XL Systems has established its position as an industry leader in large diameter connectors by developing new technologies that enhance product performance and value. Our large bore integral threading process is unique in the industry. Key technologies such as ViperLock anti-rotation, Stingray automated welding and ultrasonic phased array weld inspection allow us to deliver high performance connectors at competitive price levels.

Threading
Proprietary wedge thread technology is the key to unlocking the superior cost-efficient performance of XL Systems large-bore integral connectors. Threads are cut directly into the pipe wall, optimizing the connection geometry and function. In the madeup position, the connector threads wedge together, forming a dovetail fit that essentially locks the pin and box together. Machining a quality connector as an integral part of the pipe makes wedge thread products a cost-effective alternative to traditional connectors.

Wedge thread connectors are free-running for approximately 90% of make-up turns. The first resistance in makeup comes from thread root to thread crest interface, then metal-to-metal seal contact. In the final stage, the thread flanks wedge together, forming a dovetail fit between the negative stab and load flanks. This dovetail fit means that the threads will not radially separate or "jump out" under load.

The flush inside diameter (ID) and flush outside diameter (OD) connector profile provides some unique advantages for casing design. Platform conductor guides can be downsized and external centralizers eliminated. Smaller hole sizes can be drilled with flush OD connectors, reducing mud and cement volumes. Less annular clearance is required between large OD strings, potentially reducing the required conductor diameter.

Welding
Development of the Viper connector is a direct result of our commitment to pushing the limits of technology. Upon entering the large-bore weld-on connector market in 2003, XL Systems commissioned a review of current welding technology in an effort to identify more cost-effective methods. Our evaluation verified that submerged arc welding is still the most viable means of welding large-bore connectors to pipe.

The research identified an opportunity to reduce time spent in manual fit-up and manual root pass welding. A self-aligning edge preparation and a highly automated welding machine were developed. The resulting process, Stingray sub-arc welding, automates the alignment phase and eliminates all manual welding. Welding time is reduced by as much as 75% while weld quality is significantly improved. XL Systems currently has Stingray welding machines in operation at strategic locations across the globe.

Testing
XL Systems has a clearly established position as a technology leader in the tubular connector industry. This commitment to technology is evident in XL Systems' approach to physical testing of large diameter connectors. The Company has invested heavily in state-of-the-art equipment for load testing these large-bore connectors, including a full-scale bending test frame for 20- to 38-inch diameter connectors, a large diameter harmonic fatigue test machine for 20- to 36-inch connectors and combined pressure and axial load test frames rated up to three million pounds and 30,000 psi. XL Systems uses extensive full-scale testing to verify connector performance ratings. There is no substitute for the peace of mind that full-scale load test data provides when selecting connectors for performance-critical applications.

Weld Inspection
"The status quo is not good enough." This was XL Systems' approach when selecting a new process for inspecting pipe-to-connector welds. Most welding companies use either X-ray (RT) inspection or manual ultrasonic (UT) methods. X-ray provides a permanent inspection record (the exposed film) but presents a radiation hazard. Manual UT inspection provides no permanent inspection record. XL Systems partnered with a known technology leader in Phased Array Ultrasonic (PAUT) weld inspection to tailor this technology to pipe-to-connector welding. Perhaps the most exciting new development in weld-on connector inspection today, PAUT provides an environmentally friendly process and a permanent record of the inspection.