API TR PER15K Report

1. API TR PER15K Report Impact on SC 6 Documents by Kenneth Young PER15K Report - SC6 Meeting 6/30/2010

2. Scope of Work • Address the issues on the API TR PER15K requirements and bring plan to SC6 on recommended changes to related documents • HPHT Equipment: • Completion and Well Control Equipment • All equipment exposed to HPHT environment • Pressure rating > 15,000 psi or • Temperature rating > 350°F • Pressures and temperatures at seafloor PER15K Report - SC6 Meeting 6/30/2010

3. Activity • Meeting held ??/??/2010 at Stress Engineering Services in Houston • Attendees: • Sterling Lewis – ExxonMobil • Kris Ohman – Shell • Kenneth Young – Stress Engineering Services • Austin Freeman – Halliburton • John McCaskill – Expro Group • Joel Russo – FMC • David Zollo – FMC • Mahesha Udipi - PER15K Report - SC6 Meeting 6/30/2010

4. Status • MMS issued 30 CFR 250.807 on 1/11/2010 • Additional requirements for equipment installed in HPHT environments • MMS is drafting an NTL outlining the alternative compliance procedure necessary for MMS approval of HPHT permits • API TR PER15K • Draft technical report issued 5/?/2010 for ballot and comments • Document focuses on evaluation process for HPHT equipment • Design verification analysis • Design validation testing • Materials selection considerations • Manufacturing process controls PER15K Report - SC6 Meeting 6/30/2010

5. Functional Design Specification • User should provide a Functional Design Specification • Environmental conditions • Temperature, exposed fluids, corrosion/erosion, operational environment • Loads and characteristics • Pressures, temperatures, internal loads, external loads, thermal gradients, temporary conditions, cyclic loading, combined loading, and system analysis and integration • Life cycle requirements • Applicable industry standards PER15K Report - SC6 Meeting 6/30/2010

6. Technical Design Specification • Manufacturer document Technical Design Specification • Confirms design meets the Functional Design Specification • Environmental conditions • Loads and characteristics • Life cycle requirements • System analysis • Industry standards / regulatory requirements • Design verification analysis • Design validation testing • Manufacturing process specification • Fit-for-service basis • After market activities PER15K Report - SC6 Meeting 6/30/2010

7. Gap Analysis • API TR PER15K • Is a technical report, thus has no requirements • 30 CFR 250.807 • Must demonstrate equipment is capable of performing in the applicable HPHT environment • Include design verification analysis • Include design validation testing PER15K Report - SC6 Meeting 6/30/2010

8. Gap Analysis • NTL Draft 3/29/2010 • Material mechanical properties per ASME Div 3 KM-2 • Increased material toughness • Design verification • Elastic-plastic analysis per ASME Div 2 Part 5 • Fatigue analysis per ASME Div 3 • Design Validation • Hydro test per ASME Div 2, Part 8 • Construction • NDE per ASME Div 3, KE-3 • Monitoring of Loads PER15K Report - SC6 Meeting 6/30/2010

9. Gap Analysis – API Spec 6A • No requirement for User’s Function Design Specification • Pressure rating [4.2.1] • Need higher pressure ratings – 25 ksi and 30 ksi • What pressure increments? 5 ksi increments??? • External loads are not addressed [4.2.1.3] • Need to address system loads • Temperature rating [4.2.2] • Need higher temperature ratings – currently 250°F max • What temperature increments? PER15K Report - SC6 Meeting 6/30/2010

10. Gap Analysis – API Spec 6A • Exposed Fluid • API partially addresses environment through Material Class [4.2.3] and Annex A • Must comply with NACE MR0175 / ISO 15156 • Service Life • System Analysis PER15K Report - SC6 Meeting 6/30/2010

11. Gap Analysis – API Spec 6A • Design Methods [4.3] • API 6A currently uses ASME Sect VIII (2004) Elastic Analysis • API 6A does not require a fatigue analysis • Fatigue beyond scope of current document • MMS NTL Requirements • ASME Sect VIII, Div 2, Part 5 – elastic-plastic analysis with design margin based upon plastic collapse (structural instability) • ASME Sect VIII, Div 3 – fatigue life analysis PER15K Report - SC6 Meeting 6/30/2010

12. Gap Analysis – API Spec 6A • Closure Bolting [4.3.4] • API 6A Sallow = 0.83 Sy at hydro test pressure • ASME Div 3 Sallow = 0.55 Sy all working loads • ASME Div 2 Sallow = 0.25 Sy all working loads • Material Toughness [5.4.1] • API 6A CVN ≥ 20 ft-lb avg • ASME Div 3 CVN ≥ 30 ft-lb avg + KIc as specified • QTC [5.7] • API 6A part thickness but not required to exceed 5” ER • ASME Div 3 equal to min forged Q&T thickness PER15K Report - SC6 Meeting 6/30/2010

13. Gap Analysis – API Spec 6A • Surface NDE [7.4.2.2.8 and 7.4.2.2.9] • Ferromagnetic materials • API 6A and ASME Div 3 are the same if t ≥ 2 in. • Non-ferromagnetic materials • API 6A and ASME Div 3 are the same if t ≥ 2 in. • ASME requires < 10 rounded indications in 6 in.2 area • Volumetric NDE [7.4.2.3.15] PER15K Report - SC6 Meeting 6/30/2010

14. Recommendations • Affect on other SC6 documents will follow lead of 6A • SC6, SC16, and SC17 form a collective Task Group to address this issue • Options: • Separate Spec or RP for HPHT equipment • Annex for 6A for HPHT equipment • Including additional inputs, verifications requirements, validation requirements unique to 6A equipment • Address load monitoring and re-inspection requirements • Need agreement on single “best” method to accomplish all the objectives PER15K Report - SC6 Meeting 6/30/2010