API Winter Meeting 2016 API 17 TR 8

API Winter Meeting 2016 API 17 TR 8: High-pressure High-temperature (HPHT) Design Guidelines

Working Items of 2 nd Edition • Materials workgroup – Material characterizations (standardized testing protocols) – Welding – NDE • Design Verification workgroup – Extreme & Survival Conditions – Fatigue input parameters - Go. M – Hydrostatic pressure tests (Deepstar Project 12302) • Design Validation workgroup • API 17 TR 8 – 2 nd Edition is targeted for June 2016 Ballot

Materials Work Group • Materials Work Group met several times in 2015 to: – Address materials related issues in 17 TR 8 -SRRR 2 nd Edition – Form the following work groups: 1. Material Characterizations (Paul Bunch, Steven Shademan, Ravi Krishnamurthy and Arshad Bajvani) 2. Welding (Nash Ubale) 3. § Overlay Weld § Fabrication Weld NDE: Flaw Sizing (Curtis Dickinson)

Material Characterizations • Material Characterization section has been developed to be added as an annex to API 17 TR 8 • Material Test Procedures Draft Document 1. Defines test environments of: • Seawater with CP • Typical Go. M Production Environment for Gas Wells and Oil Wells 2. Defines Environmental Screening per SSRT – NACE TM 0198 -2011 • Materials which pass SSRT defined as not susceptible to environment • Materials not susceptible to environment; Ø S-N fatigue, FCGR (if required) and FT to be performed in air at appropriate temperature. Ø S-N fatigue in air to be validated with a limited number of tests in environment • Materials Susceptible to environment; Ø S-N fatigue and FCGR (if required) to be performed in environment at appropriate temperature at a low frequency. Limited S-N tests in air. Ø FT to be performed in environment at appropriate temperature

Material Characterizations • Material Test Procedures Draft Document (cont’d) 3. Defines Strain Limit Environmental Reduction Factor per SSRT • SSRT ratios for % elongation and RA used as reduction factor for Strain damage material parameters defined in ASME Sec VIII, Div 2 and Div 3 4. Defines test parameters for Fracture toughness Testing, KIC and KIEAC • Test Types for Environmental KIEAC; rising displacement and WOL • Krates for rising displacement tests in environment 5. Defines Test Parameters for Fatigue S-N and da/d. N vs ∆K in air and environment • Defines frequencies • Defines R ratios 6. Defined Strain Damage Test Procedures • Tests conducted using notched tensile at design temperature • Reduction factor per SSRT result 7. Tensile, True Stress-True Strain testing and Physical Properties

Material Characterizations • Material Characterization section was circulated for work group review and comments (11/8/2015). • Comments received and will be addressed by 1/30/2016

Material: Welding • Welding requirement section has been developed by the task group to be added to the existing API HPHT 17 TR 8 document: 1. Acknowledge ASME IX & API 6 A (PSL-3) base case requirements for HPHT weldments 2. Determine if there additional variables that need to be included 3. Identify additional testing for HPHT weldments per API 17 TR 8 (Article 6. 3 & 6. 4) 4. Develop qualification (WPS/PQR) philosophy for HPHT weldments 5. Provide these HPHT welding guidelines to API 17 TR 8 committee for review/approval • The Overlay Weld requirement section was sent out to members for review and comments (11/6/2015) • Comments have been collected and will be addressed by the task group members (1/30/2016)

Material: NDE • Conventional Ultrasonic Sizing Methods – ID Creeping wave Methods – Tip Diffraction Methods – Bimodal Methods – HALT / HAST Methods § Refracted Longitudinal and Shear Wave Methods § Time of Flight (TOF) Diffraction § Phased Array • No one sizing method is best for sizing flaws of any depth, height, and/or type • NDE General guidance will be developed for API 17 TR 8 – 2 nd Edition (1 Q 2016)

Design Verification: Extreme / Survival • Verbiage drafted and implemented into existing 17 TR 8 • Defined Definitions and Probability of Occurrence • Defined Design Factors – L-E & E-P DRAFT

Design Verification: Extreme / Survival • Defined Function and/or Performance Post-Event(s) • Defined Potential Impact on Fatigue Life – S-N & Fracture Mechanics • Defined Bolting/Fasteners Design Factors – L-E & E-P TABLE 3. PRESSURE CONTAINING BOLTING DESIGN STRESS ALLOWABLES Elastic-Plastic (LRFD)(1) Operating Condition Normal Extreme Survival Linear-Elastic (membrane) Global Criteria w/o Thermal Loads w/ Thermal Loads(2) 1. 45 1. 27 0. 9 × Sy 1. 33 1. 17 1. 00 × Sy 1. 2 1. 05 0. 83 × Sy DRAFT NOTES: (1) (2) The usage of the factors are defined as: LRFD × (P + Dx + T) Material properties at elevated temperature are inherent to the material models used the LRFD analysis

Design Verification: Fatigue Input Parameters • Objectives: − To expedite the fatigue calculation process for Gulf of Mexico application − Identify and standardized input parameters • Last Work Group Meeting: October 28, 2015 • Fatigue Input Parameters Template Completed • Request for input/information was circulated to industry on November 4, 2015. Response requested by March 2016. • Fatigue task group will review the data received and decide what to include into the TR 8 document. • The time to complete this process will depend on the industry response and amount of data we receive. • Estimated completion: Summer 2016.

Design Verification: Fatigue Input Parameters DRAFT

Deep. Star Project: Hydrostatic Pressure Tests • Objectives: − − Industry’s studies to assess each design path of HPHT design flow chart and the effects of: • varying hydrostatic test pressures on equipment’s strain limit damage/equivalent plastic strain and • its effects on fatigue life estimation and environmental cracking resistance These studies are to include validation testing program of the analytical results • Deep. Star’s Project 12302 – 20 ksi Systems, incorporated 17 TR 8 objectives into their project work scope. − Project Champion: Chris Kocurek (COP)

Deep. Star 12302 Executive Summary 20 K working pressure for subsea equipment has been in discussion for several years now gaining more and more traction within the various operators. This CTR will perform the design verification of a representative 5” 20 K TEE, per API SC 17 TR 8 along with a proposed validation program. § This exercise will provide an example analysis that provides independent usage of API SC 17 TR 8. § Additionally, this CTR would have current 20 K contributors and operators comment on the scope of work and the outputs of verification. § This CTR is to help put into practice and provide independent design verification as outlined in TR 8.

Deep. Star 12302 Project Status ü Generation of a functional specification, FMECA ü Conduct pre-workshop to present proposed design methodology to Deep. Star members and solicit input on gaps and path forward. § Design verification of 5” 20 K tee body, flange, bolting & gasket § Proposed validation program, schedule, and cost. § Workshop for initial results and proposed validation program review. § Investigate the Effects of Hydrostatic Test Pressure Magnitude § Load monitoring approach recommendations § Cladding – NDE & Welding requirements, potential improvements § Development of potential extreme and survival limits § Comparison of Design Life to Total Life § Post-Workshop: present verification results, solicit gaps, path forward

Design Validation • All groups to provided general failure mode list if available to share – FMC, DNV, Maersk sent data in • Dec 10: Review general failure modes list with WG and agree on methodology – PR 3 and PR 4 level alignment and detailed requirements – Failure modes reviewed and categorization work is in progress due to lack of HPHT specific • Jan 8: Review general failure modes list – Finalize categorization of failure modes specific to HPHT environments – PR 2 – PR 4 assignment to failure modes provided by WG – Excel template generated and sent for review and additional comments from Verification and Validation workgroups • Feb 5: Finalize general failure modes list to present to TG – Meeting held in ABS Katy Office