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Specification for Drill-throughEquipment Repair and Remanufacturing

ANSI/API Specification 16AR (SPEC 16AR)First Edition, ….. 2013Effective Date: ….2013

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Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years.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. API license(s).............................................................................................................14Validate map......................................................................................................................146. Responsibilities..........................................................................................................147. Verification of Initial Product Status.........................................................................158. Design Status.............................................................................................................169. Product Identification, Traceability and Marking.....................................................1610. Maintenance & Service..........................................................................................1611. Remanufacturing Service Levels...........................................................................1712. Repair and Remanufacture....................................................................................18

12.1 General...............................................................................................................1812.2 Material testing..................................................................................................18

12.2.1 Material Chemical Composition and Mechanical Properties....................1812.2.2 Mechnical properties.................................................................................1912.2.3 Non-metallic parts.....................................................................................19

13. Welding..................................................................................................................2013.1 General...............................................................................................................2013.2 Weldment design and configuration..................................................................2013.3 Welding procedure qualifications......................................................................2013.4 Welding specification requirements..................................................................2113.5 Welder specifications.........................................................................................2113.6 Materials............................................................................................................22

13.6.1 Base materials............................................................................................2213.6.2 Filler materials...........................................................................................2213.6.3 Repair welds and PWHT...........................................................................2313.6.1 Preheating..................................................................................................2413.6.2 Welding controls........................................................................................2413.6.3 Quality Assurance Quality Control...........................................................25

13.7 Welding controls................................................................................................2513.7.1 Procedures..................................................................................................2513.7.2 Application................................................................................................2513.7.3 Designed welds..........................................................................................2513.7.4 Materials....................................................................................................25

13.8 Welding procedure and performance qualifications..........................................2613.8.1 General.......................................................................................................2613.8.2 Base metals................................................................................................2613.8.3 Heat-treat condition...................................................................................2613.8.4 Procedure qualification record...................................................................26

13.9 Other requirements............................................................................................2613.9.1 ASME Section IX, Article I — Welding general requirements................26

iv

13.9.2 General.......................................................................................................2613.9.3 Hardness testing.........................................................................................2613.9.4 General.......................................................................................................2613.9.5 ASME Section IX, Article II — Welding procedure qualifications..........2713.9.6 ASME Section IX, Article III — Welding performance qualifications....28

13.10 ASME Section IX, Article IV — Welding data................................................2913.10.1 Article IV of ASME Section IX shall apply as written.............................2913.10.2 General.......................................................................................................2913.10.3 Welder qualification..................................................................................2913.10.4 Welding Process Specification (WPS)......................................................2913.10.5 Welding Process Qualification Record (WPQR)......................................2913.10.6 CRA welding.............................................................................................29

14. Decommissioning..................................................................................................3015. Certification...........................................................................................................30Annex F.............................................................................................................................32

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 F.

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, Super Duplex and MP35N. Other applicable standards missed must be added to the list.

NOTE: Must check the references for applicability and latest revisions.


3. Definitions

3.1 Decommissioning:Removing a product or system from service and make it safe by dismantling, and rendering it inoperative.

3.2 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.

3.3 Life Cycle Management Plan (LMP):A plan developed by the Life Cycle Management Service Provider (LCMSP) and approved by the owner/operator developed to provide for the traceability of monogrammed products throughout the product life cycle. The plan requires the identification, service configuration, service environment, maintenance and service requirements and interval, service personnel competency, design status review, repair and remanufacture requirements and decommissioning requirements for the traceable API monogrammed product.

3.4 Life Cycle Management Service Provider (LCMSP):The LCMSP is responsible for compliance with the LMP specification. The LCMSP may be any company, individual, owner/operator or OEM licensed by API to this specification. LCMSP’s providing services in compliance with this API specification are required to meet the requirements of API Specification Q2: Specification for Quality Programs for the Petroleum, Petrochemical and Natural Gas Industry.

3.5 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.

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

3.7 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.

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

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

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


3.11 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

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

3.13 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

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

3.15 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

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

3.17 BoltingThreaded fasteners used to join end or outlet connections

3.18 CalibrationComparison and adjustment to a standard of known accuracy

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

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

3.21 Chemical analysisDetermination of the chemical composition of material

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

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

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

3.25 ConformanceCompliance with specified requirements in every detail

3.26 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. Check with respect to S53 or CFR 250.416

3.27 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.

3.28 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. Check alignment with S53

3.29 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.

3.30 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.

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

3.32 Critical componentPart having requirements specified in this American National Standard

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

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

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

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

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

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

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


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

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

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

3.43 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.

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

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

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

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

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

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

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

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

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

3.53 Linear indicationliquid penetrant or magnetic particle examination indication whose length is equal to or greater than three⟨ ⟩

times its width

3.54 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

3.55 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.


3.56 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.

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

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

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

3.60 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.

3.61 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.

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

3.63 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.

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

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

3.66 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

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

3.68 Record, nounRetrievable information

3.69 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.

3.70 Relevant indicationLiquid penetrant or magnetic particle examination any indication with a major dimension over 1,6 mm ⟩(0,062 in)


3.71 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

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

Make sure we note when we need to test to 1.5X and not in the appropriate location.

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).

3.73 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

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

3.75 Special processOperation which converts or affects material properties

3.76 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.

3.77 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.

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

requirements

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

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

3.81 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.

3.82 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

3.83 Variable-bore ram (VBR)


Closing and sealing component in a ram blowout preventer that is capable of sealing on a range of tubular sizes

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

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

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

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

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

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

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

3.91 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.

3.92 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.

3.93 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.

3.94 Fabrication weldWeld joining two or more parts

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

3.96 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

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

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

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

3.100 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.

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

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

3.103 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.

3.104 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.

3.105 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.”

3.106 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.

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

3.108 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.

3.109 Approved Welding Procedure SpecificationAny 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.

3.110 Wrought structureStructure that contains no cast dendritic structure

3.111 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.

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


3.113 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 DiameterLP Liquid PenetrantLMP Lifecycle Management PlanLCMSP Life Cycle Management Service ProviderMP 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 FactVBR Variable-Bore RamWPS Welding Procedure Specification


5. API license(s)Validate map

Licenses are per definition voluntary Licenses have value for the owner and user. Standards provide framework for compliance verification , traceability and transparency.

MonogramEquipment design, manufacturing, repair and remanufacturing is in compliance with API-16A requirements and fully traceable in the Product History File.

Valid API Quality Management System: 1) Selected OEM repair shop has a valid and active API-Q1 certificate (API yearly audit)

2) Selected OEM repair shop is working with an API approved Quality Management System that meets the requirements of API-Q1under the registration. (API three yearly audit)

Quality Management System

Management responsibility

Resource management

Additional product design and development requirements, documentation & traceability.

Additional Design validation and testing requirements

Design control changes

Measurement and improvement

Valid API-16A license certificate and required product listing(s) without exclusions for manufacturing / remanufacturing of the equipment.

Design Requirements

Design methods

Design verification testing

Documentation Design testing

Material requirements

Welding requirements

Quality Control requirements

Marking requirements

Valid API-16AR license Equipment repair and remanufacturing is in compliance with API-16A requirements.

No License Equipment design, manufacturing, repair and remanufacturing may be in compliance with API-16A requirements

For remanufacturing and repair under this standard the following API-Q1 requirements are applicable.

a)

b)

c) etc.

6. 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, when required by this standard.

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 failure reporting as documented in Annex-F. (see Standard 53 Annex B)


If applicable, the OEM is responsible for monogramming equipment in accordance with the appropriate API standard and the requirements of API Q1 and the requirements of the manufacturer’s API monogram license agreement.

The OEM is responsible to audit OEM approved repair facilities in compliance with the requirements of API-Q1and 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 after the last unit of that model, size and rated working pressure is manufactured.

Repairer / Remanufacturer 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 as listed under the applicable API specification for manufacturing.

The repairer / Remanufacturer shall provide the product owner with an overview of equipment traceability and compliance to the OPD before selecting the Remanufacturing Traceability Level (RTL).

The repairer / remanufacturer shall in accordance with the applicable API standard for manufacturing retain documents required for repair and remanufacturing for ten years after the last unit of that model, size and rated working pressure is manufactured.

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

data book). On request and in agreement with the equipment owner, the OEM will maintain the Manufacturing Data

File for periods exceeding the record keeping requirement as listed under the applicable API specification for manufacturing.

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.

Maintenance performed by third parties

The product owner/operator is responsible for the approval of the life cycle management plan, developed by the life cycle management service provider (LCMSP), including: 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 remanufacture procedures, and decommissioning procedures as described in this standard. The LCMSP and the owner/operator are responsible for the execution of the LCMP plan and the maintenance of records of all activities associated with this standard for 5 years following documented decommissioning of the traceable products. The following graphic depicts an example of the responsibilities outlined in this standard.

7. Verification of Initial Product StatusThe LCMSP is responsible for the analysis of the initial product status and shall approve and document the compliance status of the product including:

Verification and documentation of the product API Monogram and the date of manufactureVerification and documentation of API records in compliance with the appropriate API standardVerification and documentation of the product as new, and unusedVerification of the product OPD definition


Verification and documentation of the current product design status and compliance

Products that are unable to be verified to these requirements are considered outside the scope of this standard. The owner/operator shall approve the verification of the initial product status. Records of the approval are to be included in the PHF.

8. Design Status

The LCMSP is responsible for determining and documenting the review of Design Status for traceable products at intervals specified in the Life Cycle Management Plan. The design status of traceable products shall be documented to include status of the elements of the OPD, enhancements to the product design or product obsolescence. Changes identified in the OPD and product design shall be reviewed by the product owner/operator and the LCMSP, and the impact on traceable products controlled by the Life Cycle Management Plan shall be dispositioned prior to ongoing use. Actions associated with changes in the OPD or product design shall be planned, implemented and verified by LCMSP and owner/operator in a manner consistent with the safe and reliable use of the traceable product and documented in the PHF.

9. Product Identification, Traceability and MarkingThe LCMSP is responsible for determining and documenting the existing identification, traceability and marking of traceable products in accordance with the Life Cycle Management Plan. Identification, traceability and marking of products shall meet as a minimum, the requirements of the appropriate API standards and the requirements specified by the Original Product Definition. Documentation of the acceptance of the existing identification, traceability and marking in accordance with the Life Cycle Management Plan, the product OPD and the requirements of this standard are to be included in the Product History File following approval by the LCMSP and the owner/operator.

Following the documentation of existing identification, traceability and marking, each traceable product shall be uniquely marked for traceability in accordance with the Life Cycle Management Plan. Existing traceability and identification markings may be used for this purpose if appropriate. Documentation of the designated traceability marking and the direct correlation to previous identification and traceability marking are to be included in the Product History File by the LCMSP. The LCMSP shall maintain traceability of the product throughout the product life cycle until decommissioning.

10.Maintenance & Service

The LCMSP is responsible for maintaining and servicing traceable products as defined in the Life Cycle Management Plan. Maintenance and service activities shall act to conserve as nearly and as long as possible, the original condition of traceable products while compensating for normal wear and tear. Maintenance and service requirements shall include:

Requirements specified in the OPD, the ongoing product design status and the Life Cycle Management Plan

Routine maintenance/service, preventive maintenance/service and major maintenance/service or overhaul requirements.

Maintenance and service intervals


Competency requirements for personnel performing maintenance and service including education, training, skills and experience.

Acceptable service environment parameters for performing maintenance and service. Safe work practices for maintenance and service. Condition monitoring requirements , if applicable. Recordkeeping and status reporting requirements. Field inspection and test requirements including acceptance criteria Field repair and replacement requirements.

11.Remanufacturing traceability LevelsThe minimum information required for

The level of traceability of repairs, and remanufacturing from well control equipment defines to what Remanufacturing Traceability Level (RTL) additional work can be certified.

RTL What Where History Remarks

4 Equipment started withAPI Monogram + yearly audit

API LicensedFacilitywith Q1

All previous workshall be traceableand performed by remanufacturer with access to the OPD.

From equipment with a LMP, full traceability and Monogram, status can be maintained through equipment life, until decommissioning.

3 Equipment metAPI Spec 16A when new

API LicensedFacility

All previous workshall be traceableand performed by remanufacturer with access to the OPD.

2 Equipment metAPI Spec 16A when new(All Design Verification &Testing Required)

API LicensedFacility

Traceability of all partsrequired by API 16A

Only when all repairs and/or remanufacturing is approved by the OEM, repairs can qualify under RSL-3.

1 Equipment metAPI Spec 16A when new(All Design Verification &Testing Required)

Anywhere Verification of MaterialSuitability

Product may meet API-16A requirements. Only when full traceability of all parts exists for repair and remanufacturing, repairs can qualify under RSL 2.

.


12. Repair and RemanufactureThe LCMSP is responsible for executing and documenting repair and remanufacture of traceable products in accordance with the requirements specified in the Life Cycle Management Plan. The LCMSP and Owner/operator shall approve repair and remanufacture activities and document same in the PHF.

12.1 GeneralThis 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 to the hardness limitations 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 26HRC (128 ksi) and care must be taken when hardness

exceeds 22 HRC (116 ksi). The use of Corrosion Resistant Alloy (CRA) that is SCC resistant.

12.2 Material testing12.2.1 Material Chemical Composition and Mechanical Properties

12.2.1.1 Metallic partsA written material specification shall be required for all remanufacturing of metallic pressure-containing, pressure-controlling and all other parts. The remanufacturer shall be capable to meet 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.

12.2.1.2 Base metal material IdentificationIn order to start the 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:

A. Determining hardness and approximant tensile valuesB. Determining Chemical composition C. Engineering judgment based on service/field experience

A. Determining Hardness and approximant tensile values:

Determining Hardness and approximant tensile values shall be done in accordance with ASTM E10 or ASTM E110

B. Determining Chemical Composition:

In absence of the material composition, Optical Emission Spectography (OES) can be used to establish the material chemical composition. OES is a reliable way to measure light elements in metals, such as carbon and aluminum.

Justification for the material identification equipment used shall be documented in the Quality Management System and shall address the capabilities of the Spark Method:

1. Optical Emission Spectrometry (OES)2. Portable Optical Emission Spectrometry

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:

C. Engineering judgment based on service/field experience

Certain service and field data may be taken in to account based on engineering judgment.

12.2.1.3 Filler material qualification ?Filler 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.


Material

12.2.2 Mechnical properties Hardness Sharpy impact Minimum Yield Strength (MYS) Ultimate Yield Strength (UYS) Elongation Heat treatment & Microstructure Though wall hardness

12.2.3 Non-metallic partsEach manufacturer shall have written specifications for all elastomeric materials used in the production of drill-throughequipment. 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.


13. Welding13.1 GeneralThe 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.

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.

13.2 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.

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

13.3 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 E140shall 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.


13.4 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

13.5 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.

13.6 Materials13.6.1 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.

13.6.2 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.

13.6.3 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 usedNumber 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.


13.6.4 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.

13.6.5 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.

13.6.6 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.


13.6.7 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.

13.6.7.1 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.

13.6.7.2 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.

13.6.7.3 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.

13.7 Welding controls

13.7.1 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.

13.7.2 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.

13.7.3 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.

13.7.4 Materials13.7.4.1 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.

13.7.4.2 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.

13.7.4.3 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.

13.8 Welding procedure and performance qualifications13.8.1 General

All 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.

13.8.2 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.

13.8.3 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.

13.8.4 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.

13.9 Other requirements13.9.1 ASME Section IX, Article I — Welding general requirements13.9.2 General

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

13.9.3 Hardness testing13.9.4 General

Hardness 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.

13.9.4.1 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.

13.9.4.2 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

13.9.4.3 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

13.9.4.4 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.


13.9.5 ASME Section IX, Article II — Welding procedure qualifications

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

13.9.5.2 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.

13.9.5.3 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.

13.9.6 ASME Section IX, Article III — Welding performance qualifications

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

13.9.6.2 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).


13.10 ASME Section IX, Article IV — Welding data13.10.1 Article IV of ASME Section IX shall apply as written.13.10.2 General13.10.3 Welder qualification13.10.4 Welding Process Specification (WPS)

Production weld Repair welding

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

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


14. 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.

15.Certification


Annex A(Normative)

Product History File Requirements

The table below outlines contents for the construction of the Manufacturing Data Book (MDB) and Product History File (PHF) that 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 Date of FAT Part and Serial Numbers of equipment Design Verification Report Available for review 3rd Party Review Certificate When in Purchase Order3rd Party Type Approval Certificate When in Purchase Order Material Mill Certs (including the following):

a) Chemical Analysis b) Tensile tests (QTC) c) Impact tests (QTC as required) d) Hardness tests (QTC) e) NDE Reports f) Heat Treatment (Q&T, etc.)

Material Specification Number WPS/PQR 3rd Party or Customer Review Records As required on Purchase Order NDE Records:

a) Surface NDE Records b) Volumetric NDE records c) Repair weld NDE records d) Final Hardness Records

Inspector Qualification Records As Per Purchase Order Welding Process Records

a) Welder ID b) Filler Metal

c) Heat and/or batch number d) WPS # e) PWHT Charts f) Total remaining PWHT time (per PQR)g) Weld Maps

Welder Qualification Records As Per Purchase Order


Manufacturing Data Book (MDB) continued.

Document Contents Delivered to Client Maintained by Manufacturer

Test Report(s), Pressure Testing and FATa) Pressure test records

b) Critical dimensions (as defined by OEM)

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

The intent of this table is to specify documents which should be included in the PHF if the document is available. If the document is not available, then it will not be included in the PHF.

Product History File (PHF)

Document Contents Maintained by Owner Retained by Remanufacturer

Manufacturing Data Book Product History File Log N/AManufacturing Data Book for Replacement Parts Serial Numbers of Replacement Parts N/AApplicable Product Information Bulletin Design Verification Report for Replacement Parts Available for Review

Maintenance Records

Third Party or Class Society Inspection Reports (if applicable)

N/A

Rig Test Report(s), Pressure Testing N/A

Repair/Remanufacturing Records (actual docs needed defined by RSL)

Certificate of Conformance N/Aa) include standard and service environment

to which equipment is certified to(i.e. – T-20, T-75, etc.)

b) Note any exceptions to standards or equipment limitations.


Product History File (PHF) Repair/Remanufacturing without adequate history?? Possibly merge with above.Manufacturing Data Book for replacement parts(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

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

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 theequipment 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 orfailure;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 providefailure 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 itsmanufacture, testing or use shall be formally communicated to the individual or group within themanufacturer'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 makingthis type of communication, and shall maintain records of progressive design, material changes, or othercorrective 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 writingto each and every equipment owner of the blowout prevention equipment within three weeks after theoccurrence.

B.2.2.2 The manufacturer shall communicate any design changes resulting from a malfunction or failurehistory 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.

Replacement parts or assemblies shall meet or exceed the equipment performance specifications as noted in the applicable product specification and be fully tested, design verified, and supported by traceable documentation in accordance with relevant industry specifications/standards and purchase order requirements.


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Product No: G6HT01