical feature forms a pressure seal, the seal surface must be free of raised metal or protruding corrosion deposits.

• Deposits may be detected visually or by rubbing a fingernail across the surface. Do not rub with a metallic object in order to avoid scratching the surface and compromising seal integrity.

• Any pitting or interruptions of the seal surface is cause for rejection.

B. Thread Surfaces

• Thread surfaces must be free of pits or surface imperfections that appear to exceed 1⁄16 in.[D] or ⅛ in.[d], that penetrate below the thread root, or that occupy more than 1 ½ in.[L] along any thread helix.




• Raised protrusions must be removed with a hand file or soft (non-metallic) buffing wheel. The thread profile must be checked after any buffing or filing of the threads.

5.3.2 Body Inspection Tool bodies must meet the following acceptance criteria:

A. Hardbanding

• When present, hardfacing must not extend more than 3⁄16 in. above the tool joint surface.

• Broken or missing areas larger than 1⁄8 inch across the major dimension are not allowed. Hairline cracks in the hardfacing are permissible, as long as the cracks do not extend into the base metal.

B. Cracks

• Examine all connections and tool joint bodies for visible cracks or heat checking.

• Any crack is cause for rejection. Grinding to remove cracks is not acceptable.

C. Bevel Width

• An approximately 45° degree OD bevel at least 1/32 in.[W] must be present for the full circumference on both the pin and box connection.

D. Box Swell

• Place a straightedge along the longitudinal axis of the box tool joint. If a visible gap exists between the straightedge and the tool joint, the OD must be measured using calipers.

• Compare the OD at the bevel to the OD approximately 2 in. away from the bevel. If the OD at the bevel is greater than the second measurement by 1⁄32 in. or more, the connection must be rejected.

E. Refacing

• If refacing is necessary, remove only enough material to correct the damage. Refacing limits are 1⁄32 in. for one removal and 1⁄16 in. total.

• If existing benchmarks indicate the shoulder has been refaced beyond the maximum, the connection must be rejected.

F. Pin Thread Profile

• The profile gage must mesh with the thread load and stab flanks, so that no light is visible at any of the flanks or thread roots.

• Visible gaps estimated to be no greater than 1⁄16 in. (no more than two thread crests) are permissible. Uniform flank wear estimated to be less than 1⁄100 in. is permissible. However, any visible gaps at the thread flanks require pin lead measurement.

• Perform two thread profile checks 90° apart on each connection.

G. Pin Lead

• If the profile gage indicates the pin is stretched, pin lead must be measured in 2 in. intervals—beginning at the first full-depth thread nearest the shoulder.




• Pin stretch must not exceed 0.006 in. per 2 in.[L]. Perform two lead checks 90° apart.

H. Box Taper

• Visually inspect the box taper at the back of the box connection. A smooth taper of 30-45° should be present.

• Steps or sharp taper angles are cause for rejection.

I. ID Inspection

• Use a boroscope to inspect the inside of the collar. On the outside, mark and measure areas where severe ID wash, pitting or other defects were observed.

5.4 Dimensional 3 Inspection Method Refer to T H Hill DS-1, Fourth Edition, Volume 3, Table 3.8 (Used BHA Connection Dimensional Acceptance Criteria).

1. Perform a visual connection inspection in conjunction with this inspection. Tools must meet the following acceptance criteria.

A. Box OD

• Box connection OD must be measured 4 in. (+/- ¼ in.) from the shoulder. At least two measurements must be taken at intervals of 90 degrees (°).

B. Box Counterbore Diameter

• Box counterbore diameter must be measured as near as possible to the shoulder (excluding any ID bevel or rolled metal) at diameters 90° apart.

• Counterbore diameter must not exceed the maximum counterbore dimension shown in T H Hill DS-1, Fourth Edition, Volume 3, Table 3.8 (Used BHA Connection Dimensional Acceptance Criteria).

C. Box Counterbore Depth

• Box counterbore depth must be measured (including any ID bevel) on all tools.

• Counterbore depth must not be less than the value shown in T H Hill DS-1, Fourth Edition, Volume 3, Table 3.8 (Used BHA Connection Dimensional Acceptance Criteria).

D. Bevel Width

• An approximately 45° degree OD bevel at least 1/32 in.[W] must be present for the full circumference on both the pin and box connection.

E. Drill Collar Pin Length

• The length of the connection pin must be measured and meet the requirements of T H Hill DS-1, Fourth Edition, Volume 3, Table 3.8 (Used BHA Connection Dimensional Acceptance Criteria).

F. Shoulder Flatness

• Box shoulder flatness must be verified by placing a straightedge across the diameter of the tool joint face, and rotating the straightedge at least 180° along the plane of the shoulder. Any visible gaps are cause for rejection.




• The procedure must be repeated for the pin, with the straightedge placed across the shoulder surface chord closest to the pin neck. Any visible gaps between the straightedge and the shoulder surface are cause for rejection.

2. Spray paint tools that have damage, are rejected, or repaired. Refer to Sec. 3.2.

5.5 Post-Inspection

1. Take measurements and check thread profile. Record all measurements and tool findings on the MWD Non-Mag Tubulars 3rd Party Inspection Form

2. Place a 2 in.[W] white paint band, 12 in. from the shoulder of each acceptable connection.

3. Using a permanent white paint marker, stencil OK, the name of the inspection company, and the inspector’s initials (for example, OK JCI CS).

Figure 12: Inspection Stencil

4. Apply an API tool joint compound to coat acceptable connections over all thread and

shoulder surfaces, as well as the end of the pin.

5. Ensure thread protectors are installed and securely tightened. Thread protectors must be free of debris.

6. Submit the MWD Non-Mag Tubulars 3rd Party Inspection Form (containing all pertinent dimensions and tool/connection findings) to the SDI personnel requesting inspection.




5.6 Examples of Non-Conforming Damage

Figure 13: Damaged Bevel

Figure 14: ID Pitting




Figure 15: OD Pitting

Figure 16: Set Screw Hole Washout

Figure 17: Base Metal Cracks by Hard Banding




Figure 18: Damage Marking




6 Records Title/Description Retention

Period Retained By

Non-Conformance Report 5 years Local Motor Shop

Drill Motor 3rd Party Inspection Report 3 years Local Motor Shop

DHV 3rd Party Inspection Report 3 years Local Motor Shop

MWD Non-Mag Tubulars 3rd Party Inspection Form 3 years Districts (or HTC Purchasing Department)