Process Development

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HPHT Equipment Development Process
Presented by Jim Raney Based on the work from 6HP
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API HPHT Sub-Committee Deliverables
For the Development of Safe, Reliable,
Fit-for-Use Products Outside of the Scope of
Existing International EP Standards Outline
a Detailed Methodology for the

• Establishment of Product Essential Design Inputs
  (Basis of Design)
• Identification of
• Pressure, Temperature, Applied Loads From
  Systems Analysis
• Product Life Cycle Requirements
• Product Reliability Requirements Potential
  Failure Modes
• Material Data for Exposed Environments
• Appropriate Product Design and Life Cycle
  Analysis Techniques
• Establishment of Product Design Validation
  Protocols and Qualification Criteria
• Identification of Essential
• Manufacturing Process Control
• Inspection Requirements
• Establishment of the Essential Storage, Handling
  and Use Parameters
• Identification of Ongoing Data Collection and
  Product Performance Feedback

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Drivers for API to Perform this Work

• New product technology without significant
  industry experience
• Challenging physical and environmental conditions
  of new EP
• developments, beyond the limits of traditional
  industry standards.
• Advanced design and analysis capabilities.
• Industry commitment to the technical integrity
  and HSE associated
• with industry challenges.
• Availability of significant historical experience
  and lessons-learned
• 1980s 30,000 psi wellhead and Xmas tree
  equipment
• 1990s 300 deg. F wellhead and Xmas tree
  equipment
• 2000s Advanced design analysis capabilities and
  design codes

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Product Development Process For Existing or New
Design Equipment
Both Legs Must Be Performed
Fit for Purpose Qualification Process
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API Design Verification
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API Design Validation
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Project Basis of Design
Operational Specific Basis of Design Reservoir
Pressure Temperature Fluid Chemistry Mud
Line Pressure Temperature at Various Flow
Rates External Loads Surface Pressure Temperature
at Various Flow Rates
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Users Functional Design Specification
Operational Statement of Requirements System
Description Operating Conditions System Analysis
to Obtain Component Loads Failure Modes Effect
Analysis of Components Life Cycle Operations for
System/Components Materials Used in Construction
of Equipment All Fluids/Environments in Contact
with Wetted Surfaces Material Properties in the
Environments/Temps Exposed
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Above Wellhead
System Analysis Spec Breaks
Wellhead Casing Tubing
Completion Equipment
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Surface
Riser
BOP Wellhead
System Analysis Spec Breaks
Well Construction Well Completion Well
Intervention
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Design Verification

• Design Material Properties
• Material Properties At Design Temperature (Inside
  Out)
• Material Properties In Service Environment
  (Inside Out)
• Determine Minimum Detectable Flaw Size
  (inspection)
• Comprehensive Design Conditions Analyses
• Static, Dynamic, Transient
• Pressure (Inside and Out)
• Thermal (Inside and Out)
• Loads (Tension, Bending, Torsion)
• Stress Analysis Using FEA
• Comprehensive Design Conditions (Operating)
• Hydrostatic Proof Test
• Life Cycle Fatigue Analysis
• Fracture Mechanics/S-N Curves
• Cycles to Failure

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Design Validation

• Design Test Program To Validate Verification
  Analysis
• Insitu Temperature Requirements
• Inside and Outside
• Dynamic, Transient, and Steady-State
• In-Service Load Conditions
• Pressure All Applied Loads (Tension, Bending,
  Etc)
• Inside and Outside
• Dynamic, Transient, and Steady-State
• Measure and Monitor Peak Stresses
• Establish Reliability Goals and Testing
  Methodology
• If Physical Tests are Impractical
• Analytical Simulations
• Scale Model Tests
• Tests of Less Magnitude - Scale

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Design
Design Basis
Manufacture
Functional Specification
Manufacture
Design Verification
Purchase Specs
API RECOMMENDED PRACTICE
Materials
Design Validation
QA/QC
Inspection
FAT
Re-certify
Repair
Use Documentation
Elements Required to Complete The Manufacturing
Process
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Design Meets Specification

• Design Meets Specification
• Both Legs of the Flowchart Must be Performed
• The Design Verification Process Uses the
  Functional Specification as Inputs
• The Design Validation Process Confirms the Design
  Verification Results
• Both Legs Must Satisfy the Functional
  Specification

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Roadmap and next steps

• The committee will identify the functional
  requirements of the components in HP/HT
  environment and select the component product to
  be designed, the design and development verified
  (6 HP work) and the design and development
  validated (FEMAs by TPEE) for use in the HP/HT
  environment. The product will be developed using
  current best practices.
• API subcommittee responsible for the component
  products requiring development verification and
  validation to meet HP/HT environments, will
  undertake
• A suitable design and development verification
  process like 6 HP.
• FMEA on the component products using the
  methodology outlined including a review of the
  methodology and how it can be applied to the
  component products of the subcommittee
• a detailed evaluation of the development
  validation to meet HP/HT environments including
  identifing additional or unnecessary requirements
  associated with the committees specific
  products
• the development of the subcommittee plan to
  validate any amended methodology on one or more
  of the subcommittees products.

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API ORGANIZATIONAL RECOMMENDATION

• Matrix Organization

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