As soon as you walk into our shop you'll realize we're set up to maintain and build our downhole tools properly. We have a CNC 6.25" thru bore that can take on any job for cased hole complimented by two manual lathes that can do thread repairs. The CNC is crucial for making threads and o-ring grooves within spec. Our horizontal / vertical mill is extremely handy especially when using dual dividing heads for rigidity while making angled cuts or holes. We've converted a log splitter, added a 3 hp hydraulic motor, and mounted it to the floor inline with a skate system and three heavy duty pipe vises. This allows us to pull apart and service tools with 50,000 pounds of force. We have a pressure wash bay to take care of those muddy and oily tools with out getting our machines dirty. From there our tools go to our paint booth which has a down draft vent connected to it to keep the fumes down while working in the shop. Our only complaint is we could use more room for our fast growing company.
API x-overs and fishing tools
When we produce downhole tools, we start off by drawing the model in Solidworks. We analyze the overlapping profiles to make sure there are no weak spots. Then analyze the tool for ball drop operations, ease of use, fluid turbulence, etc... Only an Oilfield Guy would truly understand this. From there it goes to our Journeyman Chad Martin who has worked in the tool manufacturing business for 18 plus years. He programs the 6.25" thru bore CNC to make sure the tool is created exactly like the drawing. Before the tool leaves the shop it goes through a corrosion treatment process which also makes it aesthetically nicer for our customer. Unlike most machine shops, our API threads are all machined using master thread gauges that were created in a lab. We don't cheat, as we know how critical this is in preventing a lost tool or a leaky joint!
3d Modelling downhole tools with Solidworks
To make any money in this competitive industry you need to make the wear components tougher. If it doesn't have to be ductile it can hardened, so some of our internals have been modified for wear resistance. Our temperature controlled kiln is crucial in controlling the hardening process. You don't have to be a metallurgist to modify the properties of the steel because most tools are a 4140 alloy steel and it makes it easy when only dealing with one type. Drop by our shop when we're in the process, come see the flames shoot up in the air when quenching... it's fun making Oil Tools!
2500 Degree fahrenheit kiln for hardening, tempering, and normalizing steel.
We can MPI parts to ensure there's no hidden cracks and pressure test it to make sure the oil tools are field ready. We can also do thread repairs on API threads which can save you a lot of money by avoiding buying a new tool. With our two 5" hydraulic rams we mimic the max forces ever seen in the field with coil tubing. We can pull test to 100,000 pounds beyond the yield strength of some 2 3/8" coil tubing. We record our test with a Go-Pro camera. After, we can analyze what the weakest link was. We've been surprised how strong and weak some existing tools actually are. Honestly, we just like putting a friendly wager on when or if it's going to fail.
Two 50,000 pound rams to mimic forces found with deployed tools. Event recorded by a Go-Pro camera.