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Specification for Drill-throughEquipment Repair and Remanufacturing

ANSI/API Specification 16AR (SPEC 16AR)First Edition, ….. 2014Effective Date: ….2014

SPECIAL NOTES

API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws.

Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect five years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Standards department telephone (202) 682-8000. A catalog of API publications, programs and services is published annually and updated biannually by API, and available through Global Engineering Documents, 15 Inverness Way East, M/S C303B, Englewood, CO 80112-5776.

This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or comments and questions concerning the procedures under which this standard was developed should be directed in writing to the Director of the Standards department, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. [email protected] Requests for permission to reproduce or translate all or any part of the material published herein should be addressed to the Director, Business Services.

API standards are published to facilitate the broad availability of proven, sound engineering and operating practices. These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices.

Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.

All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C.

20005.

Copyright © 2005 American Petroleum Institute

FOREWORDThis standard shall become effective on the date printed on the cover but may be used voluntarily from the date of distribution.Standards referenced herein may be replaced by other international or national standards that can be shown to meet or exceed the requirements of the referenced standard. Manufacturers electing to use another standard in lieu of a referenced standard are responsible for documenting equivalency.This American National Standard is under the jurisdiction of the API Subcommittee on Drilling WellControl Systems.

In this American National Standard technical modifications and corrections will be incorporated.A complete list of these modifications and corrections can be found in Annex J.

This American National Standard replaces the repair and remanufacturing chapter from API 16A edition.

Please note that Annex I, API Monogram, has been amended to clarify what equipment is eligible for the repair/remanufacture monogram.

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal state, or municipal regulation with which this publication may conflict.Suggested revisions are invited and should be submitted to the API, Standards Department, 1220 L Street, NW, Washington, DC 20005, or by email to [email protected] Specification 16A / ISO 13533

CONTENTS

Table of Contents1. Scope............................................................................................................................1

1.1 General.................................................................................................................12. Normative References................................................................................................23. Definitions...................................................................................................................44. Abbreviated terms......................................................................................................135. Quality Control Requirements...................................................................................14

5.1 General...............................................................................................................145.2 Measuring and testing equipment......................................................................14

5.2.1 General...........................................................................................................145.2.2 Pressure-measuring devices...........................................................................14

5.3 Quality control personnel qualifications............................................................145.3.1 Non-destructive examination (NDE) personnel............................................145.3.2 Visual examination personnel........................................................................155.3.3 Welding inspectors........................................................................................155.3.4 Welder performance qualification.................................................................155.3.5 Third Party Inspection...................................................................................155.3.6 Certification...................................................................................................155.3.7 Other personnel..............................................................................................16

5.4 Quality control requirements for equipment and parts......................................165.4.1 General...........................................................................................................165.4.2 Material requirements....................................................................................165.4.3 Quality control instructions...........................................................................165.4.4 Non-destructive examination (NDE).............................................................165.4.5 Acceptance status...........................................................................................17

5.5 Quality control requirements for specific equipment and parts.........................175.6 Requirements for quality control records..........................................................21

6. Quality Management System Requirements.............................................................226.1 Communications................................................................................................226.2 Control of Documents........................................................................................226.3 Personnel Competence ......................................................................................226.4 Training and Awareness....................................................................................226.5 Control of testing, measuring, monitoring equipment.......................................236.6 Contract Review................................................................................................23

6.6.1 General...........................................................................................................236.6.2 Determination of Requirements.....................................................................236.6.3 Review of Requirements................................................................................24

6.7 Purchasing..........................................................................................................246.7.1 Purchasing Control........................................................................................24

6.8 Design and Development...................................................................................246.8.1 Design and Development Planning...............................................................246.8.2 Design documentation...................................................................................256.8.3 Design and Development Inputs....................................................................256.8.4 Design Verification........................................................................................256.8.5 Design Validation..........................................................................................25

iv

6.8.6 Control of design and development changes.................................................257. Responsibilities..........................................................................................................268. Quality requirements for Operation Service Levels..................................................269. Repair / Remanufacturing Service Level Minimum Requirements..........................28

9.1 Requirements for Pressure Testing....................................................................289.1.1 General...........................................................................................................289.1.2 Hydrostatic Proof/Shell Test..........................................................................289.1.3 Operating Chamber Pressure Test.................................................................289.1.4 Hydrostatic proof and operating chamber pressure tests...............................289.1.5 Closed-preventer test.....................................................................................289.1.6 Low Pressure Test..........................................................................................299.1.7 High Pressure Test.........................................................................................299.1.8 Acceptance Criteria.......................................................................................299.1.9 Annular packing unit tests.............................................................................299.1.10 Rams lock test............................................................................................299.1.11 Blind-shear rams........................................................................................29

9.2 Elastomeric Seal Requirements.........................................................................309.2.1 Wellbore Sealing Components and Consumables.........................................309.2.2 Operating Sealing Components and Consumables........................................309.2.3 Equipment Marking and Storage...................................................................30

9.3 Dimensional check.............................................................................................329.4 NDE – Initial Inspection....................................................................................329.5 Hardness –.........................................................................................................329.6 Personnel Qualification Requirements – see QA program requirements..........329.7 Inspection on closure bolting (pressure retaining).............................................339.8 Visual Inspection at disassembly.......................................................................339.9 Drift Test............................................................................................................339.10 Replacement Parts – Qualifications...................................................................339.11 Hot work Qualifications/Procedures..................................................................339.12 Documentation...................................................................................................34

10. Materials................................................................................................................3510.1 Compliance to NACE MR 0175 / ISO 15156...................................................3510.2 Material Chemical Composition and Mechanical Properties............................3510.3 Mechanical properties........................................................................................3510.4 Non-metallic parts.............................................................................................3610.5 Base metal material Identification.....................................................................36

10.5.1 Determining Hardness and approximate ultimate tensile values:..............3610.5.2 Determining Chemical Composition:........................................................3610.5.3 Engineering judgment based on service/field experience.........................37

10.6 Filler material qualification...............................................................................3711. Welding..................................................................................................................38

11.1 General...............................................................................................................3811.2 Weldment design and configuration..................................................................3811.3 Welding procedure qualifications......................................................................3811.4 Welding specification requirements..................................................................4011.5 Welder specifications.........................................................................................40

11.6 Materials............................................................................................................4011.6.1 Base materials............................................................................................4011.6.2 Filler materials...........................................................................................4111.6.3 Repair welds and PWHT...........................................................................4211.6.4 Preheating..................................................................................................4411.6.5 Corrosion-resistant and wear-resistant overlays........................................4411.6.6 Welding controls........................................................................................4411.6.7 Quality Assurance Quality Control...........................................................45

11.7 Welding controls................................................................................................4511.7.1 Procedures..................................................................................................4511.7.2 Application................................................................................................4511.7.3 Designed welds..........................................................................................4511.7.4 Materials....................................................................................................45

11.8 Welding procedure and performance qualifications..........................................4611.8.1 General.......................................................................................................4611.8.2 Base metals................................................................................................4611.8.3 Heat-treat condition...................................................................................4611.8.4 Procedure qualification record...................................................................46

11.9 Other requirements............................................................................................4611.9.1 ASME Section IX, Article I — Welding general requirements................4611.9.2 General.......................................................................................................4611.9.3 Hardness testing.........................................................................................4611.9.4 General.......................................................................................................4611.9.5 ASME Section IX, Article II — Welding procedure qualifications..........4811.9.6 ASME Section IX, Article III — Welding performance qualifications....48

11.10 ASME Section IX, Article IV — Welding data................................................4911.10.1 Article IV of ASME Section IX shall apply as written.............................4911.10.2 General.......................................................................................................4911.10.3 Welder qualification..................................................................................4911.10.4 Welding Process Specification (WPS)......................................................4911.10.5 Welding Process Qualification Record (WPQR)......................................4911.10.6 CRA welding.............................................................................................49

12. Decommissioning..................................................................................................5013. Certification...........................................................................................................50Annex A.............................................................................................................................52Annex B.............................................................................................................................55Annex C.............................................................................................................................56Annex D.............................................................................................................................57Annex E (informative) Recommended weld preparation design dimensions..................58Annex E.............................................................................................................................62Annex F.............................................................................................................................63

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SPECIFICATION FOR REPAIR AND REMANUFACTURING OF WELL CONTROL EQUIPMENT 1

1. Scope1.1 GeneralThis American National Standard specifies requirements for repair, remanufacturing, testing, inspection, welding, marking, certification, recertification, handling, storing and shipping of drill-through equipment used for drilling for oil and gas build under API-16A. When desired this standard can also be voluntary adopted for other well control equipment build under a different specification, but this will not automatically make them API products. This standard defines Repair Service Levels for the below listed equipment and the required equipment traceability that is required to proof compliance. The repair and remanufacturing supported under this standard requires that the associated service conditions of the equipment in terms of internal pressure, temperature and wellbore fluids and ambient temperature limits for which the equipment is designed remains unchanged and is supported by the Original Product Definition.

This American National Standard is applicable to and establishes requirements for the following specific equipment:

a) ram blowout preventers;

b) ram blocks, operators, packers and top seals;

c) annular blowout preventers;

d) annular packing units;

e) hydraulic connectors;

f) drilling spools;

g) adapters;

h) loose connections;

i) clamps.

j) drilling riser

Dimensional interchangeability is limited to end and outlet connections. Typical equipment defined by this American National Standard is shown in Figures 1 and 2.

Recommendations for failure reporting are outlined in Annex B.

This API standard supports the requirements of life cycle management systems for new, individual, API monogrammed products or system parts throughout their functional life cycle.

1


Key:1. Ring gaskets ISO 104232. Annular BOP3. Clamp4. Ram BOP5. Drilling spool6. Valve ISO 10423

7. Wellhead8. Casing9. End and outlet connections10. Drill-through equipment ISO 1353311. Wellhead equipment ISO 10423

Figure 1 — Typical surface drill-through equipment

2


Key:1. Riser connector2. Flex/ball joint3. Annular BOP4. Hydraulic connector5. Adapter6. Ram BOP7. Valve ISO 10423

8. Hydraulic connector9. Wellhead10. Riser equipment, including kill, choke,

booster and control fluid conduit lines.11. Drill-through equipment ISO 1353312. Wellhead equipment ISO 10423

Figure 2 — Typical subsea drill-through equipment

4 API SPECIFICATION 16AR

2. Normative ReferencesThe following normative documents contain provisions, which, through reference in this text, constitute provisions of this American National Standard. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this American National Standard are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies. Members of IEC and ISO maintain registers of currently valid International Standards. When the latest edition is specified it may be used on issue and shall become mandatory 6 months from the date of the revision.

Standards referenced in this specification may be replaced by other international or national standards that can be proven to meet or exceed the requirements of the referenced standard. Product manufacturers, product owner/operators and repairers who use other standards in lieu of standards referenced herein are responsible for documenting the equivalency of the standards in order to provide traceability for compliance to this standard.

1) ISO 2859-1:1989, Sampling procedures for inspection by attributes — Part 1: Sampling plans indexed by acceptable quality level (AQL) for lot-by-lot inspection

2) ISO 6506-1, Metallic materials, Brinell hardness test, Part 1: Test method

3) ISO 6507-1, Metallic materials, Vickers hardness test, Part 1: Test method

4) ISO 6508-1, Metallic materials, Rockwell hardness test, Part 1: Test method (scales A, B, C, D, E, F, G, H, K, N,T)

5) ISO 6892, Metallic materials , Tensile testing at ambient temperature

6) ISO 10423:2001, Petroleum and natural gas industries — Drilling and production equipment — Wellhead and Christmas tree equipment

7) ISO 11961:1996, Petroleum and natural gas industries — Steel pipes for use as drill pipe — Specification

8) ISO 13665, Seamless and welded steel tubes for pressure purposes — Magnetic particle inspection of the tube body for the detection of surface imperfections

9) API Bulletin 6AF, Capabilities of API flanges under combinations of load

10) ASME Boiler and Pressure Vessel Code Section V, Article 5, UT Examination Methods for Materials and Fabrication

11) ASME Boiler and Pressure Vessel Code Section VIII, Division 1, Appendix 4, Rounded Indication Charts Acceptance Standard for Radiographically Determined Rounded Indications in Welds

12) ASME Boiler and Pressure Vessel Code Section VIII, Division 2, Pressure Vessel — Alternate Rules, Appendix 4, Design Based on Stress Analysis

13) ASME Boiler and Pressure Vessel Code Section VIII, Division 2, Pressure Vessel — Alternate Rules, Appendix 6, Experimental Stress Analysis

14) ASME Boiler and Pressure Vessel Code Section IX, Articles I, II, III and IV

15) ASTM A 193:1999, Specification for Alloy Steel and Stainless Steel Bolting Materials for High Temperature Service

16) ASTM A 320:1999, Specification for Alloy Steel Bolting Materials for Low Temperature Service

17) ASTM A 370:1997, Test Methods and Definitions for Mechanical Testing of Steel Products


18) ASTM A 453:1999, Specification for Bolting Materials, High Temperature, 50 to 120 ksi Yield Strength, with Expansion Coefficients Comparable to Austenitic Steels

19) ASTM D 395:1998, Standard Test Methods for Rubber Property — Compression Set

20) ASTM D 412:1998, Test Methods for Vulcanized Rubber, Thermoplastic Rubbers and Thermoplastic Elastomers

21) ASTM D 471:1998, Standard Test Method for Rubber Property — Effect of Liquids

22) ASTM D 1414:1994, Standard Test Methods for Rubber O-Rings

23) ASTM D 1415:1994, Standard Test Method for Rubber Property — International Hardness

24) ASTM D 1418:1999, Standard Practice for Rubber and Rubber Lattices — Nomenclature

25) ASTM D 2240:1997, Test Method for Rubber Property — Durometer Hardness

26) ASTM E 94:1993, Standard Guide for Radiographic Testing

27) ASTM E 140:1999, Hardness Conversion Tables for Metals

28) ASTM E 165:1995, Standard Test Method for Liquid Penetrant Examination

29) ASTM E 569:1997, Standard Practice for Acoustic Emission Monitoring of Structures During Controlled Simulation

30) ASTM E 747:1997, Standard Practice for Design, Manufacture, and Material Grouping Classification of Wire Image

31) Quality Indicators (IQI) used for Radiography

32) ASNT-SNT-TC-1A:1992, Recommended Practice for Personnel Qualification and Certification in Nondestructive

33) Testing

34) NACE MR0175–2000, Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment

35) SAE AMS-H-6875A:1998, Heat Treatment of Steel Raw Materials

36) Specification Q1: Specification for Quality Programs for the Petroleum, Petrochemical and Natural Gas Industry

37) Specification Q2: Specification for Quality Programs for the Petroleum, Petrochemical and Natural Gas Industry

38) API Specification 16A / ISO 13533

NOTE: Must check if the required standards for welding, welder qualification and inspection are included, including those for CRA low and high alloys like, and Super Duplex. Other applicable standards missed must be added to the list.NOTE: Must check the references for applicability and latest revisions.


3. Definitions

3.1 Design Status: The status of a traceable product with regard to changes to elements of the Original Product Definition (OPD) as well as improvements to the OPD or obsolescence of the product.

3.2 Original Product Definition (OPD): The complete definition of the requirements for the original assembled product, single equipment unit or component part, including specified limits and tolerances, health, safety and environmental requirements, limitations of use, customer specific requirements, design acceptance criteria, materials of construction, materials processing requirements and physical properties, physical dimensions and requirements for manufacturing process controls, inspection, assembly and testing, marking, handling, storage, maintenance, service and records requirements.

3.3 Product Owner/Operator:The owner or operator of the product repaired or remanufactured in compliance with this specification.

3.4 Product History File (PHF): The composite file of records from a traceable API product. The PHF includes all records associated with the original API product (including Monogram requirements) and those certification records required by this specification.

3.5 Traceable Product: An API product managed under the requirements of this specification.

3.6 Acceptance criteriaDefined limits placed on characteristics of materials, products or service

3.7 AdapterPressure-containing piece of equipment having end connections of different nominal size designation and/or pressure rating

3.8 Annular blowout preventerBlowout preventer that uses a shaped elastomeric sealing element to seal the space between the tubular and the wellbore or an open hole

3.9 Blind connectionEnd or outlet connection with no centre bore, used to completely close off a connection

3.10 Blind-Shear Ram (BSR)Closing and sealing component in a ram blowout preventer that first shears the tubular in the wellbore and then seals off the bore or acts as a blind ram if there is no tubular in the wellbore

3.11 Blind ramClosing and sealing component in a ram blowout preventer that seals the open wellbore API Specification 16A / ISO 13533


3.12 Blowout preventer (BOP)Equipment (or valve) installed at the wellhead to contain wellbore pressure either in the annular space between the casing and the tubulars or in an open hole during drilling, completion, testing or workover operations

3.13 BodyAny portion of equipment between end connections, with or without internal parts, which contains wellbore pressure.

3.14 BoltingThreaded fasteners used to join end or outlet connections

3.15 CalibrationComparison and adjustment to a standard of known accuracy

3.16 Cast, verbPour molten metal into a mould to produce an object of desired shape

3.17 Casting, nounObject at or near finished shape obtained by solidification of a substance in a mould

3.18 Chemical analysisDetermination of the chemical composition of material

3.19 Clamp, nounDevice with internal angled shoulders used to fasten mating hubs

3.20 Clamping loadAxial load applied to clamp hubs by the clamp due to bolt tightening

3.21 Closure boltingThreaded fasteners used to assemble pressure-containing parts other than end and outlet connections

3.22 ConformanceCompliance with specified requirements in every detail

3.23 Certificate Of Statutory Compliance: Document in which the OEM, OEM licensed facility, Repairer, Remanufacturer, or recognized technical authority certifies that the equipment and / or system meets the required standards or rules as depicted in the relevant area of operations regulatory requirement.

3.24 Certificate Of Conformance (COC): Document in which the OEM, OEM licensed facility, Repairer, Remanufacturer, or recognized technical authority certifies that the assembly or part has been manufactured / remanufactured in conformance to the mentioned standard(s), specifications and guidelines in accordance with the Original Product Definition, including design changes resulting from a malfunction or failure history of drill-through equipment manufactured, remanufactured and / or repaired to the appropriate American National Standard / Specification.

3.25 Certificate Of Usage Compatibility: Document in which a Manufacturer, Repairer, Remanufacturer, or recognized technical authority certifies that the part or system is compatible with the Original Product Definition, including design changes resulting from a malfunction or failure history of drill-through equipment manufactured, remanufactured or repaired to the appropriate American National Standard / Specification and is fully compatible and can be integrated into other systems guaranteeing the operations envelope as defined by the OEM.

3.26 Statement Of Fact (SOF):


Document in which the OEM, OEM licensed facility, Repairer, Remanufacturer, or recognized technical authority certifies that the maintenance / repair performed on a part or system is either not covered by a full service history and required traceability, or the maintenance / repair was made with limited scope defined by the Owner. The OEM, OEM licensed facility, Repairer, Remanufacturer, or recognized technical authority can therefore not provide the required guarantee that the whole part / system is in conformance with the Original Product Definition, including design changes resulting from a malfunction or failure history of drill-through equipment manufactured, remanufactured and / or repaired to the appropriate American National Standard / Specification.

3.27 Certificate Of Service: Document in which the equipment OEM, OEM licensed facility, Repairer, Remanufacturer, recognized technical authority / Owner or Operator certifies that that the equipment has been inspected, properly maintained and tested in accordance with Original Equipment Manufacturer (OEM) specifications.

3.28 Corrosion-resistant ring grooveRing groove lined with metal resistant to metal-loss corrosion

3.29 Critical componentPart having requirements specified in this American National Standard

3.30 Data acquisition systemSystem for storing and/or providing permanent copies of test information, like strip chart recorders, circular chart recorders or computer systems.

3.31 Date of manufactureDate of the manufacturer's final acceptance of finished equipment

3.32 Drilling spoolPressure-containing piece of equipment having end connections, used below or between drill-through equipment, manufactured in compliance with API-16A.

3.33 End connectionFlange (studded or open-face), hub connection or other end connection (3.47) used to join together equipment and integral to that equipment.

3.34 EquipmentAny single completed unit that can be used for its intended purpose without further processing or assembly

3.35 FlangeProtruding rim, with holes to accept bolts and having a sealing mechanism, used to join pressure-containing equipment together by bolting to another flange

3.36 Forge, verbPlastically deform metal, usually hot, into desired shapes with compressive force, with open or closed dies

3.37 Forging, nounShaped metal part formed by the forging method.

3.38 Gasket-seating loadThat portion of the clamping load required to seat the gasket and bring the hub faces into contact

3.39 Gasket-retaining loadThat portion of the clamping load required to offset the separating force the gasket exerts on the hubs when pressurized.


3.40 HeatCast lot material originating from a final melt.

NOTE For remelted alloys, a heat is defined as the raw material originating from a single remelted ingot.

3.41 Heat treatment / heat treatingAlternate steps of controlled heating and cooling of materials for the purpose of changing physical or mechanical properties

3.42 heat treatment loadThat material moved as a batch through one heat treatment cycle.

3.43 Hot-work, verbDeform metal plastically at a temperature above the recrystallization temperature

3.44 HubProtruding rim with an external angled shoulder and a sealing mechanism used to join pressure-containing equipment

3.45 Hydraulic connectorHydraulically actuated drill-through equipment that locks and seals on end connections

3.46 IndicationVisual sign of cracks, pits or other abnormalities found during liquid penetrant and magnetic particle examinations

3.47 Integral, adjParts joined by the forging, casting or welding process

3.48 Job-lot traceabilityAbility for parts to be traced as originating from a job lot which identifies the included heat(s)

3.49 LeakageVisible passage of pressurized fluid from the inside to the outside of the pressure-containment area of the equipment being tested

3.50 Loose connectionFlange (studded or open-face), hub connection or other end connection (3.47) used to join together equipment, but not integral to the equipment

3.51 MaintenanceRig based upkeep of the well control equipment which is performed in accordance with the equipment owner’s PM program and the manufacturer’s guidelines. These procedures may include but are not limited to, inspections, function testing, pressure testing, non-destructive examination and change out of parts.

3.52 Original Equipment Manufacturer (OEM)The design owner or manufacturer of the traceable assembled equipment, single equipment unit, or component part.

NOTE: If any alterations to the original design and/or assembled equipment or component part are made by anyone other than the OEM, the assembly, part, or component is not considered an OEM product. The party that performs these alterations is then designated as the OEM.

3.53 Other End Connection (OEC)Connection which is not specified in an API / ISO standard

NOTE: This includes API / ISO flanges and hubs with non-API / ISO gasket preparations and manufacturer's proprietary connections.


3.54 PartIndividual piece used in the assembly of a single unit of equipment

3.55 Pipe ramClosing and sealing component in a ram blowout preventer that seals around tubulars in the wellbore

3.56 Post-Weld Heat Treatment (PWHT)Any heat treatment subsequent to welding, including stress relief

3.57 Pressure-containing partPressure-containing member part exposed to wellbore fluids whose failure to function as intended would result in a release of wellbore fluid to the environment

EXAMPLES: Bodies, bonnets and connecting rods.

3.58 Pressure-controlling part / pressure-controlling memberParts intended to control or regulate the movement of wellbore fluids

EXAMPLES: Packing elements, rams, replaceable seats within a pressure-containing member or part.

3.59 Pressure end loadAxial load resulting from internal pressure applied to the area defined by the maximum seal diameter

3.60 Pressure-retaining part / pressure-retaining memberPart not exposed to wellbore fluids whose failure to function as intended will result in a release of wellbore fluid to the environment

EXAMPLES: Closure bolts and clamps.

3.61 Product DefinitionThe design documentation of a particular product which includes the complete set of design verification and validation files.

3.62 Product familyModel or type of specific equipment listed in clause 1 of this American National Standard

3.63 Qualified personnelIndividual with characteristics or abilities gained through training, experience or both, as measured against the manufacturer's established requirements

3.64 Ram blowout preventerBlowout preventer that uses metal blocks with integral elastomer seals to seal off pressure on a wellbore with or without tubulars in the bore

3.65 Rated working pressureMaximum internal pressure that the equipment is designed to contain and/or control

3.66 Record, nounRetrievable information

3.67 Recognized Technical AuthorityThe OEM holding the manufacturing and quality licenses, or registered professional engineer, or a technical classification society, or engineering firm in which its employees hold appropriate licenses to perform the verification in the appropriate jurisdiction, and evidence to demonstrate that the individual, society, or firm has the applicable expertise and experience necessary to perform the required verifications.

3.68 Linear indication


Dye Penetrant Inspection or magnetic particle Inspection indication whose length is equal to or greater than three times its width.

3.69 Relevant indicationDye Penetrant or Magnetic Particle Inspection with any indication with a major dimension over 1.6 mm (0.062 in) CHECK against Standard

3.70 RemanufactureProcess of disassembly, reassembly and testing of drill-through equipment, with or without the replacement of parts, in which machining, welding, heat treatment or other manufacturing operation is employed

3.71 RepairProcess disassembly, reassembly and testing of drill-through equipment, with or without the replacement of parts

NOTE Repair does not include machining, welding, heat treating or other manufacturing operation of component parts and does not include the replacement of pressure-containing part(s) or member(s). Repair may include replacement of parts other than pressure-containing part(s) or member(s) and is performed in a workshop (not on the rig).

3.72 Rounded indicationLiquid penetrant or magnetic particle examination any indication that is approximately circular or elliptical and whose length is less than three times its width

3.73 SerializationAssignment of a unique code to individual parts and/or pieces of equipment to maintain records

3.74 Special processOperation which converts or affects material properties

3.75 StabilizedPressure testing in a state in which the initial pressure-decline rate has decreased to within the manufacturer's specified rate

NOTE: Pressure decline can be caused by such things as changes in temperature, setting of elastomer seals or compression of air trapped in the equipment being tested.

3.76 StabilizedTemperature testing in a state in which the initial temperature fluctuations have decreased to within the

manufacturer's specified range

NOTE Temperature fluctuation can be caused by such things as mixing of different-temperature fluids, convection or conduction.

3.77 Standard connectionflange, hub or studded connection manufactured in accordance with an ISO standard, including dimensional

requirements

3.78 Stress reliefControlled heating of material to a predetermined temperature for the purpose of reducing any residual stresses

3.79 Studded connectionConnection in which thread-anchored studs are screwed into tapped holes


3.80 Surface finishRa measurement of the average roughness of a surface

NOTE 1 It is expressed in micrometres (μm).

NOTE 2 All of the surface finishes given in this American National Standard are to be considered maxima.

3.81 Trepan, verbProduce a hole through a part by boring a narrow band or groove around the circumference of the hole and removing the solid central core of material

3.82 Variable-bore ram (VBR)Closing and sealing component in a ram blowout preventer that is capable of sealing on a range of tubular sizes

3.83 Visual examinationExamination of parts and equipment for visible defects in material and workmanship

3.84 Volumetric non-destructive examinationExamination for internal material defects by radiography, acoustic emission or ultrasonic testing

3.85 Pressure-containing weldWeld whose failure will reduce the pressure-containing integrity of the component

3.86 Weld grooveArea between two metals to be joined that has been prepared to receive weld filler metal

3.87 Weld, verbAct of fusing materials, with or without the addition of filler materials

3.88 Weld jointFitting together of components in order to facilitate their joining by a fusion welding process.

3.89 Fabrication WeldA weld that joins two or more pieces of metal.

3.90 Welding Procedure Specification (WPS)A WPS is a written welding procedure that is qualified to provide direction for welding in accordance with requirements of this standard. The completed WPS shall describe the specific essential, nonessential, and supplementary essential variables required for each welding process. These variables and their meanings are defined, respectively, in Article II, QW-250 through QW-280 and Article IV of the ASME Boiler & Pressure Vessel Code Section IX–Welding and Brazing Qualifications.

3.91 WeldmentThat portion or area of a component on which welding has been performed. A weldment includes the weld metal, the heat-affected zone (HAZ), and the base metal unaffected by the heat of welding.

3.92 WeldingThe application of any one of a group of welding processes, which applies heat energy sufficient to melt and join one or more pieces of metal through localized fusion and coalescence.

3.93 Fabrication weldWeld joining two or more parts

3.94 Full-penetration weldWeld that extends throughout the complete wall section of the parts joined

3.95 Heat-Affected Zone (HAZ)


That portion of the base metal which has not been melted, but whose mechanical properties or microstructure has been altered by the heat of welding or cutting

3.96 Major repair weldWeld whose depth is greater than 25 % of the original wall thickness or 25 mm, whichever is less

3.97 Non-pressure-containing weldWeld whose failure will not reduce the pressure-containing integrity of the component

3.98 Postweld heat treatment (PWHT)Heating and cooling a weldment in a controlled manner to obtain desired properties.

3.99 Procedure Qualification Record (PQR)A PQR is a record of the welding data used to make the test weldment. It contains the actual values or ranges of the essential and supplementary essential variables used in preparing the test weldments, including the test results.

3.100 Major Repair WeldA weld that is the greater in thickness of either 1 inch or 25 percent of the original base metal thickness.

3.101 Minor Repair WeldA weld that is the lesser in thickness of either 1 inch or 25 percent of the original base metal thickness.

3.102 Base Metal Heat-Affected Zone (HAZ)That portion of the weld metal or base metal, whose mechanical properties and microstructure were altered by a source of heat energy (usually welding, thermal cutting, or brazing) without melting.

3.103 Weld Metal Heat-Affected Zone (WM-HAZ)That portion of the HAZ from which the mechanical properties are more depending on the dynamic nature of certain elements in the weld metal solidification process.

3.104 Critically Stressed AreasAll areas or sections of a weldment (weld metal, base metal, heat-affected zones) whose mechanical properties must meet the minimum requirements of the base metal specification and are deemed critical to the design and safe operation of the component. Unless otherwise specified by product engineering, all areas and sections of a weldment are presumed to be “critically stressed.”

3.105 Critical PWHT SectionsDistinct thin and thick sections of a weldment (weld metal or base metal) whose heat absorption properties and section thickness make them susceptible, respectively, to degradation in strength from overheating and excessive hardness from under heating. Critical PWHT sections shall be identified by product engineering as required.

3.106 Buildup WeldA weld that is used to add features to a part or restore wrong machined, worn, or corroded surfaces to factory dimensions.

3.107 Approved Welding ProcessAny process that has been qualified in accordance with this specification and the ASME Boiler & Pressure Vessel Code Section IX to join, repair, or buildup the welds and base metals referenced in Section IX and this standard.

3.108 Approved Welding Procedure Specification


Any WPS that has been reviewed and independently approved by a qualified welding engineer to meet the required welding specifications to meet the me. All WPSs, PQRs, and associated documents (PWHT charts, CMTRs, test lab reports, etc.) shall be approved before use.

3.109 Wrought structureStructure that contains no cast dendritic structure

3.110 Yield strengthStress level, measured at room temperature, at which material plastically deforms and will not return to its original dimensions when the stress is released

NOTE 1 It is expressed in Newton’s per square millimeter (pounds per square inch) of loaded area.

NOTE 2 All yield strengths specified in this American National Standard are considered as being the 0,2 % yield offset strength in accordance with ISO 6892.

3.111 Remanufacturing Level (RL)The level of traceability of repairs, and remanufacturing that well control equipment is qualified under and to which the work can be certified.

3.112 Product Specification Licensee OEM licensed facility that has access to the required details of the Original Product Specification, Product History File, Product Data Book, technical support, processes and procedures to perform specific remanufacturing and / or repairs as listed in the agreement.


4. Abbreviated termsANSI American National Standards InstituteAPI American Petroleum InstituteAQL Acceptance Quality LevelASME American Society of Mechanical EngineersASNT American Society for Nondestructive TestingASTM American Society for Testing and MaterialsAWS American Welding SocietyBSR Blind Shear RamBOP Blowout PreventerCOC Certificate Of ConformanceCOS Certificate Of ServiceHAZ Heat-Affected ZoneID Inside DiameterITP Inspection Test PlanLP Liquid PenetrantMP Magnetic ParticleNACE National Association of Corrosion EngineersNDE Non-Destructive ExaminationOD Outside DiameterOEC Other End ConnectionOEM Original Equipment ManufacturerOPD Original Product DefinitionOS Operating SystemPHF Product History FilePQR Procedure Qualification RecordPWHT Post-Weld Heat TreatmentRSL Remanufacturing Service LevelSOF Statement Of FactTPI Third Party InspectionVBR Variable-Bore RamWPS Welding Procedure Specification


5. Quality Control Requirements5.1 General

This clause specifies the quality control requirements and quality control requirements for equipment and material manufactured to meet this standard.The following subjects are covered:a) Measuring and testing equipment (Clause 5.2).b) Quality control personnel qualifications (clause 5.3).c) Quality control requirements for equipment and parts (clause 5.4).d) Quality control requirements for specific equipment and parts (clause 5.5)e) Quality control records (clause 5.6)

5.2 Measuring and testing equipment 5.2.1 General

Equipment used to inspect, test or examine material or other equipment shall be identified, controlled, calibrated and adjusted at specified internals in accordance with documented manufacturer instructions, and consistent with nationally or internationally recognized standards specified by the manufacturer, to maintain the accuracy required by this American National Standard.

5.2.2 Pressure-measuring devices5.2.2.1 Type and Accuracy

Test pressure-measuring devices shall be accurate shall be accurate to at least ±0.5% of full-scale range.

If pressure gauges are used in lieu of pressure transducers, they shall be selected such that the test pressure is indicated within 25% or more than 75% of full-pressure span of the gauge. Pressure gauges shall have a minimum face diameter of 100mm (4 in).

Pressure tests must be displayed as a chart in the PHF or MDB.The record shall identify the recording device, and shall be dated and signed.

5.2.2.2 Calibration procedurePressure-measuring devices shall be periodically calibrated with a master pressure-measuring device or a deadweight tester to at least three equidistant points of full scale (excluding zero and full scale as required points of calibration).

5.2.2.3 Calibration IntervalsIntervals shall be established for calibrations based on repeatability and degree of usage.

Calibration intervals shall be a maximum of three months until recorded calibration history can be established by the manufacturer and new intervals established, not exceeding ASTM minimum requirements.

5.3 Quality control personnel qualifications5.3.1 Non-destructive examination (NDE) personnel

Personnel performing NDE shall be qualified in accordance with the manufacturer's documented training program that is based on the requirements specified in ISO 9712, EN 473 or ASNT SNT-TC-1A.


5.3.2 Visual examination personnel Personnel performing visual examinations, including welders, shall take and pass an annual an annual vision examination in accordance with the manufacturer's documented procedures that meet the applicable requirements of ISO 9712, EN 473, or ASNT SNT-TC-1A.

5.3.3 Welding inspectorsPersonnel performing visual inspection of welding operations and completed welds shall be qualified and certified as follows:

a) AWS certified welding inspector; orb) AWS-senior certified welding inspector, orc) AWS certified associate welding inspector; ord) Welding inspector certified by the manufacturer or service provider’s documented training

program.

5.3.4 Welder performance qualificationThe following applies:a) Testing requirements:

Welders and welding operators shall be qualified in accordance with ASME, BPVC:2004, Section IX, Article III.

Welders and welding operators shall be qualified in accordance with AWS D1.1 for structural welding.

Welder qualification shall meet or exceed the requirements for the WPS qualification. The most stringent requirement shall apply.

b) Records: Records of welder performance qualification (WPQ) tests shall be in accordance

with ASME, BPVC:2004, Section IX. For structural welding records of welder performance qualification (WPQ) tests

shall meet or exceed the requirements of AWS D1.1.c) Weld position:

Welder’s qualification / certification shall meet or exceed the requirements of AWS D1.1 or ASME BPVC:2004 for the weld position required under the Weld Process Specification (WPS).

5.3.5 Third Party InspectionIf Third Party Inspection is used, the following applies:a) Third Party Inspectors (TPI) shall be competent based on the appropriate education, training,

skills and experience needed to perform the inspection service and certification related product requirements defined in the inspection scope.

b) Evidence of the determination of competence of TPI personnel shall be recorded and maintained by the TPI company in accordance with their QMS documented procedures and requirements for competence.

c) The TPI scope shall be clearly defined in the purchase order by the client.d) The TPI requirements defined in the purchase order shall be included in the Inspection Test

Plan for the product.

5.3.6 CertificationCertification shall be approved by a Recognized Technical Authority.


5.3.7 Other personnel All other personnel performing measurements, inspections or tests for acceptance shall be qualified in accordance with the manufacturer's Q1 QMS documented procedures and requirements for competence.

5.4 Quality control requirements for equipment and parts5.4.1 General

All pressure-containing and pressure-controlling parts exposed to wellbore fluid shall be in conformance with the requirements of NACE MR0175, ISO 15156 (all parts).

5.4.2 Material requirementsMaterial used for pressure-containing parts or members shall comply with API-16A, clause 6.

5.4.2.1 Closure BoltingClosure bolting and other parts shall conform to, or exceed, the manufacturer's written specification and API-16A standard revision under which originally built. The manufacturer shall retain individual-heat-traceability records for closure bolting, as required.

5.4.2.2 Studs and nuts other than closure boltingStuds and nuts shall conform to the requirements of API-6A.Carbon steel studs and nuts shall be in conformance with API-6A or API-20E, BSL-2 specifications.Materials and consumables shall be fully traceable.

5.4.2.3 Bolting environmentBolting selection for surface and subsea pressure control equipment shall consider the maximum hardness requirements, in relation to the operational environment and selected corrosion protection system in order to prevent hydrogen embrittlement.

5.4.3 Quality control instructionsAll quality control work shall be controlled by the manufacturer's documented instructions, which includes an appropriate Inspection Test Plan (ITP) or other methodology that provides an auditable tracking document with quantitative and qualitative acceptance criteria.

5.4.4 Non-destructive examination (NDE)NDE instructions shall be detailed regarding the requirements of this International Standard and those of all applicable nationally or internationally recognized standards specified by the manufacturer. All NDE instructions shall be approved by a NDE Level III examiner.

5.4.4.1 NDE qualification levelsNDE level I:a) The NDE Level I is qualified to perform system calibrations, Implement techniques and

conduct limited evaluation in the NDE method in which the individual is certified. b) The NDE Level I does not Interpret test results for acceptance or rejection.

NDE Level II:a) The NDE Level Il is qualified to setup and calibrate equipment, Interpret and evaluate results

with respect to applicable codes, standards, and specifications. b) The NDT Level Il is familiar with the scope and limitations of the used methods for which

qualified.


c) The NDE Level II can provide training of NDE Level I personnel. d) The NDE Level II is qualified to prepare written Instructions, and report the NDE results.

NDE Level III:a) The NDE Level III is qualified to select the appropriate NDE techniques based on knowledge

of materials, fabrication methods and product design for the part. b) The NDE Level III is responsible to establish techniques and procedures for the examination

of a part. c) The NDT Level III evaluates and interprets the results of the NDE method in conformance

with the codes, standards and specifications. d) The NDE Level III establishes acceptance criteria where none are available.e) The NDE Level III is responsible for the training and certification examination of NDE Level I

and II personnel.

5.4.5 Acceptance statusThe acceptance status of all equipment, parts and materials shall be indicated either on the equipment, parts or materials or in the records traceable to the equipment, parts or materials.

5.5 Quality control requirements for specific equipment and partsUnless specified differently in this standard, quality control requirements for API-16A equipment will be in conformance with API-16A, clause 8.5.

All new manufactured or replacement parts shall be in full conformance to API-16A requirements, including design verification and testing under clause 5 and 6.

Remanufacturing Service Levels (RSL) for remanufactured parts / assemblies indicate the level of traceability and conformance of the API-16A, clause 8.5 requirements.

API-16A, Clause 8.5 requirementTensile testing RSL-1 RSL-2 RSL-3Pressure-containing parts material qualification tensile testing in conformance with API-16A.

Repairs excluding base

material.

Repairs including base

material

All parts, repairs and

base materialPressure-controlling parts material qualification tensile testing in conformance with API-16A..


material.


material


base materialImpact testing RSL-1 RSL-2 RSL-3Pressure-containing parts material qualification impact testing in conformance with API-16A..


material.


material


base materialPressure-controlling parts material qualification impact testing in conformance with API-16A..


material.


material


base material


Hardness testing RSL-1 RSL-2 RSL-3Hardness testing methods shall be in accordance with ISO 6892, ISO 6506-1, ISO 6507-1 or ISO 6508-1, as appropriate.

API-16A API-16A API-16A

At least one hardness test shall be performed on each part tested, at a location determined by the manufacturer's specifications.

Remanufacturer specification

OEM specification

OPD specification

The hardness testing used to qualify each part shall be performed after the last heat-treatment cycle (including all stress-relieving heat-treatment cycles) and after all exterior machining operations.


When equipment is a weldment composed of different material designations, the manufacturer shall perform hardness tests on each component part of the weldment after the final heat treatment (including stress-relieving). The results of these hardness tests shall satisfy the hardness value requirements for each respective part.


OEM specification

OPD specification

Hardness measurements on parts manufactured from carbon low alloy and martensitic stainless type steels shall exhibit maximum values in accordance with NACE MR0175 and minimum values equal to or greater than those specified in API-16A.


The part does not exhibit the required minimum hardness level for the API material designation: The average tensile strength, as determined from the tensile tests results, shall be used with the hardness measurements in order to determine the minimum acceptable hardness value for parts manufactured from the same heat.


OEM specification

OPD specification

The part does not exhibit the required minimum hardness level for the API material designation: The minimum acceptable hardness value for any part shall be determined by the minimum acceptable Brinell hardness for the part after the final heat-treatment cycle (including stress-relieving cycles)


OEM specification

OPD specification

Critical dimensions RSL-1 RSL-2 RSL-3Critical dimensions, as defined by the manufacturer, shall be documented for each part and such documentation shall be retained by the manufacturer in accordance with API-16A.


OEM specification

OPD specification

The manufacturer shall define and document the extent to which dimensions shall be verified.


OEM specification

OPD specification

Traceability RSL-1 RSL-2 RSL-3Parts and material shall be traceable to the individual heat and heat-treatment lot.

Partial traceability

through MDB and PHF to


Full traceability


OEM specification

Full traceability


OPD

Identification shall be maintained on materials and parts, to facilitate traceability, as required by documented manufacturer requirements.




Full traceability


OEM specification

Full traceability


OPD

Manufacturer-documented traceability requirements shall include provisions for maintenance or replacement of identification marks and identification control records.

Reconstructed PHF and MDB




Full traceability


OEM specification

Full traceability


OPD


Chemical analysis RSL-1 RSL-2 RSL-3Chemical analysis shall be performed on a heat basis. Reconstructed

PHF and MDBPartial

traceability through MDB and PHF to


Full traceability


OEM specification

Full traceability


OPD

Chemical analysis shall be performed in accordance with the manufacturer's written procedure.


OEM specification

OPD specification

The chemical composition shall meet the requirements of API-16A.


Visual examination RSL-1 RSL-2 RSL-3Each part shall be visually examined. API-16A API-16A API-16AVisual examination of castings and forgings shall be performed in accordance with the manufacturer's written specification.


OEM specification

OPD specification

Acceptance criteria shall be in accordance with manufacturer's written specifications.


OEM specification

OPD specification

Non-well fluid-wetted and non-sealing surfaces shall be examined in accordance with visual examination methods described in API-16A.


Surface NDE RSL-1 RSL-2 RSL-3All accessible well fluid-wetted surfaces and all accessible sealing surfaces of each finished part shall be inspected after final heat treatment and after final machining operations by either magnetic particle (MP) or liquid penetrant (LP) methods.


All accessible well fluid-wetted surfaces of each finished part shall be inspected after final heat treatment and after final machining operations by the LP method.


MP examination shall be in accordance with procedures specified in ISO 13665. Prods are not permitted on well fluid-wetted surfaces or sealing surfaces.


LP examination shall be in accordance with procedures specified in ASTM E 165.


Acceptance criteria for MP and LP in conformance with API-16A. API-16A API-16A or exceeded by

OEM specification

API-16A or exceeded by

OPD specification

Weld NDE general RSL-1 RSL-2 RSL-3100 % of all surfaces prepared for welding shall be visually examined prior to initiating welding.


Examinations shall include a minimum of 12 mm (0,5 in) of adjacent base metal on both sides of the weld.

API-16A API-16A or exceeded by

OEM specification


OPD specification

Weld NDE surface preparation acceptance shall be in accordance with the manufacturer's written specification.


OEM specification

OPD specification

All welds shall be examined according to manufacturer's written specification.


OEM specification

OPD specification

Any undercut detected by visual examination shall be evaluated in accordance with the manufacturer's written specification.


OEM specification

OPD specification

Surface porosity and exposed slag are not permitted on or within 3 mm (0,125 in) of sealing surfaces.


OEM specification


OPD specification


Weld NDE — Surface examination (other than visual) RSL-1 RSL-2 RSL-3100 % of all pressure-containing welds repair and weld metal overlay welds and repaired fabrication welds shall be examined by either MP or LP methods after all welding, post-weld heat treatment and machining operations are completed.


The examination shall include 12 mm (0,5 in) of adjacent base material on both sides of the weld.


OEM specification


OPD specification

Acceptance criteria for MP and LP in conformance with API-16A. API-16A API-16A or exceeded by

OEM specification


OPD specification

Repair welds RSL-1 RSL-2 RSL-3All repair welds shall be examined using the same methods and acceptance criteria used in examining the base metal.


OEM specification


OPD specification

The examination shall include 12 mm (0,5 in) of adjacent base material on both sides of the weld.


OEM specification


OPD specification

Surfaces of ground-out areas for repair welds shall be examined prior to welding to ensure defect removal using the acceptance criteria for fabrication welds


OEM specification


OPD specification

Weld NDE — Volumetric examination of fabrication weld RSL-1 RSL-2 RSL-3100 % of all pressure-containing welds shall be examined by either radiography, ultrasonic or acoustic emission methods after all welding and post-weld heat treatment.


All repair welds for which the repair is greater than 25 % of the original wall thickness or 25 mm (1 inch) (whichever is less) shall be examined by either radiography, ultrasonic or acoustic emission methods after all welding and post-weld heat treatment.


Examinations shall include at least 12 mm(0,5 in) of adjacent base metal on all sides of the weld.


OEM specification


OPD specification

Radiography examination RSL-1 RSL-2 RSL-3Radiographic examinations shall be performed in accordance with procedures specified in ASTM E 94, to a minimum equivalent sensitivity of 2 %.


Acceptance criteria for radiography in conformance with API-16A. API-16A API-16A or exceeded by

OEM specification


OPD specification

Ultrasonic examination RSL-1 RSL-2 RSL-3Ultrasonic examinations shall be performed in accordance with procedures specified in ASME Boiler and Pressure Vessel Code, Section V, Article 5.


OEM specification


OPD specification

Acceptance criteria for Ultrasonic examination in conformance with API-16A..


OEM specification


OPD specification

Acoustic emission examination RSL-1 RSL-2 RSL-3Acoustic emission (AE) examinations shall be performed in accordance with procedures specified in ASTM E 569.The acoustic emission examination shall be conducted throughout the duration of the hydrostatic “in-plant” test.


Acceptance criteria for Acoustic emission examination in conformance with API-16A.


OEM specification


OPD specification


Weld NDE — Hardness testing RSL-1 RSL-2 RSL-3All accessible pressure-containing, non-pressure-containing and major repair welds shall be hardness tested.


At least one hardness test shall be performed in both the weld and in the adjacent unaffected base metal after allheat treatment and machining operations.


OEM specification


OPD specification

The hardness recorded in the PQR shall be the basis for acceptance if the weld is not accessible for hardness testing.


OEM specification


OPD specification

Non-metallic sealing materials and moulded sealing assemblies

RSL-1 RSL-2 RSL-3

Testing of each batch shall be in accordance with ASTM procedures.


If a suitable ASTM procedure cannot be applied, the manufacturer shall provide a written procedure for testing.


OEM specification


OPD specification

Characteristics shall be defined by measurements of physical properties.


OEM specification


OPD specification

Mechanical property data shall include hardness, tensile, elongation and modulus.


Acceptance shall be in accordance with manufacturer's written specifications.


OEM specification

OPD specification

Metallic inserts in moulded assembliesSampling shall be in accordance with manufacturer's written requirements or ISO 2859-1, Level II 4.0 AQL.


All methods shall be in accordance with manufacturer's written requirements.


OEM specification

OPD specification

Acceptance shall be in accordance with manufacturer's written specifications.


OEM specification

OPD specification

Acceptance shall be in accordance with manufacturer's written requirements and NACE MR0175.


OEM specification

OPD specification

Welding NDE shall be in accordance with manufacturer's written specifications.


OEM specification

OPD specification

Annular packers when shipped separately from a BOP RSL-1 RSL-2 RSL-3When shipped separately (not part of an assembled BOP), annular packers shall be pressure-tested and drift tested in accordance with API-16A.


All other drill-through equipment RSL-1 RSL-2 RSL-3All quality control requirements shall be documented in the manufacturer's written specifications.


OEM specification

OPD specification

Assembled equipment RSL-1 RSL-2 RSL-3The quality control requirements for assembled equipment shall include drift tests, pressure tests and hydraulic operating system tests.


Serialization is required on all assembled equipment and shall be carried out in accordance with the manufacturer's written specification.


OEM specification

OPD specification

A report shall be prepared in which all serialized and individual-heat-traceable parts are listed as traceable to the assembly (e.g., assembly part number, serial number).


A drift test is required on ram BOP, annular BOP, hydraulic connectors, drilling spools and adapters.


The hydrostatic proof or shell test pressure shall be determined by the rated working pressure for the equipment and be in conformance with API-16A.


The hydraulic operating system test shall be tested on each assembled blowout preventer and hydraulic connector.


The hydraulic operating chamber shall be tested at a minimum test pressure equal to 1,5 times the operating chambers rated working pressure.



Closed-preventer test RSL-1 RSL-2 RSL-3Each ram and annular blowout preventer shall be subjected to a closed-preventer test after the hydrostatic proof test.The hydraulic operating system pressure used shall be equal to or less than the manufacturer's specified operating pressure.


Annular packing tests shall require pressure-testing on the appropriate size drill pipe and without out drill pipe in accordance with API-16A.


VBRs shall be tested on the minimum and maximum sizes for their range.


Each preventer equipped with blind-shear rams shall be subjected to a shearing test.


The closed-preventer test for each blowout preventer equipped with a hydraulic ram-locking system shall be pressure tested with the locking system engaged.


Hydraulic connector tests RSL-1 RSL-2 RSL-3Since there is no closure unit in a hydraulic connector, the hydrostatic proof test shall take the place of any rated working pressure tests.


5.6 Requirements for quality control records5.6.1 General

The quality control records required by this American National Standard are those documents and records necessary to substantiate that all materials and equipment made to this American National Standard do conform to the specified requirements.

5.6.2 NACE records requirementsRecords required substantiating conformance of equipment to NACE requirements shall be in addition to those described in other clauses of this American National Standard, unless the records required by this American National Standard also satisfy the NACE MR0175 requirements.

5.6.3 Records controlThe organization shall maintain a documented procedure to define the controls and responsibilities needed for the initiation, identification, collection, storage, protection, retrieval, retention time, and disposition of records.

Records, including those from outsourced activities, shall be established and controlled to provide evidence of conformity to requirements and of the effective operation of the quality management system.

Records shall be retained for a minimum of ten years following the date the equipment was received by the service provider, or as required by customer, legal and other applicable requirements, whichever is longer.

All records required by this American National Standard shall be signed and dated.

Records shall be legible, identifiable, retrievable and protected from damage, deterioration or loss.

Records can be hard copies and/or computer-stored as defined in the organization records control system procedure.

5.6.4 Records to be maintained by remanufacturerThe remanufacturer shall retain all documents and records as required in clause 5.6.4.1.


The remanufacturer shall provide a PHF and MDB in conformance with Annex-A to their client in either electric format, hard copy or both, as specified in the purchase order by the client.

5.6.4.1 Parts or components covered in API-16AThe following records shall be retained:a) weld procedure qualification record;b) welder qualification record;c) material test records:

chemical analysis; tensile tests (QTC); impact tests (QTC, as required); hardness tests (QTC);

d) NDE personnel qualification records;e) NDE records:

surface NDE records; full penetration fabrication; weld volumetric NDE records; repair weld NDE records;

f) hardness test records;g) welding process records:

welder identification; weld procedures; filler materials; post-weld heat treatments;

h) heat treatment records: actual temperature; actual times at temperature;

i) volumetric NDE records;j) hydrostatic pressure test records;k) critical dimensions as defined by the manufacturer.


6. Quality Management System Requirements6.1 Control of Documents

The organization shall maintain documented procedures for the identification, distribution, and control of documents, including required documents of an origin external to the organization. The procedure shall define the controls needed:a) To ensure that documents required by the quality management system, including revisions,

translations, and updates, are reviewed and approved for adequacy prior to issue and use. b) To define responsibilities for approval and re-approval of documents;c) To identify changes to the documents; d) To ensure that documents remain legible and readily identifiable; ande) To ensure relevant versions of applicable documents are available where the activity is being

performed.

Obsolete documents shall be removed from all points of issue or use, or otherwise identified to prevent unintended use if they are retained for any purpose. A master list or equivalent shall be established to identify the current revision status of documents.

6.2 Personnel Competence Personnel performing activities shall be competent based on the appropriate education, training, skills and experience needed to meet service and service-related product requirements. Evidence of the determination of competence of personnel shall be recorded and maintained.

6.3 Training and AwarenessThe organization shall:a) Provide Quality Management System training to the organization’s personnel and contractors

who affect the execution of services or provision of service-related products;b) Ensure that customer-specified training and/or customer-provided training, if required, is

included in the training program; c) Maintain appropriate records on education, training, skills and experience.

6.4 Control of testing, measuring, monitoring equipmentThe remanufacturer shall maintain a documented procedure which defines the required testing, measurement, monitoring, and detection equipment to be controlled and necessary to provide evidence that service or service-related product meets specified requirements.

The procedure shall address equipment traceability, frequency of calibration, calibration method, acceptance criteria, suitable environmental conditions, storage and handling.

The procedure shall identify required assessments and maintain records when the validity of the previous testing, measuring, monitoring, or detection results are found not to conform to calibration requirements. The organization shall take appropriate action on the equipment and any service affected.

Testing, measuring, monitoring and detection equipment shall have unique identification. When the equipment is externally provided, the organization shall verify that the equipment is suitable to provide evidence of conformity of service or service-related product to specified requirements.


6.5 Contract Review 6.5.1 General

The organization shall maintain a documented procedure for the review of contract requirements related to the execution of services or provision of service-related products.

6.5.2 Determination of RequirementsThe organization shall determine:a) Requirements specified by the customer, including the requirements for service planning,

execution, and evaluation;b) Legal and other applicable requirements; andc) Requirements not stated by the customer but considered necessary by the organization or

industry recognized Standards for the execution of service and provision of service related product.

d) Documentation requirements pertaining to the certificate of compliance/conformance, MDB, PHF, and any other required traceable documents.

Where the customer has provided incomplete, incorrect or unachievable requirements in the purchase order, the customer requirements shall be informed by the remanufacturer and records maintained.

6.6 Purchasing ControlThe organization shall maintain a documented procedure and qualification of outsourced services to ensure that purchased or outsourced services and service-related products conform to specified requirements.

Selection of outsourced service suppliers by the remanufacturer shall include the following prior to initiation of the purchase agreement:1) Assessment of the supplier at supplier’s facility to meet the organization’s purchasing

requirements, and2) Verification that the supplier’s quality management system conforms to the quality system

requirements specified for suppliers by the organization.

6.7 Design and Development 6.7.1 Design and Development Planning

The organization shall maintain a documented procedure to plan and control the design and development of the product, including the use of service-related products. The procedure shall identify:a) the design and development stages; b) the activities required for completion, review, and verification of each stage; c) the interfaces between different groups involved in design and development; and d) the responsibilities and authorities for the design and development activities.

The organization shall manage the interfaces between different groups involved in design and development to ensure effective communication and clear assignment of responsibilities.When design and development are outsourced, the organization shall ensure the supplier meets the requirements of clause 6.6 and provide objective evidence that the supplier has met these requirements.

6.7.2 Design documentationDesign documentation shall include the methods, assumptions, formulas and calculations.


6.7.3 Design and Development InputsInputs relating to design of the product shall be determined and records maintained.These inputs shall include:a) customer-specified requirements b) legal requirements; and c) other applicable requirements including:

1. requirements provided from an external source, 2. requirements for products and service-related products, including its functional and

technical requirements, 3. environmental and operational conditions4. historical performance and other information derived from previous similar product

designs.

6.7.4 Design VerificationThe design and development requirements are to be examined and confirmed to be in conformance with specified requirements of the contract and relevant standards.

NOTE Design verification activities includes one or more of the following:a) confirming the accuracy of design results through the performance of alternative calculations,b) review of design output documents independent of activities of design and development,c) comparing new designs to similar proven designs.

6.7.5 Design ValidationDesign and development validation shall be performed in accordance with planned arrangements (see clause 6.7.1) to ensure that the resulting product is capable of meeting the requirements for the specified application or intended use, where known. Wherever practicable, validation shall be completed prior to the delivery or implementation of the product. Records of the results of validation and any necessary actions shall be maintained.

NOTE Design validation includes one or more of the following:a) prototype tests;b) functional and/or operational tests of production products;c) tests specified by industry standards and/or regulatory requirements;d) field performance tests and reviews.

6.7.6 Control of design and development changesDesign and development changes shall be identified and records maintained. The changes shall be reviewed, verified and validated, as appropriate, and approved before implementation. The review of design and development changes shall include evaluation of the effect of the changes on constituent parts and product already delivered. Records of the results of the review of changes and any necessary actions shall be maintained.

7. ResponsibilitiesOEM:

The original product manufacturer (OEM) of the API product is responsible for compliance to the standard in manufacturing, documentation Product data book and certification.

The OEM is responsible for the definition of the original product definition (OPD) and the ongoing product design status.


The OEM is responsible for documenting design changes resulting from a malfunction or failure history of drill-through equipment manufactured, remanufactured and / or repaired in the Original Product Definition.

The OEM is responsible to audit OEM approved repair facilities in compliance with the requirements of this product standard to assure compliance.

The OEM shall in accordance with the applicable API standard for manufacturing retain documents required for repair and remanufacturing for ten years.

On request and in agreement with the equipment owner, the OEM will maintain the Manufacturing Data File for periods exceeding the record keeping requirement of ten years as listed under this standard.

Repairer / Remanufacturer The repairer / Remanufacturer shall provide the product owner with an overview of

equipment traceability and compliance to the OPD before selecting the Remanufacturing Level (RL) defined in this standard.

The Repairer / Remanufacturer is responsible to audit Repairer / Remanufacturer approved repair facilities in compliance with the requirements of this product standard to assure compliance.

The repairer / remanufacturer shall in accordance with the applicable API standard for manufacturing retain documents required for repair and remanufacturing for ten years.

On request and in agreement with the equipment owner, the Repairer / Remanufacturer will maintain the Manufacturing data book for periods exceeding the record keeping requirement of ten years as listed under this standard.

Product Owner: The product owner is responsible to keep an up to date Product History File (including the

manufacturing data book). The product owner is responsible to keep accurate records of product use and exposure to

Sulfide Stress Cracking environment. The product owner is responsible for scheduling the required maintenance for the product,

including the recommendations from the OEM. The product owner/operator is responsible for the product status verification and

traceability, field configuration assessment and service conditions, maintenance and service procedures, inspection and test procedures, design status assessment and disposition, usage and performance history evaluation, repair and selection of remanufacture procedures as described in this standard.

.

8. Repair / Remanufacturing Service Level Minimum RequirementsThe requirements in section 9.1 through 9.12 are the minimum that must be performed for qualification of repair and remanufacturing under this standard. Repair and remanufacturing under this standard excludes work performed on equipment under maintenance.

8.1 Requirements for Pressure Testing8.1.1 General

All drill-through equipment shall be subjected to a hydrostatic proof test prior to shipment from the service or repair facility. Water with soluble oil should be used as the testing fluid to avoid corrosion of the drill-through equipment. The type of soluble oil and concentration used shall be documented in the test records. Water can be used in the bore for pressure testing, but requires preservation of the drill-through equipment afterwards.


8.1.2 Hydrostatic Proof/Shell TestDrill-through equipment shall be tested with its sealing mechanisms in the open position, if applicable. When a BOP requires PWHT, regardless if the BOP has traceability to a previous shell proof test, the hydrostatic test pressure shall be tested at a minimum test pressure equal to 1.5 times the rated working pressure. When a BOP requires NO PWHT, and has traceability to a previous proof test, the hydrostatic test pressure shall be tested at a minimum test pressure equal to the rated working pressure. For equipment with end or outlet connections having different working pressures, the lowest rated working pressure shall be used to determine the shell pressure test.

8.1.3 Operating Chamber Pressure TestThe hydraulic operating system test shall be tested on each assembled blowout preventer and hydraulic connector. The hydraulic operating chamber shall be tested at a minimum test pressure equal to 1.5 times the operating chamber’s rated working pressure. When a BOP requires PWHT, regardless if the BOP has traceability to a previous operating chamber pressure test, the operating chamber test pressure shall be tested at a minimum test pressure equal to 1.5 times the rated working pressure. When a BOP requires NO PWHT, and has traceability to a previous operating chamber pressure test, the operating chamber test pressure shall be tested at a minimum test pressure equal to the rated working pressure.

8.1.4 Hydrostatic proof and operating chamber pressure testsThe hydrostatic proof test and the operating chamber pressure tests shall consist of three steps:

a) an initial pressure-holding period of not less than 10min;b) reduction of the pressure to zero;c) a second pressure-holding period of not less than 15 min.

The timing of the test shall not start until the test pressure has been stabilized within the manufacturer’s specified range and the external surfaces have been thoroughly dried. The acceptance criteria shall be zero leakage.

8.1.5 Closed-preventer testEach ram and annular blowout preventer shall be subjected to a closed-preventer test after the hydrostatic proof test. The hydraulic operating system pressure used shall be equal to or less than the specified operating pressure. The test fluids used for all closed preventer tests shall meet the requirements of 9.1.1.The timing of all closed-preventer tests shall not start until the test pressure has stabilized. Closed-preventer tests shall be performed at low and high pressures, with the low pressure test always preceding the high pressure test.

8.1.6 Low Pressure TestA pressure of 1.4 MPa to 2.1 MPa (200 psi to 300 psi) shall be applied and held below the closed ram or annular packing unit for not less than 10 min after stabilization.

8.1.7 High Pressure TestA pressure at least equal to the rated working pressure of the preventer shall be applied and held below the closed ram or annular packing unit for not less than 15 min after stabilization (see exception for annular packing units in 9.1.9).

8.1.8 Acceptance CriteriaThere shall be no visible leakage.

Jan.VanWijk, 11/12/13,

Need to check the yellow text for correctness.


All high pressure tests must have the same hold time. Only the use of advanced electronic measurements will allow shorter times, when recording and measure difference against base line tests.


All low pressure tests must have the same hold time. Only the use of advanced electronic measurements will allow shorter times when recording and measure difference against base line tests...


8.1.9 Annular packing unit testsAnnular packing units shall be tested in two stages. The stage one test shall require pressure-testing on the appropriate size drill pipe in accordance with Table 9.1.The stage two test shall require pressure-testing without drill pipe in the preventer, i.e. on the open hole. The high pressure test for this stage shall be as specified in 10.1.7, except as a minimum it shall be performed at 50% of the rated working pressure of the preventer.

Table 10.1 – Pipe Size RequirementsBore Size Pipe Diameter

mm (in) mm (in)179 and 228 7 1/16 and 9 88.9 3 ½

279 and larger 11 and larger 127.0 5

Note API-16A has updated this table

8.1.10 Rams lock testThe closed-preventer test for each blowout preventer equipped with a hydraulic ram-locking system shall be pressure-tested with the locking system engaged. This test shall apply to each included ram that is designed to operate with the ram-locking system. The preventer shall be tested in accordance with 9.1.6 and 9.1.7 after the rams are closed, the locks engage and then all operating pressure(s) released.

8.1.11 Blind-shear ramsEach preventer equipped with blind-shear rams shall be subjected to a shearing test when the BOP that has transferred from one OEM spec to a new OEM spec. The minimum size shear pipe used shall conform to Table 9.2. These tests shall be performed without tension in the pipe and with zero wellbore pressure. Shearing and sealing shall be achieved in a single operation. The piston-closing pressure shall not exceed the manufacturer’s rated working pressure for the operating system. Documentation shall include the manufacturer’s shear ram and blowout preventer configurations, the actual pressure and force to shear the pipe. Documentation shall also include pipe description (size, mass and grade), actual pipe tensile properties, and impact properties as specified in ISO 11961.

Table 9.2 – Shear Pipe Requirements BOP Size Shear pipe (minimum)

179 mm (7 1/16 in) 3 ½ in 13.3 lb/ft Grade E-75279 mm (11 in) 5 in 19.5 lb/ft Grade E-75

346 mm (13 5/8 in) and larger 5 in 19.5 lb/ft Grade G-105Note API-16A has updated this tableShear test not required as part of the FAT.Pressure testing will be required for verification of cavitieskClarify ownership of design – reference Annex CNeed BOP that has transferred from one OEM spec to a new OEM spec the first time to undergo a shear test at FAT

8.2 Elastomeric Seal Requirements If the ram packer or packing element had been replaced prior to the service or repair shop receiving the BOP, and if traceability is available identifying it either being an OEM part or a part


that meets or exceeds those requirements, this part may NOT be required to be replaced and will maintain compliance to OSL 1. If no traceability is available, packers and/or packing elements will be quoted for replacement to maintain compliance with OSL 1 requirements. Should the equipment owner require the service facility to complete the OSL and not supply a replacement packer or packing element, the service provider must have a documented process that will allow for the service provider to use an OEM part or a part that meets or exceeds those requirements required for testing to be removed prior to returning to the equipment owner.

All elastomer components used for FAT of units repaired or remanufactured in compliance with 16AR must be fully validated in the BOP design in which they are being used.

8.2.1 Wellbore Sealing Components and Consumables For identification of wellbore non-metallic components, such as ram and annular type BOP Packers, the manufacturer shall have a written procedure for affixing the required codification to the product or its package. All BOP system elastomeric seal elements shall be addressed in the equipment owner’s PM program for the system. If the service provider must provide components to allow for testing those parts/components will be removed after testing when conformance has been proven. Responsibility will be with the equipment owner to add those components when putting the system into service. Traceability must be maintained of the parts added to maintain compliance with the standard and to maintain the equipment’s Operation Service Level. Independent ram assemblies and operators will be treated as a separate component from the blowout preventer. Markings and traceability must still be maintained and can be done through a traceable number by the service provider, permanently stamped or etched into the ram assembly. Ram assemblies and operators will be provided with a separate certificate showing conformance or compatibility (where applicable).

8.2.2 Operating Sealing Components and ConsumablesIdentification of non-wellbore non-metallic components, such as elastomeric seals used in ram and annular type BOP actuation systems, shall be in accordance with the seal manufacturer’s written specification.

8.2.3 Equipment Marking and Storage• Marking and storage of sealing components of BOP systems shall be in accordance with API

6A, API 16A, or API 17D, as applicable, including identification marking of elastomeric seals.• Specialized components, including proprietary design BOP seals and packing units, shall be

stored in accordance with the OEM recommendations.


Tricky as there will be no guarantee what will be used.


8.3 Dimensional check For recertification all API and sealing dimensions should be within product definition tolerances. From the structural side, one needs to look for severe corrosion on the body which might weaken the part. In the event there is no hot work and hence no PWHT; the product definition owner must establish acceptable “wear tolerances”. In this instance the BOP would be “endorsed” as suitable for service.

Function & Fit – terminology

Dimensional checks shall include at a minimum the following:

1. Wear and sealing surfaces (e.g. – Dimensionals of cavities) 2. Flange and Bore Dimensions3. Pressure Retaining Components4. Any Critical Areas per the Product Defnition

Dimensional must be documented and approved by a supervisor who is deemed competent and can assure the technician is competent to record and take measurements in accordance with the established QMS.

8.4 NDE – Initial Inspection The following inspections shall be performed before proceeding with remanufacture of equipment.

All wetted surfaces shall be MPI or DPI inspected.All weld necks shall be MPI or DPI inspected.External surfaces shall be visually inspected and any anomalies further investigated with MPI or DPI.Unacceptable indications found with MPI or DPI shall be removed. Reference API-16A, section 8.5.1.9.4

If full weld records are not available it is advisable to acid etch the BOP to determine any previous weld repair.

Reference MPI as part of the non negotiable list..

8.5 Hardness – Reference section 10 Hardness

8.6 Personnel Qualification Requirements – see QA program requirements Reference welder and NDE qualifications in chapter 11 section API 8.3 see QMS requirements.


8.7 Inspection on closure bolting (pressure retaining)If closure bolting identification is lost, it shall be replaced.

If closure bolting or other closing devices are intended for reuse, they shall undergo a thorough inspection which includes:1) Wet particle MPI or DPI.2) Hardness measurements on bolts & nuts.3) Threads (internal / external) must be inspected for wear and stretch. The bolt

holes can also be etched to determine if there has been previous weld repair. 4) Dimensional inspection of pressure retaining of non-threaded devices.

8.8 Visual Inspection at disassemblya. include critical wear areas and body structureb. all threaded lifting bolt holes. – look for abnormalities (bent, deformed) c. Sealing surface check – look for anomaliesd. Example

1. Bent and worn components2. scoring3. coating or chrome chipping4. Damage to running surfaces 5. Flatness of face seals (use straight edge against)6. Door/Bonnet assembly alignment 7. Corrosion / pitting

8.9 Drift TestRef API 16A/ISO 13533 – 8.5.8.4.1 for the Method and 8.5.8.4.2 for acceptance

After remanufacturing the assembly must be drifted..

8.10 Replacement Parts – Qualifications

Replacement parts shall be etc, etc see also certificate of compatibility.

Verification testing – define requirements for ensuring equivalency/compatibilitya. Set out parts

Complete list or replaced components. Preferably backed up with a bill of materials from the supplier. – PHF Requirement.

b. Ensure parts which are not OEM are still compatible Consider as design review. There are established companies that, given a sample, can replicate any seal and have done so even for OEM’s.

c. Traceabilityin the form of Certificate of Conformance, to either OEM or Design Review.

8.11 Hot work Qualifications/ProceduresAdherence to ASME or AWS (reword text below)


8.12 Documentation a. Certifications The question is, will there be different certifications like non-NACE, NACE, will the repair procedures be the same or different for high pressures above 10K and/or subsea.

COC is meant to define the state of the equipment on the date the COC is issued and to which standard it conforms to.

b. Repair Serialization/Marking The repaired component must have a unique identification number stamped into the body per 16A allowing future verification/validation of Recertification, process, and procedures. 1. Maintain temperature ratings, only with MTR traceability on the pressure containing, retaining, and controlling parts.c. Drawings

1. General Arrangement2. Assembly (with a BOM)

d. Pressure ChartsAll component part and serial numbers, elastomer batch numbers, cure and elastomer expiration

dates must be recorded.


9. Materials9.1 Compliance to NACE MR 0175 / ISO 15156

This clause describes the material performance, processing and compositional requirements for pressure-containing members and all other parts which shall as a minimum satisfy the OPD design requirements for the product repaired and /or remanufactured under this American National Standard.

Metallic materials exposed to well bore fluids and gasses shall meet the design requirements of NACE MR0175 / ISO 15156 does allow shear blades not to be Sulfide Stress Cracking (SSC) resistant. Suitability of the shear blades that do not comply with the hardness limitations and its potential influence on the sealing capability in SSC environment is the responsibility of the user.

Meeting NACE MR0175 / ISO 15156 for prevention of Sulfide Stress Cracking (SSC) can be achieved by: Deployment of the Well Control Equipment in a non-SSC environment The use of the WCE in an inhibited fluid environment. Material hardness shall not exceed 22HRC and care must be taken when hardness

exceeds 26 HRC (rams only). The use of Corrosion Resistant Alloy (CRA) and its application that is SCC resistant.

9.2 Material Chemical Composition and Mechanical PropertiesA written material specification shall be required for all manufacturing / remanufacturing of metallic pressure-containing, pressure-controlling and all other parts. The remanufacturer shall be capable to meet or exceed the material specifications for the product as listed in the OPD, which shall contain the following information:a) material composition with tolerance;b) material qualification;c) allowable melting practice(s);d) forming practice(s);e) heat treatment procedure, including cycle time and temperature with tolerances, heat

treating equipment and cooling media;f) NDE requirements;g) mechanical property requirements.

9.3 Mechanical properties Hardness Sharpy impact Minimum Yield Strength (MYS) Ultimate Yield Strength (UYS) Elongation Heat treatment & Microstructure


9.4 Non-metallic partsEach manufacturer shall have written specifications for all elastomeric materials used in the production of drill-through equipment. These specifications shall include the following physical tests and limits for acceptance and control:a) hardness in accordance with ASTM D 2240 or ASTM D 1415;b) normal stress-strain properties in accordance with ASTM D 412 or ASTM D 1414;c) compression set in accordance with ASTM D 395 or ASTM D 1414;d) immersion testing in accordance with ASTM D 471 or ASTM D 1414.

9.5 Base metal material IdentificationIn order to start the repair and remanufacturing process control must also be established over the material properties.

Original Material Test Records (MTRs). If no original Material Tests Records are available, the following must be tested and documented to establish material identification:1. Determining hardness and approximant tensile values2. Determining Chemical composition 3. Engineering judgment based on service/field experience

9.5.1 Determining Hardness and approximate ultimate tensile values:Determining Hardness and approximate tensile values shall be done in accordance with ASTM E10(Brinnell) or ASTM E110(portable testing) or E18 for Rockwell or E92 for Vickers

The hardness of a material is in principle related to the UTS and not to the YS. Yield Strength and tensile strength show a linear correlation with hardness for most steels. However, for steel that shows evidence of strain hardening, a lower strength can be measured for a given hardness. At low hardness and low strength levels, there can be a non-linear relation between strength and hardness.

If uncertainty exists with respect to the material specification, it is required to validate the material properties per the RSL.

9.5.2 Determining Chemical Composition:

In absence of material specifications for the parts of the system, PMI shall be used to confirm that the material from the pressure containing and pressure controlling parts meets the requirements of the product definition.

The material identification shall be done using an industry recognized process that is capable of: a) Determining carbon contentb) Determining all alloying elementsc) Determining Nickel and sulfur content for NACE MR0175 applications.

When welding or repair by welding, all elements in the carbon equivalency formula shall be adequately identified:


Align with 16A allowances for carbon equivalency. Check AWS.

9.5.3 Engineering judgment based on service/field experienceCertain service and field data may be taken in to account based on engineering judgment.

9.6 Filler material qualificationFiller metals shall be specified in each WPS by ASME II, Part C/AWS specification and classification or other recognized international standard.

Welding consumables shall be clearly identified by trade name, as applicable, and the identity maintained until consumed.

Move to welding


10. Welding10.1 General

The welding specification of this standard defines the minimum requirements for joining and repairing pressure containing and load bearing parts by fusion welding and for qualification of fusion-welding procedures.

Welding of all pressure containing and non-pressure containing parts exposed to well bore fluids or gasses shall be performed with procedures qualified in accordance with the welding requirements of NACE MR0175.

Welding of all pressure containing and load bearing parts not exposed to well bore fluids or gasses shall also be performed with procedures qualified in accordance with this standard but the maximum hardness requirements as defined in NACE MR0175 do not necessary apply.

No fabrication or repair welding is allowed on equipment from which the material composition and material specs are not known (no traceability) or cannot be reestablished. Weld exclusions as defined in API-6A are equally applicable to this standard.

The manufacturer's system for controlling welding shall include procedures for monitoring, updating and controlling the qualification of welders, welding operators and the use of welding-procedure specifications. Dimensions of groove and fillet welds with tolerances shall be documented in the manufacturer's specification.

10.2 Weldment design and configurationDesign of groove and fillet welds with tolerances shall be documented in the manufacturer's specifications.

Pressure-containing fabrication weldments contain and are wetted by wellbore fluid. Only full penetration welds fabricated in accordance with the manufacturer's written specification shall be used.

Load-bearing weldments are those subject to external loads and not exposed to wellbore fluids.Joint design shall be in accordance with the manufacturer's written procedures.

Design of groove and fillet welds with tolerances shall be documented in the manufacturer's specifications.Annex D recommends weld-preparation designs.

Annex E recommends weld-preparation designs (API-6A).

10.3 Welding procedure qualificationsThe following applies:

a) written procedure:Welding shall be performed in accordance with welding procedure specifications (WPS), written and qualified in accordance with ASME, BPVC Section IX, Article II. The WPS shall describe all the essential, nonessential and supplementary essential (if required; see ASME, BPVC Section IX) variables.

The PQR shall record all essential and supplementary essential (if required) variables of the weld procedure used for the qualification test(s). Both the WPS and the PQR shall be maintained as records in accordance with the requirements of this standard.

WPS’s for weld overlay shall include the chemical composition/composition ranges of the major elements for the particular alloy.


Weld Procedures using any consumable with a “G” classification shall be restricted to the brand and type of electrode used for the PQR. The nominal chemical composition of the specified brand and type of consumable should be identified on the WPS.

SAW procedures shall be requalified whenever the welding flux is changed from one manufacturer’s tradename to another. Equivalence under ASME BPVC Section II, Part C, or AWS filler metal specifications shall not be considered adequate for substitution without requalification. Recrushed slag is not permitted for welding pressure-containing parts.

Combining two or more welding processes that use alloy filler metals of different nominal compositions requires qualification as a combination procedure.

When joining dissimilar ferritic steels (P-1 though P-5), the filler metal shall conform to the nominal chemical composition of either base metal or an intermediate composition. However, when attaching nonpressure parts to pressure parts the filler metal chemical composition shall match the nominal chemical composition of the pressure part.

Where metallic backing material is permitted, the P-number or its nominal chemical composition shall be specified in the WPS and/or the applicable fabrication drawing. For joints between similar materials, the chemical composition of backing materials shall match the nominal base metal chemical composition.

Temporary attachments welded to the base metal shall be compatible with the base metal and welded in accordance with a qualified weld procedure. Temporary attachments shall be removed by gouging or grinding and the base metal restored to its original condition before final heat treatment (if required), pressure testing, and final acceptance. The base metal shall be inspected with MT or PT upon removal of the attachment.

b) base metal groupings:The manufacturer may establish a P-number grouping for material(s) not listed in ASME, BPVCSection IX. Materials not listed in ASME BPCV Section IX must have their own WPS. NOT in all circumstances see Base materials section.

c) heat-treat condition:All testing shall be done with the test weldment in the post-weld heat-treated condition. Post-weld heattreatment of the test weldment shall be in accordance with the manufacturer's written specifications.

When PWHT is required for, all-weld-metal test coupons shall be PWHT’d with the nominal temperature and maximum time to be used in production. The tensile strength, yield strength and elongation shall meet the base metal properties.

All WPS’s specifying PWHT should indicate the following:o maximum heating rate,o holding temperature range,o holding time,o maximum cooling rate.

d) hardness testing:For material required to meet NACE, hardness tests across the weld and base-material heat-affectedzone (HAZ) cross-section shall be performed and recorded as part of the PQR. Results shall be inaccordance with ISO 15156 (all parts) (NACE MR0175; see Clause 2). (Delete)The manufacturer shall specify the hardness testing locations in order to determine maximum hardness.Testing shall be performed on the weld and base-material HAZ cross-section in accordance with ISO 6508(all parts) or ASTM E18, Rockwell method; or ISO 6507 (all parts), using the 98 N method or ASTM E384,Vickers 10 kgf method. Results shall be converted to Rockwell C, as applicable. ISO 18265 or ASTM E140


shall be used for the conversion of hardness readings for materials within the scope of their application. Other conversion tables also exist. Users may establish correlations for individual materials outside the scope of ISO 18265 or ASTM E140.

e) impact testing:If impact testing is required for the base material, the testing shall be performed in accordance with ISO 148 (all parts) or ASTM A370 using the Charpy V-notch technique. Results of testing in the weld and base material HAZ shall meet the minimum requirements of the base material. Records of results shall become part of the PQR.

10.4 Welding specification requirements The minimum requirements of each weld joint, weld repair, or weld buildup in a weldment shall be defined

by a weld specification (WS) and approved by engineering before welding. The WS shall determine the qualification requirements of all WPSs used in the well process. Each weld joint, weld repair, or weld buildup shall be made with WPSs that have been qualified to meet or

exceed the mechanical properties specified by the WS. Any deviation from the WS and the use of procedures that do not guarantee the mechanical properties as

required in the OPD shall be fully documented and approved by the OEM product lead engineer or Remanufacturer lead engineer.

When PWHT is required, the WPSs shall be capable of producing the WS specified mechanical properties in each weld joint, weld repair, or weld buildup after all required production or repair post weld heat treatments.

When it is necessary to repair defects or machining errors in previously post weld heat-treated weldments, the weldments shall be capable of meeting the WS specified requirements after all PWHT cycles.

Capability shall be established by qualifying WPSs for both, the shortest and longest PWHT cycle times at temperature using the same parameters used in the original WPSs (base metal, filler metal, process, etc.

For the hardenable low alloy steels, the shortest PWHT cycle shall be specified in the OPD (x hours at temperature). The longest PWHT cycle shall be x hours plus x hours multiplied by the number of cycles necessary to equal or exceed the cumulative time-at-temperature to which the weldment will be exposed. However thicker joints may require longer PWHT times.

When the weld metal hardness is below the minimum required by the WS, or the parameters used in the previously used WPSs are unknown, or the mechanical properties from the weld are not traceable through the approved PQR, the entire weld shall be removed and rewelded with WPSs qualified in accordance with the OPD.

When it is not possible to qualify WPSs for the required number of 4-hour PWHT cycles, the OEM product lead engineer or Remanufacturer lead engineer shall provide a disposition, guaranteeing the minimum material specifications and weld and HAZ composition, before any welding is performed.

Before welding commences on any component or part, verification and implementation of the correct and approved manufacturer / remanufacturer written welding procedure specification (WPS), the supporting procedure qualification record (PQR), the use certified equipment required to control the fusion welding process and Post Weld Heat Treatment (PWHT) process shall be validated and recorded

10.5 Welder specificationsThe following applies:a) Testing requirements:

Welders and welding operators shall be qualified in accordance with ASME BPVC Section IX, Article III.

b) Records:Records of welder performance qualification (WPQ) tests shall be in accordance with ASME BPVC Section IX.

c) Position qualification:Welders shall be qualified for the welding position applicable for the fusion welding process as defined in AWS DS1.1.


10.6 Materials10.6.1 Base materials

The base metals used to manufacture or repair shall be in compliance with the OPD. The metals used for procedure qualification test coupons shall meet but not exceed the material

specifications and material composition requirements of the base material as defined in the OPD and used in the product.

The base metals of all products to be weld repaired or built up shall be positively identified before weld repairs are performed. The chemical composition and material properties of the base metal shall be traceable by component serial number, engineering drawing, manufacturing records, repair records, or other means, to a mill certificate and mill test report.

When Positive Material Identification (PMI), (Spark Emission Spectrography), is required to determine the material composition, a qualified laboratory using industry-accepted practices and techniques shall perform the analysis. Consideration shall be given that the analysis is made from one or more samples of the original base metal. This includes the substrate of previous weld repairs, buildups, or other areas that are not previously deposited weld metal. A suitable etchant, such as specified in ASME IX QW-470, can be used to determine that these areas are in fact original base metal. The areas, from which metal must be removed for chemical analysis, shall be approved by the OEM product lead engineer or Remanufacturer lead engineer and shall be restored by welding with an approved WPS when required.

If the material specifications are not positively traceable to a material certificate of the base material, test coupons must be taken from the base material to reestablish establish those in order to qualify the WPS under ASME IX. The areas, from which metal must be removed for testing, shall be approved by the OEM product lead engineer or Remanufacturer lead engineer and shall be restored by welding with an approved WPS.

Equivalent P-Number (EP) groupings for the purpose of procedure qualification are not permitted for any of the hardenable materials referenced in this standard (8630M, 4130, F22, etc), because these materials have differences in hardenability, temper resistance, and product heat-treat conditions that require different PWHT cycles to guarantee the required mechanical properties.

Only when the mechanical properties of each component member do not require being equal, then combinations of these materials may be welded, provided the WPSs used and qualified to weld them are qualified separately. This requires a separate PQR test weld to be made using the higher PWHT temperature of the two materials for welding each of the two materials to themselves. This ensures that the HAZ of the more temper resistant and hardenable material meets the maximum hardness and mechanical properties requirements of the design.

WPSs shall be qualified on the base material specification and shall meet the minimum yield and maximum yield strength requirements defined in the OPD.

Metals that do not appear in ASME IX QW-422 as either an S-Number or a P-Number metal are considered “unassigned metals” and shall be qualified separately, except as otherwise permitted in QW-420.1 for base metals having the same UNS numbers. Unassigned metals shall be identified in the WPS and on the PQR by specification, type, and grade or by chemical analysis and mechanical properties.

Procedures qualified with P-Number materials are qualified to weld all P-Number and S-Number metals of the same grouping. However, the S-Number materials listed in ASME IX QW-422 shall not be used to qualify procedures (See ASME IX, QW-420.2).

When the WS calls for welding materials of different mechanical properties (heat treatment condition, strength levels, etc.), the material with the lesser properties shall meet or exceed the mechanical properties specified in the WS.

10.6.2 Filler materials Welding consumables shall conform to the American Welding Society's or manufacturer's specifications.

The manufacturer shall have a written procedure covering the storage, segregation, distribution, and return of all welding consumables. Filler metal identity must be maintained including Fluxes. Materials shall be stored and used as recommended by the manufacturer of the welding consumable. Controls shall be in place to ensure recovered flux, when allowed, is not contaminated in the recovery process and that the process meets the flux manufacturer’s requirements for protection from moisture.


Storage and baking of welding consumables shall be carried out in separate ovens. The ovens shall be heated by electrical means and shall have automatic temperature control. Welding consumable storage and baking ovens shall have a visible temperature indicator.

The deposited weld metal mechanical properties, as determined by the procedure qualification record (PQR), shall meet or exceed the minimum specified mechanical properties for the base material.

Welding rods, electrodes, fluxes, filler metals, and carbon and low-alloy steel welding consumables containing more than 1% nickel shall not be used for welding products required to meet the maximum hardness requirements under NACE MR0175.

Welding consumables containing more than 1% nickel may be used for welding of products that do not require to meet the maximum hardness requirements under NACE MR0175.

AWS/ASME classified filler metals that are qualified with the WPS for a given number of postweld heat-treat cycles shall be listed in the WPS by either the trade name or the classification number.

Unclassified filler metals, which are so qualified, shall also be listed on the WPS and PQR by trade name or nominal chemical composition of the weld deposit. The nominal chemical composition of such deposits shall be taken from either the PQR test weld or the manufacturer’s certificate of compliance.

The certificate of compliance for SAW filler metals shall show that the deposit was made with the same flux as that used on the original PQR test weld.

Since the purpose of the testing for classification is different than it is for procedure qualification (multiple PWHT), the ASME/AWS SAW flux classification system shall not be used to document the SAW flux-wire combinations used on WPSs that are qualified for welding any of the hardenable materials like (8630M, 4130, F22, etc). The WPSs for these materials shall identify both the flux and the wire separately by brand name and the manufacturer’s designation. If the wire is classified and the flux is not, then the flux must be identified on the WPS by the manufacturer’s designation.

If ASME/AWS SAW flux classification does not give assurance that the deposit will meet the 1% maximum nickel requirement of NACE MR0175, or that the deposit will develop the required mechanical properties after more than 1-hour post weld heat treatment the qualification is not acceptable.

The deposited weld metal mechanical properties (after post-weld heat treatment(s), if applicable) shall meet or exceed all the minimum specified mechanical properties of the WS, defined in the OPD.

10.6.3 Repair welds and PWHTRepairing a PWHT’d component without PWHT requires that the repair meet all applicable construction code requirements.

When repairs are made to cladding or overlay welds on low-alloy steels without subsequent PWHT, a minimum remaining clad or overlay thickness of 3/16 in. (5 mm) [API-RP 582] is recommended but all cases it is required to demonstrate that no new HAZ is formed in the base metal with thinner overlay.

The minimum left over is what is qualified under the WPS. The parent material is not affected by the cold weld repair. Some go down as 0.080 in. for min overlay thickness depending on the used process. You have to proof that no new HAS has been formed in the base material.

Exemption of code required PWHT for ferritic materials based on the use of austenitic or nickel-base fillermaterials is not permitted.

All repair welding shall be carried out in accordance with the manufacturer's written specification. All major repair welds to pressure-containing members performed subsequent to original heat treatment shall be mapped. Weld maps shall contain the following Information, at a minimum:Part Sketch denoting weld Repair AreaPart NumberSerial numberWelder’s nameWelders Stamp NumberPT / MT Report Number of verification of Defect Removal WPS usedFiller Material Heat/Batch/LotWeld Flux Heat/Batch/Lot, if used


Number PWHT Hours usedNumber PWHT Hours remaining

Welding and completed welds shall meet the requirements of Section documentation?.

The post-weld heat treatment of the test weldment and the production weldment shall be in the same range as that specified on the WPS. Allowable range for the post-weld heat treatment on the WPS shall be a nominal temperature of ± 14 °C (± 25 °F).

Within the defined bandwidth, the actual PWHT temperatures in combination with the heating and cooling rates can vary between the various WPSs, however the stress-relieving heat-treatment(s) time(s) at temperature(s) of parts shall be equal to or greater than that of the test weldment.

When a weldment requires postweld heat treatment, it shall be performed in accordance with WPSs that are qualified to meet the WS specified requirements after all required production and repair PWHT cycles.

WPSs to be used for welding hardenable materials (8630M, 4130, F22, etc) shall be qualified as follows: Weldment 1 shall be post weld heat treated one time. Depending on the thickness of the joint, the minimum

time at temperature shall be specified in the OPD (x hours), and the temperature shall be < 25 °F below the PWHT temperature. Heating and cooling rates above 800°F shall be at the upper boundary.

Weldment 2 shall be post weld heat treated such that the minimum cumulative time at temperature equals or exceeds minimum time at temperature (x hours) plus x hours multiplied by the number of PWHT cycles necessary to equal or exceed the cumulative time-at-temperature to which the weldment will be exposed. The temperature shall be < 25 °F above the PWHT temperature given for the specific materials to be welded. Heating and cooling rates above 800°F shall be at the lower boundary.

The PQR post weld heat treatment cycle shall be considered sufficiently representative of the production post weld heat treat cycle if a comparison of the PQR PWHT chart with the production PWHT chart shows that:

a) All welds and critical PWHT sections reached the soak temperature specified in the WPS at the same time (±15 minutes) and were held within the allowable temperature range for the time range specified in the WPS, or

b) The last weld to reach temperature was held within the allowable temperature range for the minimum time specified in the WPS, the first weld to reach temperature was held within the allowable temperature range no longer than the maximum time specified in the WPS, and none of the critical PWHT sections exceeded the allowable temperature range at any time.

WPSs that are qualified with the above-specified PWHT cycles or meet the requirements do need not be validated with a furnace survey. However, WPSs that are qualified with PWHT cycles different than the PWHT cycles specified in the OPD do not meet the requirements and shall be validated with a furnace survey.

When a furnace survey is required to validate the production/repair PWHT cycle, it shall be performed as follows: The survey shall be made on a weldment that represents the largest weldment on which the WPSs will be

used. The survey shall be conducted with thermal couples attached directly to each weld joint, buildup, and

critical PWHT section in the weldment. An accurate thermal couple attachment-unit (TAU) and redundant thermocouples should be used to ensure that accurate readings are obtained in these critical areas.

Note: thermal couples shall not be installed on areas that are outside the heated zone of subsequent PWHTs.

Post weld heat treating equipment shall be properly calibrated and meet the requirements specified by the equipment manufacturer, the applicable code, or the remanufacturer, whichever is more stringent.

Post weld heat treatment may be performed locally or in a furnace. Local post-weld heat treatment shall consist of heating a circumferential band around the weld at a temperature within the range specified in the qualified WPS. The minimum width of the controlled band at each side of the weld on the face of the greatest weld width shall be the thickness of the weld or 50 mm (2 in) from the weld edge, whichever is less. Heating by direct flame impingement on the material shall not be permitted.


When spot repairs of finished-machined parts are post weld heat treated locally, special fixtures and pre- and post-heat treating procedures should be used to minimize the distortion that can occur, particularly on finished-machined parts having a low ratio of wall thickness to diameter.Distortion effects can be minimized when background heating is applied to the entire circumference of the part during the post weld heat treat cycle, however all local pre- and post weld heat treatments must be in accordance with one or more WPSs qualified to make the repairs.

The total PWHT time applied shall be equal or less than the time for which the WPS is qualified. It is recommended to qualify the WPS for 1.25 times the total required PWHT time at temperature.

10.6.4 PreheatingPreheating, where required, applies to all welding, tack welding, and thermal cutting. Minimum preheatrequirements shall follow the applicable code and recommended practice such as Appendix R of ASME BPVC Section VIII Division 1, Table 330.1.1 of ASME B31.3, and Annex XI of AWS D1.1. Any recommendations or requirements for preheat listed in the relevant code shall be considered mandatory.

Preheating of assemblies or parts, when required, shall be performed in accordance with the WPS. The preheat and interpass temperature shall be checked by use of thermocouples, temperature indicating crayons, pyrometers or other suitable methods. Preheating temperature shall be verified and recorded before any welding is performed. Heating by direct flame impingement on the material shall not be permitted.

10.6.5 Corrosion-resistant and wear-resistant overlaysThe manufacturer shall use a written procedure that provides controls for consistently meeting the manufacturer-specified material surface properties in the final machined condition. As a minimum, this shall include inspection methods/technique for measuring the specified overlay thickness and acceptance criteria.

Qualification shall be in accordance with Articles II and III of ASME Boiler and Pressure Vessel Code Section IX for corrosion-resistant weld metal overlay or hardfacing weld metal overlay as applicable.

10.6.6 Welding controlsAll instruments, meters and gauges used to confirm welding parameters and post weld heat treatment furnace settings shall be serviced and calibrated to the manufacturer's written specifications by equipment traceable to a nationally or internationally recognized standard specified by the manufacturer or to the remanufacturer recommendations, whichever is more stringent.

All welding equipment (power sources, ram manipulators, rotating tables, power rolls, and other manual, semi-automatic, mechanized, and machine welding equipment) shall be capable of reproducing settings of all specified variables.

The calibration intervals shall be a maximum of six months until recorded calibration history can be established by the manufacturer. Intervals may be lengthened (six months maximum increment) or shall be shortened based on the recorded history. Written records shall document the calibration date, procedure used, accuracy, frequency and hardness results.


10.6.7 Quality Assurance Quality ControlThe equipment, materials, and services used in the remanufacturing conforming to this standard shall be consistent with the welding and inspection requirements of the quality plan, order specification, other agreed specifications in addition to this standard and API Q1.

10.6.7.1 Corrosion-resistant ring groovesStandard dimensions for the preparation of type SR ring grooves for overlays are specified in 5.3. Standarddimensions for type R and BX ring grooves are specified in ISO 10423.

10.6.7.2 Corrosion-resistant and wear-resistant overlays other than ring groovesThe manufacturer shall use a written procedure that provides controls for consistently meeting the manufacturerspecifiedmaterial surface properties in the final machined condition. As a minimum, this shall include inspectionmethods and acceptance criteria.Qualification shall be in accordance with Articles II and III of ASME Boiler and Pressure Vessel Code Section IX forcorrosion-resistant weld metal overlay or hardfacing weld metal overlay as applicable.

10.6.7.3 Mechanical propertiesMechanical properties of the base material shall retain the minimum mechanical property requirements after thermal treatment. The manufacturer shall specify the methods to ensure these mechanical properties, and shall record the results as a part of the PQR.

10.7 Welding controls

10.7.1 ProceduresThe manufacturer's system for controlling welding shall include procedures for monitoring, updating and controlling the qualification of welders, welding operators and the use of welding-procedure specifications.

10.7.2 ApplicationWelding shall be performed by personnel qualified in accordance with the requirements of 7.4.1.Welding shall be performed in accordance with written WPS and qualified in accordance with Article II of ASMESection IX. The WPS shall describe all the essential, non-essential and supplementary essential (in accordance with ASME Section IX) variables. Welders and welding operators shall have access to, and shall comply with, the welding parameters as defined in the WPS.

10.7.3 Designed weldsFor all welds that are considered part of the design of a production part, the manufacturer shall specify therequirements for the intended weld.Dimensions of groove and fillet welds with tolerances shall be documented in the manufacturer's specification.Figures 9 through 12 depict some typical joint designs.

10.7.4 Materials10.7.4.1 Welding consumablesWelding consumables shall conform to American Welding Society (AWS) or the consumable manufacturer's approved specifications. The manufacturer shall have a written procedure for storage and control of welding


consumables. Materials of low hydrogen type shall be stored and used as recommended by the consumable manufacturer to retain their original low hydrogen properties.

10.7.4.2 Deposited weld metal propertiesThe deposited weld metal mechanical properties shall meet or exceed the minimum specified mechanical properties of the base material. Verification of properties shall be established through the implementation of the manufacturer's WPS and supporting PQR. When materials of differing strength are joined, the weld metal shall meet the minimum requirements of the lesser material.

10.7.4.3 Post-weld heat treatmentPost-weld heat treatment of components shall be in accordance with the manufacturer's written procedures.Furnace post-weld heat treatment shall be performed in equipment meeting the requirements specified by themanufacturer.Local post-weld heat treatment shall consist of heating a band around the weld at a temperature within the rangespecified in the qualified WPS. The minimum width of the controlled band adjacent to the weld, on the face of thegreatest weld width, shall be the thickness of the weld. Localized flame-heating is permitted provided the flame isbaffled to prevent direct impingement on the weld and base material.

10.8 Welding procedure and performance qualifications10.8.1 GeneralAll weld procedures, welders and welding operators shall be qualified in accordance with the qualification and testmethods of Section IX, ASME Boiler and Pressure Vessel Code, as amended below.

10.8.2 Base metalsThe manufacturer may use ASME Section IX P number materials.The manufacturer may establish an equivalent P number (EP) grouping for low alloy steels not listed in ASME Section IX with nominal carbon content equal to or less than 0,35 %.Low alloy steels not listed in ASME Section IX with a nominal carbon content greater than 0,35 % shall be specifically qualified for the manufacturer's specified base material.Qualification of a base material at a specified strength level also qualifies that base material at all lower strengthlevels.

10.8.3 Heat-treat conditionAll testing shall be done with the test weldment in the post-weld heat-treated condition. Post-weld heat treatment ofthe test weldment shall be according to the manufacturer's written specifications.

10.8.4 Procedure qualification recordThe PQR shall record all essential and supplementary essential (when required by ASME) variables of the weldprocedure used for the qualification test(s). Both the WPS and the PQR shall be maintained as records in accordancewith the requirements of clause 8.

10.9 Other requirements10.9.1 ASME Section IX, Article I — Welding general requirements10.9.2 General

Article I of ASME Section IX shall apply with additions as given below.

10.9.3 Hardness testing10.9.4 GeneralHardness testing shall be conducted across the weld and base material heat-affected zone (HAZ) cross-section and shall be recorded as part of the PQR. Manufacturer shall specify the hardness testing method to be used.


Testing shall be performed on the weld and base material HAZ cross-section in accordance with ISO 6508-1, Rockwell; or ISO 6507-1, Vickers 10 kg. Minimum results shall be converted to Rockwell C as applicable in accordance with ASTM E 140.

10.9.4.1 Rockwell method (ISO 6508-1)If the Rockwell method is selected by the manufacturer, the following procedure shall be used:a) for a weld cross-section thickness less than 12 mm (1/2 in), four hardness tests each shall be made in the basematerial(s), the weld and the HAZ;b) for a weld cross-section thickness equal to or greater than 12 mm (1/2 in), six hardness tests each shall be madein the base material(s), the weld and the HAZ;c) HAZ hardness tests shall be performed in the base material within 1,5 mm (0,06 in) of the weld interface and atleast one each within 3 mm (0,125 in) from top and bottom of the weld. See Figure 13 for test locations.

10.9.4.2 Vickers method (ISO 6507-1)If the Vickers method is selected by the manufacturer, the following procedure shall be used:a) for a weld cross-section thickness less than 12 mm (1/2 in), four hardness tests each shall be made in the basematerials and the weld;b) for a weld cross-section thickness equal to or greater than 12 mm, six hardness tests each shall be made in thebase material(s) and the weld;c) multiple HAZ hardness tests equally spaced 3 mm (0,125 in) apart shall be performed in each of the basematerials within 0,25 mm (0,01 in) of the weld interface and at least one within 1,5 mm (0,06 in) from the top andthe bottom of the weld. See Figure 14 for test locations.

Key1 Weld2 HAZ3 Basea TypicalFigure 13 — Rockwell hardness test locations

10.9.4.3 Hardness testing (optional) — Minimum mechanical propertiesFor the purpose of hardness inspection and qualifying production weldments, a minimum of three hardness tests inthe weld metal shall be made and recorded as part of the PQR. These tests shall be made by the same methods usedto inspect production weldments. These tests may be used to qualify weld metal with hardness less than shown in8.5.1.4 by the method shown in the same subclause.Dimensions in millimetres (inches)Key1 Weld2 HAZ3 Basea TypicalFigure 14 — Vickers hardness test locations

10.9.4.4 Impact testingWhen impact testing is required by the base material specification, the testing shall be performed in accordance with ASTM A 370 using the Charpy V-notch technique. Results of testing in the weld and base material HAZ shall meet the minimum requirements of the base material. Records of results shall become part of the PQR.When impact testing is required of the base material, one set of three test specimens each shall be removed at the ¼ thickness location of the test weldment for each of the weld metal and base material HAZ. The root of the notch shall be oriented normal to the surface of the test weldment and located as follows:

a) weld metal specimens (three each) 100 % weld metal;b) HAZ specimens (three each) shall include HAZ material as specified in the manufacturer's written

procedure;


c) when weld thickness of the product is equal to or greater than 50 mm (2 in), impact testing shall be performed on weld metal and HAZ material removed within 1/4 thickness.

10.9.5 ASME Section IX, Article II — Welding procedure qualifications

10.9.5.1 GeneralArticle II of ASME Section IX shall apply with additions as shown in this subclause.

10.9.5.2 Heat treatmentThe post-weld heat treatment of the test weldment and the production weldment shall be in the same range as thatspecified on the WPS. Allowable range for the post-weld heat treatment on the WPS shall be a nominal temperatureof ± 14 °C (± 25 °F). The stress-relieving heat-treatment(s) time(s) at temperature(s) of production parts shall be equalto or greater than that of the test weldment.

10.9.5.3 Chemical analysisChemical analysis of the base materials for the test weldment shall be obtained from the supplier or by testing andshall be part of the PQR.For corrosion-resistant ring groove overlay, chemical analysis shall be performed in the weld metal in accordance with the requirements of ASME Section IX at a location of 3 mm (0,125 in) or less from the original base metal surface. The chemical composition of the deposited weld metal at that location shall be as specified by the manufacturer. For 300 series or austentic stainless steel, the chemical composition shall be within the following limits:a) nickel 8,0 % mass fraction minimum;b) chromium 16,0 % mass fraction minimum;c) carbon 0,08 % mass fraction maximum.Welds for use in hydrogen sulfide service shall conform to the requirements of NACE MR0175.

10.9.6 ASME Section IX, Article III — Welding performance qualifications

10.9.6.1 GeneralArticle III of ASME Section IX shall apply with additions as shown in this subclause.

10.9.6.2 Bolt, tapped and blind hole repair performance qualificationThe welder or welding operator shall perform an additional repair welding performance qualification test using amock-up hole (refer to Figure 11). The repair welding qualification test hole shall be qualified by radiography accordingto clause 8, or shall be cross-sectioned through the centreline of the hole and both faces shall be examined by NDE inaccordance with clause 8. This evaluation shall include the total depth of the hole.The repair weld qualification shall be restricted by the following essential variables for performance controls.a) The hole diameter used for the performance qualification test is the minimum diameter qualified. Any hole with adiameter greater than that used for the test shall be considered qualified.b) The depth-to-diameter ratio of the test hole shall qualify all repairs to holes with the same or smaller depth-todiameterratio.c) The performance qualification test shall have straight parallel walls. If any taper, counter-bore or other aid is usedto enhance the hole configuration of the performance test, that configuration shall be considered an essentialvariable.


For welder performance qualification, ASME Section IX P-1 base metals may be used for the test coupon in place ofthe low alloy steels covered by this American National Standard (Table 20).

10.10 ASME Section IX, Article IV — Welding data10.10.1 Article IV of ASME Section IX shall apply as written.10.10.2 General10.10.3 Welder qualification10.10.4 Welding Process Specification (WPS)

Production weld Repair welding

10.10.5 Welding Process Qualification Record (WPQR) Including mechanical properties Microstructure

10.10.6 CRA welding Stainless steel (316L) High nickel alloy (Alloy 625) High nickel alloy (Alloy 718), (delta Phase) Super Duplex


11. Decommissioning

The LCMSP is responsible for determining and documenting and executing requirements for the decommissioning of traceable products in accordance with the Life Cycle Management Plan. The plan and execution shall include:

A. The decision point(s) that will lead to the decommissioning of the equipment. If there are multiple options for the decommissioning of the equipment, they shall be outlines, along with the process for deciding which one will be chosen.

B. A risk assessment of the hazards associated with decommissioning, with a plan to manage the risks appropriately. This risk assessment shall be updated immediately prior to the actual decommissioning process with the risk management plan updated as necessary, to ensure that it is current.

C. A review of the relevant legal requirements of the jurisdiction where the equipment is planned or expected to be decommissioned from, and a plan to satisfy those requirements as part of the decommissioning process. Such requirements shall include, but not being limited to, disposal of hazardous materials.

D. A plan describing how the equipment will be decommissioned. This shall include the steps to be taken before decommissioning, the activities to decommission. And what will be done with the equipment after decommissioning. The plan shall include removing the equipment from the deployed location, unless a case is made within the plan not to do so.

E. Criteria by which success of the decommissioning process is defined.

If it is not possible to remove the equipment, post-decommissioning actions may be required to ensure compliance to the legal requirements – for example environmental monitoring or access control. If such actions are required, they shall be specified in the decommissioning plan.

At the end of the decommissioning process, a report shall be written capturing the date and location of the decommissioning, the parties involved, and the outcome of the decommissioning process, including the criteria by which success was to be measured, as outlined in the plan.All documentation shall be retained and available for a minimum of five years past the date of decommissioning of the equipment. The decommissioning report shall be approved by the LCMSP and the owner/operator and included in the PHF.

12.Certification


Annex A(Normative)

Manufacturing Data Book Requirements

The below mentioned document contents for the construction of the Material Data Book (MDB) and Project History File (PHF) shall be provided and recorded in order to provide the minimum traceability requirements for maintenance and remanufacturing of pressure control equipment manufactured under API-16A.

Manufacturing Data Book (MDB)

Document Contents Delivered to Client Maintained by Manufacturer

Date of Manufacturing √ √Serial Numbers of equipment and location √ √Design Verification Report Only if requested by customer √Material Test Records (including the following): a) Chemical Analysis √ √

b) Tensile tests (QTC) √ √

c) Impact tests (QTC as required) √ √

d) Hardness tests (QTC) √ √

e) NDE Personnel qualification records May be difficult to get for older products, can be retrieved if brought in for repair at

original facility

√

Material Specification Number √ √Welding Process Records √

Most OEM's give a Weld Data Sheet which includes:

- Welder ID - Filler Metal

- Heat and/or batch number - WPS #

- Stress Charts - PWHT

√All remaining

documentation required as defined in API 16A are kept at OEM facility for required length of

time

NDE Records:

a) Surface NDE Records √ √

b) Full penetration fabrication √ √

c) Weld volumetric NDE records √ √

d) Repair weld NDE records √ √

Heat Treatment Records

a) Actual Temperature√ √

b) Actual times at temperature√ √

Third Party or Class Society Inspection Reports√ √


Manufacturing Data Book (MDB) continued.


Test Report(s), Pressure Testing and FAT a) Volumetric NDE Records / radiographic UT Records

√ √

b) Hydrostatic pressure test records √Limited scope and pressure test only

√

c) Critical dimensions (as defined by OEM) √Limited scope and basic dimensions only

(height, weight, etc…)

√Critical dimensions

kept by OEM.

Certificate of Conformance a) include standard to which equipment is certified to

√ √

Product History File (PHF) Repair with Original parts Only


Manufacturing Data Book √ N/ASerial Numbers of equipment and location √ N/ADesign Verification Report Still covered by original design

verification , however design verification reports remain proprietary to OEM

N/A

Third Party or Class Society Inspection Reports√ N/A

Test Report(s), Pressure Testing and FAT N/A

a) Volumetric NDE Records / radiographic UT Records

√ N/A


N/A

c) Critical dimensions (as defined by OEM) √Limited scope and basic dimensions only

(height, weight, etc…)

N/A

Certificate of Conformance a) include standard to which equipment is certified to

√ N/A


Product History File (PHF) Repair with NON-OEM parts OnlyManufacturing Data Book (if available)

√ N/A

Serial Numbers of equipment and location √ N/A

Design Verification Report (if available)

Repair facility will be required to ensure that all design verification is

compliant with API 16A.

N/A

PMI Test √ N/A

Material Specification Number √ N/A

Welding Process Records (if applicable)

√Most OEM's give a Weld Data Sheet

which includes: - Welder ID

- Filler Metal - Heat and/or batch number

- WPS # - Stress Charts

- PWHT

N/A

NDE Records √ N/A

Heat Treatment Records (if applicable)√ N/A

Third Party or Class Society Inspection Reports√ N/A

Test Report(s), Pressure Testing and FAT √ N/A

a) Volumetric NDE Records / radiographic UT Records

√ N/A


N/A

c) Critical dimensions (as defined by OEM) √Limited scope and basic dimensions

only (height, weight, etc…)

N/A

Certificate of Compatibility a) include standard to which equipment is certified to

√ N/A


Annex B(Normative)

Failure reporting (Copy of S53)B.1 User Recommendations

B.1.1 The equipment owner of blowout prevention equipment shall provide a written failure report to the equipment manufacturer of any malfunction or failure that occurs.

B.1.2 The failure report shall include the following:a) as much information as possible on the operating conditions that existed at the time of the malfunction or failure;b) an accurate a description as possible of the malfunction or failure;c) any operating history of the blowout prevention equipment leading up to the malfunction or failure (e.g. field repair, modifications made to the blowout prevention equipment, etc.).

B.1.3 The manufacturer shall respond to receiving the failure report and provide a timeline to provide failure resolution.

B.2 Manufacturer’s Recommendations

B.2.1 Manufacturer’s Internal Recommendations

B.2.1.1 All significant problems experienced with blowout prevention equipment noted during its manufacture, testing or use shall be formally communicated to the individual or group within the manufacturer's organization responsible for the design and specification documents.

B.2.1.2 The manufacturer shall have a written procedure that describes forms and procedures for making this type of communication, and shall maintain records of progressive design, material changes, or other corrective actions taken for each model and size of blowout prevention equipment.

B.2.2 Manufacturer’s External Recommendations

B.2.2.1 All significant problems experienced with blowout prevention equipment shall be reported in writing to each and every equipment owner of the blowout prevention equipment within three weeks after the occurrence.

B.2.2.2 The manufacturer shall communicate any design changes resulting from a malfunction or failure history to every equipment owner using the affected equipment. That notice shall be within 14 days after the design change.


Annex C(Normative)

OEM ownership

Original Equipment Manufacturer (OEM) as per API-53STD.The design owner or manufacturer of the traceable assembled equipment, single equipment unit, or component part.

NOTE: If any alterations to the original design and/or assembled equipment or component part are made by anyone other than the OEM, the assembly, part, or component is not considered an OEM product. The party that performs these alterations is then designated as the OEM.

New pressure control equipment

Repair / Maintenance

Remanufacture(hot work)

OEM parts Non OEM

Assembly after repair contains parts from various suppliers.

OEM will only guarantee

performance of the original product.

OEM remains the same for the whole assembly

after repair

Owner / User controls the specification of the hybrid system, unless one of the suppliers of

parts adopts the assembly as OEM and will provide a COC for

the assembly.

Yes

No OEM or OEM licensed facility

Non OEMNo

Repairer of the part becomes the OEM

for the partOEM remains the same for the

remanufactured part

Yes


Annex D(Informative)

Certificate Of Conformance (COC)


Annex E(informative)

111Recommended weld preparation design dimensions

Dimensions in millimetres (inches) unless otherwise indicated

a) V-groove

b) U-groove

c) Heavy-wall V-groovea Maximum misalignment.

Figure 1A1 — Pipe butt welds



a Maximum misalignment (unless removed by machining).b Remove to sound metal by machining.c Maximum misalignment.d Backing shall be removed. Material shall be compatible with base material.

Figure 1A2 — Attachment welds



a Ratio of d1 to D2 shall not exceed 1,5:1.b Depth required to maintain a maximum of 1,5:1 depth, d1, to diameter, D2, ratio.

a) Hole repair

Key1 side2 enda Original area.

b) Excavation for repair (removal of sample discontinuities in weld metal and base metal)Figure 1A3 — Repairs

Dimensions in millimetres (inches)


a) Bushing/seat cavity (W) b) Ring groove (X)

c) Body cavity (Z) d) Body repair (Y)Key1 optional additional layers

a Thickness of weld after machining equal to approx. 5 (3/16).b Weld thickness after machining.c Maximum weld after machining (approx.).d By 19 (3/4) width.e Minimum build-up.

Figure 1A4 — Weld repair and overlay, typical weld bead sequences


Annex E(Informative)


Annex F(Informative)

Additional copies are available through Global Engineering Documents at (800) 854-7179 or (303) 397-7956Information about API Publications, Programs and Services is available on the World Wide Web at http://www.api.org

Product No: G6HT01

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