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Transcript of API Manf
8/10/2019 API Manf
http://slidepdf.com/reader/full/api-manf 1/3
APIProto
High-
FIRST EDITI
This report
pressure hi
petroleum
design verif selection c
controls ne
service in t
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a) the co
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temper
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seafloo
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NOTE In h
methodologi
The design
methods to
performanc
component
selection. T
evaluating
the effects/
appropriate
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validation o
defines the
process an
evaluate th
environmen
HPHT equip
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Teol for
emper
ON | MARCH
ocuses on an
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nd natural ga
ication analysnsiderations,
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ts are intend
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reater than 1
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he design vali
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consequence
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against the id
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s industries
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ntrol equipme
reater than 3
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this document
ocess focuse
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s service life
dation proces
ailure modes
s of the failur
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formance. Th
t parameters
s the procedu
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ipment in the
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nt assigned a
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ellhead or at
llhead; orthan 350 °F
ellhead or on
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applications, n
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nd material
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RODUCT NO.
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API
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G1PER15K11
design verific
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plement the
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mation:
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54-7179
in the U.S. an
-397-7056
d Internation
-397-2740
eive a 30% dis
K-1press
ation protocol
us API subco
rds on equip
This report isspecifications
accepted pra
ed in order to
ment. This rep
ent: wellhead
ctions, seals,
hokes, and we
ther equipme
d Canada)
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pplicable.
8/10/2019 API Manf
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Contents
Page
1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Existing Designs and In-service Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Abbreviations and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Functional Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Specified Loads and Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Life Cycle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Applicable Industry Standards and/or Regulatory Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.5 Response to Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.6 Fit-for-service Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.7 Aftermarket Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Best Practices and Guidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206.2 Design Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3 Design Validation Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Manufacturing Process Specification (MPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.5 Aftermarket Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Annex A (informative) Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Annex B (informative)Metallurgical-related Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Annex C (informative) Failure Modes and Effects Analysis (FMEA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Annex D (informative) Technical Considerations on the Selection of Castings and Forgings . . . . . . . . . . . . . 81
Annex E (informative) Quality Management System Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figures
1 System Analysis Specification Breaks (Completion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 System Analysis Specification Breaks (Drilling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Performance Envelope Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Combined Loading Capacity Chart from API 6AF1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Example of True Stress for 2 1 /4Cr-1Mo True Strain Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Validation Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A.1 Example of Effect of Temperature on Thermophysical Properties of 4130 and 4340 (MMPDS) . . . . . . . 55
v
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Contents
Page
A.2 Example of Effect of Temperature on the Tensile Ultimate Strength (Ftu) and Tensile
Yield Strength (Fty) of AISI Low-alloy Steels (All Products) (MMPDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
A.3 Example of Compendium of Cyclic Curves for Carbon Steel and 2 1 /4Cr-1Mo . . . . . . . . . . . . . . . . . . . . . 58
A.4 Example of Effect of Temperature on Tensile Properties of Alloy N08535 in 125 ksi
Minimum Yield Strength Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
A.5 Example of Effect of Temperature on Strength of Alloy 25CrW (UNS S39274) . . . . . . . . . . . . . . . . . . . . . 60
A.6 Example of Effect of Temperature on the Thermophysical Properties on UNS N07718 (MMPDS) . . . . . 62
C.1 FMEA Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
C.2 General Validation FMEA Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
C.3 Detailed Validation FMEA Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
C.4 Modified Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tables
1 API References for Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Material Properties Cited by Design Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Typical Carbon and Low-alloy Steels for HPHT Use (T > 350 °F or P > 15,000 psi) . . . . . . . . . . . . . . . . . . 23
4 Stainless Steel and Corrosion Resistant Alloys for HPHT Use (T > 350 °F or P >15,000 psi). . . . . . . . . . 24
5 List of Typical Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 Typical Protocols for Property Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7 Summary of Test Protocols for Nonmetallic Materials in M-710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Cross References of Industry Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Reference Industry Standards for Design Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10 Reference Industry Standards for Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A.1 Example of Thermal Decay of API 5CT Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
A.2 Recommended Yield Strength Reduction Ratios in Percent by Temperature for Low-alloy Steels . . . . 55
A.3 Example of Composition of 4130M7 Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
A.4 Example of Hot Tensile Testing of 4130M7 Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57A.5 Recommended Yield Strength Reduction Ratios in Percent by Temperature for Stainless
Steels and CRA Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A.6 Example of Mechanical Properties of Alloy 825 (Cold Worked) from 4 in. Diameter Tube. . . . . . . . . . . . 61
A.7 Example of Chemical Composition of Heats Tested. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
A.8 Example of Tensile Properties as a Function of Temperature for INCONEL® Alloy 725. . . . . . . . . . . . . . 63
A.9 Example of Composition of Alloy Tested in the Accompanying Tensile Data . . . . . . . . . . . . . . . . . . . . . . 66
A.10 Example of Tensile Properties of Titanium 6-2-4-6 (UNS R56260). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
B.1 Field Failures of Completion and Production Equipment from 1975 to Present . . . . . . . . . . . . . . . . . . . . 68
C.1 Validation FMEA Worksheet Headings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
C.2 Severity Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
C.3 Occurrence Matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
C.4 Detection Matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
C.5 Verification Results and Load Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
C.6 Test Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
C.7 Test List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
C.8 Tests Ranked by TPN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80