Selection of Wellhead & Christmas Tree Products in compliance with

Transcription

1 Wood Group Pressure Control Selection of Wellhead & Christmas Tree Products in compliance with API 6A 19 th Edition Mandatory February 1,

2 API specs are for CUSTOMERS to use API specifications are for the user: For selecting materials suited to well conditions For ordering equipment API specifications impact the manufacturing process: (Criteria) Temperature Class Material Class (trim) PSL (Product Specification Levels) Recommended by API to the user for various service conditions PR (Performance Requirements) Levels of testing done to qualify product designs for monogram API requires every monogrammed product to meet API specs for all 4 Criteria

3 With or without the API monogram builds all new products to meet API requirements for Temperature Class Material Class PSL PR Companies can be API Licensed for marketing reasons, but then rarely comply with API requirements Licensed for 2 or 3 product types? Don t actually monogram parts? Buy-out equipment of someone else s design?

4 CO2 Partial Pressure API Material Classes (Trims) w/ limits for 17-4 SS (0.5 psia) and 410 SS (1.5 psia) stems & hanger mandrels standard sour service ratings are 0,5 or NL 0 to < 7 psia 7 psia to 30 psia > 30 psia to < 200 psia 200 psia and up Corrosion resistant alloys may be needed. H2S Partial Pressure 0 to < 0.05 psia 0.05 to 0.5 psia > 0.5 and < 1.5 psia ¹ > 1.5 psia ¹ AA EE-0,5 or DD-0,5 DD-1,5 or EE-1,5 ² DD-NL or EE-NL ³ Non-Sour Sour Sour Sour Non-Corrosive Non-Corrosive Non-Corrosive Non-Corrosive BB EE-0,5 EE-1,5 ² EE-NL ³ Non-Sour Sour Sour Sour Slightly Corrosive Slightly Corrosive Slightly Corrosive Slightly Corrosive CC FF-0,5 FF-1,5 ² FF-NL ³ Non-Sour Sour Sour Sour Moderately to Highly Corrosive Moderately to Highly Corrosive Moderately to Highly Corrosive Moderately to Highly Corrosive CC or HH FF-0,5 or HH-0,5 FF-1,5 or HH-1,5 FF-NL or HH-NL Non-Sour Sour Sour Sour Highly Corrosive Highly Corrosive Highly Corrosive Highly Corrosive Wood Group Pressure Control recommends that Corrosion Resistant Alloys be considered beginning at CO2 partial pressures of 200 psia. Consult with engineering for material selection. Additional factors should be considered. ¹ Material Class ZZ may be used when materials and trims previously used for sour service will not comply with current NACE MR0175/ISO15156 standards ² 17-4 stainless steel is not allowed for stems or tubing hangers above 0.5 psia H2S. ³ 410 stainless steel is not allowed for stems or tubing hanger above 1.5 psia H2S

5 Temperature Classes API 6A 19 th Edition All products are built for a specific API temperature class Consider max flowing and min ambient temperature (mud temp?) K -75 to 180 F L -50 to 180 N -50 to 140 P -20 to 180 R Room Temperature S 0 to 140 T 0 to 180 U 0 to 250 V 35 to 250 X 0 to 350 (ref Annex G) Y 0 to 650 (ref Annex G) Choosing temperature ratings is the ultimate responsibility of the user

6 NACE: limits for materials in H2S service 17-4 Stainless Steel Industry has historically used 17-4 SS for valve stems and tubing hangers for EE and FF sour service up to 3 or more psia H2S API 6A 19 th Edition 17-4 SS is not allowed in sour service for hanger mandrels and stems above 0.5 psia H2S partial pressure Inconel has NO LIMIT for H2S partial Pressure In many applications, 410 SS cannot be used as a substitute due to tensile strength requirements (re: hanger mandrels, stems) WGPC 19 th Edition products for sour service: Hanger Mandrels and Products with stems 17-4 SS up to.5 psia max H2S partial pressure Inconel for No Limit to H2S partial pressure

7 NACE: limits for materials in H2S service 316 Stainless Steel Industry has historically used 316 SS for fittings, needle valves and pressure gauges for EE and FF Sour service with no limit to H2S partial pressure API 6A 19 th Edition 316 SS is not allowed in sour service when chlorides are present and temperatures are above 140 F Effects grease & test fittings in all products in standard temperature ranges Next NACE expected to change to max 200 F? WGPC 19 th edition products for sour service: Low alloy fittings will be used in all alloy bodies Nickel plated alloy or Inconel fittings are used in Stainless Steel bodies

8 NACE effects API Material Classes 19 th Edition sour service Material Classes (Trims) must be labeled with the maximum allowable H2S partial pressure, depending on the materials of construction (may vary by manufacturer) WGPC 19th Edition Sour Service Material Classes (Trims) API 6A 17 th Edition & earlier API 6-A 19 th Edition DD EE FF DD-0,5 (17-4 SS stem is allowed) or DD-NL (w/ low alloy NACE stem * inconel stem is allowed) EE-0,5 (w/ 17-4 SS stem) or EE-NL (w/ inconel stem) FF-0,5 (w/ 17-4 SS stem) or FF-NL (w/ inconel stem)

9 19 th Edition Changes NACE changes affect API materials 0,5 suffix will appear on our products with internal parts Valves Tubing Hanger Mandrels* API considers the tubing hanger mandrel an internal part of a wellhead assembly (as a stems are considered internal parts of valves) NL suffix will appear on our products with no internal parts Heads, Spools & Flanges Tubing Heads (lockscrews are not addressed by API 6A) Tubing Head Adapters, DSA s (with or without packoffs) Tees, Crosses, Tree Caps

10 API 6A 19 th Edition Determine the required material class for sour service (EE or FF) Find the exact H2S partial pressure Your well(s) may be able to use 17-4 SS stems & tubing hangers It takes a lot of H2S to go over.5 5,000# 100 PPM H2S =.5 10,000# 50 PPM H2S =.5 15,000# 33.3 PPM H2S =.5 psia If WGPC quotations dept. doesn t know the H2S partial pressure WGPC will quote Valves & Hanger Mandrels (as applicable) rated by API for.5 psia maximum H2S partial pressure. A statement will appear on the quotation. Choosing material class and specific materials for specific conditions is the ultimate responsibility of the user

11 PSL (Product Specification Level) Quality Control & testing recommendations increase with severity of service Working Pressure H2S Concentration More quality control = more measurements during manufacture & more extensive pressure testing PSL 3G (new in 19 th edition) Replaces PSL 4 in API decision tree PSL 3 QC for manufacturing + gas testing PSL 4 is still available (if customer elects) PSL decision tree criteria Alternate questions can be used

12 PSL (Product Specification Level) API recommendations to users Many customers don t follow these recommendations Do customers assume this is taken care of because their supplier follows API requirements? PSL s are recommended by API to the user to specify his requirements to the manufacturer Are customers unaware of the details of API recommendations? PSL recommendations apply to the 4 Primary Parts of a wellhead assembly Tubing Head Tubing Hanger Tubing Head Adapter Lower Master Valve» In some frac operations, the customer may consider the annulus valve on the side of the tubing head as a primary part as well

13 PSL (Product Specification Level) Decision Tree Alternate questions High H2S Concentration? Yes, if a leak will result in 70 PPM or more in air If your well has less than 70 PPM H2S, the answer is NO Alternate: Is the 100 PPM radius of exposure greater than 50 ft. from the wellhead? Depending on flow rate, it is possible for wells with 70 PPM H2S or more to have a 100 PPM ROE less than 50 ft. from the wellhead Radius of Exposure formulas are shown in API 6A, Annex A, A

14 PSL (Product Specification Level) Decision Tree Alternate questions Gas Well? Alternate: customer may use Close Proximity and Radius of Exposure Analysis Yes, if 100 PPM ROE > 50 ft. and includes any part of a public area except a public road Yes, if 500 PPM ROE > 50 ft. and includes any part of a public area including a public road Yes, if well is located: In any environmentally sensitive area such as parks, wildlife preserve, city limits, etc. Within 150 ft. of an open flame or fired equipment Within 50 ft. of a public road (lease road excluded) In or near inland navigable waters In or near domestic water supplies Within 350 ft. of any dwelling

15 PR (Performance Requirement) Performance Requirement Testing of product designs is required by API before a product is eligible to be monogrammed by the manufacturer PR 1 (minimum required) At room Temperature Pressure and mechanical cycles PR 2 (option of customer or manufacturer) At room temperature Additional pressure and mechanical cycles Annex F adds temperature cycles (option of customer or manufacturer) F PR 1 adds temperature max & min F PR 2 most severe testing includes added # of cycles

16 Quality Control at different PSL s Bodies, End/Outlet Connections And Hub End Connections Requirement PSL 1 PSL 2 PSL 3/3G ¹ PSL 4 ¹ Impact Testing of Raw Material Temp K and L only Test at or below bottom of temp range Temp K, L, N and P only Test at or below bottom of temp range Temp K, L, N, P, R, S, T, U and V only Test at or below bottom of temp range Same as PSL 3/3G Same as PSL 3/3G 5M & below - sample testing Hardness Testing of Raw and Machined Parts 10M & above - test every part Test all parts for all working pressures Same as PSL 2 plus test locations on each end connection face Same as PSL 3/3G Sour service - test every part Surface NDE ² of Machined Parts Not Required Examine all accessible wetted and sealing surfaces Examine ALL accessible surfaces plus areas prepped for weld overlay Same as PSL 3/3G Volumetric NDE ² of Raw Material Not Required Not Required Examine 100% volume as practical, both After heat treating and Before machining Same as PSL 3/3G plus restricted acceptance criteria ¹ PSL 3, 3G and 4 require serialization of each part ² Non-Destructive Examination

17 Quality Control at different PSL s Stems Requirement PSL 1 PSL 2 PSL 3/3G¹ PSL 4 ¹ Impact Testing of Raw Material Manufacturer's Material Specification Temp K, L, N and P only Test at or below bottom of temp range Temp K, L, N, P, R, S, T, U and V only Test at or below bottom of temp range Same as PSL 3/3G Same as PSL 3/3G Hardness Testing of Machined Parts 5M & below - sample testing 10M & above - test every part Sour service - test every part Test all parts for all working pressures Surface NDE² of Machined Parts Not Required Examine all accessible wetted and sealing surfaces Examine ALL accessible surfaces plus areas prepped for weld overlay Same as PSL 3/3G Volumetric NDE² of Raw Material Not Required Not Required After heat treating and Before machining Same as PSL 3/3G ¹ PSL 3, 3G and 4 require serialization of each part ² Non-Destructive Examination

18 Quality Control at different PSL s Valve Bore Sealing Mechanisms And Choke Trim³ Requirement PSL 1 PSL 2 PSL 3/3G ¹ PSL 4¹ Tensile Testing of Raw Material Not required Not required Manufacturer's Material Specification Manufacturer's Material Specification Hardness Testing of Machined Parts Test all parts for sour service (DD, EE, FF, HH trims) Test all parts for all working pressures Surface NDE² of Machined Parts Not Required Examine all accessible wetted and sealing surfaces Examine ALL accessible surfaces plus areas prepped for weld overlay Same as PSL 3/3G ¹ PSL 3, 3G and 4 require serialization of each part ² Non-Destructive Examination ³ Choke trim: only surface NDE and serialization are required

19 Quality Control at different PSL s Valve Testing Requirement PSL 1 PSL 2 PSL 3 PSL 3G PSL 4 Hydrostatic Body Test Two 3-minute holds Two 3-minute holds One 3-minute hold plus one 15- minute hold One 3-minute hold plus one 15- minute hold One 3-minute hold plus one 15-minute hold Hydrostatic Seat Test Two 3-minute holds Two 3-minute holds One 3-minute hold plus one 15- minute hold One 3-minute hold plus one 15- minute hold One 3-minute hold plus one 15-minute hold Gas Body Test Not required Not required Not required Gas Seat Test Not required Not required Not required Gas Back-Seat Test Not required Not required Not required One 15-minute WP One 15-minute WP plus one 15-minute 300 psi Optional One 15-minute WP One 15-minute WP One 1-hour WP fully open & close valve, one 1- hour hold at 5 to 10% WP One 1-hour WP, disengage / reengage, one 1-hour 5 to10% WP

20 Quality Control at different PSL s Casing and Tubing Hanger Mandrels/Bodies Requirement PSL 1 PSL 2 PSL 3 ¹ PSL 4 ¹ ² Impact Testing of Raw Material Temp K & L only Test every part Same as PSL 2 Same as PSL 2 Hardness Testing after all heat treatment and machining Test every part Same as PSL 1 Same as PSL 2 plus additional test locations Same as PSL 2 plus additional test locations Surface NDE ³ of Machined Parts Not Required Examine all accessible wetted and sealing surfaces Examine ALL accessible surfaces plus areas prepped for weld overlay Same as PSL 3 Volumetric NDE³ of Raw Material Not Required Not Required Examine 100% volume as practical, both After heat treating and Before machining Same as PSL 3 plus restricted acceptance criteria ³ Non-Destructive Examination

21 Quality Control at different PSL s Testing Of Casing & Tubing Heads, Tubing Head Adapters, Chokes, Crossover Connectors, Adapter And Spacer Spools Requirement PSL 1 PSL 2 ¹ PSL 3 ¹ PSL 3G ¹ ² PSL 4 ¹ Hydrostatic Test ³ Two 3-minute holds Two 3-minute holds One 3-minute hold plus one 15- minute hold One 3-minute hold plus one 15- minute hold One 3-minute hold plus one 15-minute hold Gas Test ³ Not required Not required Not required One 15-minute WP One 15-minute WP ¹ PSL 2 and above: Serialization of assemblies is required. ² PSL3G assemblies are built with PSL3 components. ³ Separate tests are required above & below crossover seal