Technology Bulletin No.

: SWT-10-009
Date: September 30, 2010
PO Box 819052, Dallas, Texas 75381-9052 USA Issued: SW/MW
CPS-Surface Well Testing Approved: HK

Subject: Halliburton 10K and 15K Frac Flowback Test (FFT) Choke Manifold

Introduction

This purpose of this bulletin is to inform all locations about the abrasion-resistant inlay in
the 10K (SAP No. 101788314) and 15K (SAP No.101788324) choke manifolds. This
issue has been raised following nondestructive examination (NDE) inspections
subsequent to the initial NDE performed by the manufacturer. On delivery, certain
surface discontinuities can be seen in the various components containing the abrasion-
resistant weld inlay. These discontinuities are an observed characteristic of the inlay
material and do not negatively affect the structural integrity of the product. See Table 1
for a list of affected equipment.

Also, the supplied MDRs might include a nonconformance report (NCR) marked with a
“Reject” disposition, which should be replaced.

Background

The purpose and design of the frac flowback test (FFT) choke manifold is to stage the
pressure drop and wear incurred when flowing solids through the choke manifold across
multiple choke beans and surface area. In addition to this staging of the pressure drop
across multiple choke beans, the flow-wetted surfaces of the FFT choke manifold have
also been protected, as much as practical, with a thin layer of a tungsten carbide-based
material applied as a welded overlay.

As identified during the qualification of the weld procedure used to apply it, this overlay
will contain discontinuities, which NDE will reveal as surface indications. These
indications are not considered by Testing and Subsea Engineering to affect the
structural integrity of the product.

Destructive testing of the weld-procedure qualification samples revealed that some of

these discontinuities were open to the surface but none extended from the surface to the
parent material. The supplier was able to reduce the size and frequency but not
eliminate the discontinuities. The overlay is applied for abrasion resistance only and is
not structural.

CONFIDENTIAL HALLIBURTON INFORMATION

This document is confidential, proprietary property of Halliburton Energy Services, Inc. It is supplied for
use by Halliburton employees only and shall not be copied, published, or disclosed in whole or in part
without the prior written consent of Halliburton.

© 2010 Halliburton

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Testing and Subsea Engineering believes that because of the limited thickness of the
overlay–0.09 in. (2.3 mm)–and the broad difference in physical properties between it and
the parent material, any discontinuity in the overlay would not adversely affect the parent
material.

Long-term suitability is contingent on post-job visual inspections to determine if these

discontinuities will be detrimental to the abrasion resistance of the applied overlay.

Required Action

Figs. 1 and 2 show the expected appearance of the weld inlay. Any characteristics that
are not similar to the aforementioned descriptions should be reported to technology.
Specifically, in-focus photographic evidence should be documented and emailed to
technology for review, along with the SAP Nos. and original documentation associated
with the pictures. All descriptions of anomalies will be handled on a case-by-case
scenario.

Fig. 1—Surface discontinuities on the ID of the FFT choke-manifold block.

Because of the hardness of the weld material, the inlay is ground rather than machined
to the above finish. After grinding, the discontinuities can be seen in greater detail; this is
a very normal appearance. The surface discontinuities initiate during the first weld
rotation and then propagate throughout the remainder of the welded material. The
depths of the discontinuities do not exceed 75% of the inlay thickness. The inlay does
not affect the integrity of the base material.

© 2010 Halliburton

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Fig. 2—Dye penetration-test result.

The green arrows signify acceptable dye penetration into the weld material. It is the
inherent nature of the product to bubble or to develop surface discontinuities large
enough for liquid seepage. It is important that discontinuities should not be located on
any of the sealing surfaces identified by the red arrow.

Please alert technology if any indications can be seen on the sealing surfaces of the
flange ends.

Figs. 3 and 4 show a post-delivery NDE test performed by third-party personnel in Brazil.
These photos are considered to be expected appearance of the inlay material.

© 2010 Halliburton

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Date: September 30, 2010 Technology Bulletin

Fig. 3—15K choke-manifold block with special inlay material.

Fig. 4—15K choke manifold with special inlay material.

Some MDRs have been identified that include NDE NCRs with a “Reject” disposition
(Fig. 5). The NCR should have an “Accept as is” disposition.

Please contact WOM, Inc. for a copy of the most recently updated NCR (Fig. 6).

Aaron Bishop
Worldwide Oilfield Machine, Inc., Houston, Texas
Business: 713-729-9200, Mobile: 281-433-0618
aaronb@womusa.com

© 2010 Halliburton

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Date: September 30, 2010 Technology Bulletin

Fig. 5—Sample original datasheet with “Reject” marked as the disposition.

© 2010 Halliburton

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Fig. 6—Sample updated supplier NCR.

© 2010 Halliburton

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Table 1—Affected FFT Choke-Manifold Equipment

SAP No. Description
101788314 CHOKE MAN, FRAC, 3 1/16-10K, H2S, CE, SWT
101827253 CHOKE, ADJ, SPCL INLAY, 3 1/16-10K, H2S, CE
101827254 SPOOL, WEAR, SPECIAL, 3 1/16 10K × 18.63L, SWT
101827255 CROSS, 4W, SPECIAL, 3 1/16 10K, SWT
101827256 FLGD XO, 3 1/16-10K × 3IN FIG 1502(T), SWT
101827257 FLGD XO, 3 1/16-10K × FIG.1502(W), SWT
101827258 T, STDED, SPECIAL INLAY, 3-1/16-10K, SWT

101827261 CROSS, SPECIAL, 4W STUD, 3 1/16-10K, SWT

101788324 MANIFOLD, CHOKE, FRAC, 3 1/16-in. 15K, CE, SWT
101829544 CHOKE, ADJ., SPCL, 3 1/16-in.-15K, H2S, CE, SWT
101829545 SPOOL, WEAR, SPECIAL, 3 1/16 15K × 21.66L, SWT
101829546 CROSS, SPECIAL, 4WAY, 3 1/16 15K, SWT
101829547 BLOCK, SPECIAL, 3WAY, 3 1/16 15K, SWT
101829549 CROSS, SPECIAL, 4WAY, 3 1/16 15K, SWT
101829553 CROSS, SPECIAL, 4W STUD, 3 1/16-15K, SWT

For more information, contact:

Matthew Wyatt, Technical Professional, SWT
Telephone: 972-418-3143
Matthew.Wyatt@halliburton.com

Steven Woolsey, Global Advisor, SWT

Telephone: 281-871-7309
Steven.Woolsey@halliburton.com

© 2010 Halliburton

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