1、Protocol for Verification and Validation of High-pressure High-temperature EquipmentAPI TECHNICAL REPORT 1PER15K-1FIRST EDITION, MARCH 2013Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local,state, and federal laws and regul
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13、or any partof the material published herein should also be addressed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-timeextension of up to two years may be added to this review cycle. Status of the publication can be ascer
14、tained from theAPI Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is publishedannually by API, 1220 L Street, NW, Washington, DC 20005.Standards referenced herein may be replaced by other international or national standards that can be shown to meetor exc
15、eed the requirements of the referenced standard.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW,Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Existing Designs and In-service Equipme
17、nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Terms and Definitions
18、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Abbreviations and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.1 A
19、bbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20、 . . . . . . . . . . . . . . . . . . 74 Functional Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.1 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.2 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3 Specified Loads and Characteristics . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4 Life Cycle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.5 Applicable Industry Standards and/or Regulatory
23、Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.1 General . . . . . . . . . . . . . . . . . . . . . . . . .
24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.2 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.3 Personnel Requi
25、rements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.4 Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26、 . . 165.5 Response to Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.6 Fit-for-service Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27、 . . . . . . . . . . 195.7 Aftermarket Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Best Practices and Guidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、 . . . . . . . . . . . . . . . . . . . . 206.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206.2 Design Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.3 Design Validation Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456.4 Manufacturing Process Specification (MPS) . . . . .
30、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516.5 Aftermarket Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Annex A (informative) Material Properties . .
31、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Annex B (informative) Metallurgical-related Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Annex C (informative) Failure Modes and
32、 Effects Analysis (FMEA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Annex D (informative) Technical Considerations on the Selection of Castings and Forgings . . . . . . . . . . . . . 81Annex E (informative) Quality Management System Guidelines . . . . . . . . . . . . . .
33、 . . . . . . . . . . . . . . . . . . . . . . . . 82Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Figures1 System Analysis Specification Breaks (Completion) . . . . . . . .
34、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 System Analysis Specification Breaks (Drilling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Performance Envelope Example . . . . . . . . . . . . . . . . . . . . . . . . . . .
35、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Combined Loading Capacity Chart from API 6AF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Example of True Stress for 2 1/4Cr-1Mo True Strain Curve. . . . . . . . . . . . . . . . . . .
36、. . . . . . . . . . . . . . . . . . . 336 Validation Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48A.1 Example of Effect of Temperature on Thermophysical Properties of 4130 and 4340 (MMPDS) . . .
37、 . . . . 55vContentsPageA.2 Example of Effect of Temperature on the Tensile Ultimate Strength (Ftu) and Tensile Yield Strength (Fty) of AISI Low-alloy Steels (All Products) (MMPDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56A.3 Example of Compendium of Cyclic Curves for Carbon Steel a
38、nd 2 1/4Cr-1Mo . . . . . . . . . . . . . . . . . . . . . 58A.4 Example of Effect of Temperature on Tensile Properties of Alloy N08535 in 125 ksi Minimum Yield Strength Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59A.5
39、Example of Effect of Temperature on Strength of Alloy 25CrW (UNS S39274) . . . . . . . . . . . . . . . . . . . . . 60A.6 Example of Effect of Temperature on the Thermophysical Properties on UNS N07718 (MMPDS) . . . . . 62C.1 FMEA Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71C.2 General Validation FMEA Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72C.3 Detailed Validation FMEA Workflow . . . . . . . . . . . .
41、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72C.4 Modified Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Tables1 API References for Equipment. . .
42、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Material Properties Cited by Design Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Typical Carbon and Low-alloy Steels
43、for HPHT Use (T 350 F or P 15,000 psi) . . . . . . . . . . . . . . . . . . 234 Stainless Steel and Corrosion Resistant Alloys for HPHT Use (T 350 F or P 15,000 psi). . . . . . . . . . 245 List of Typical Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44、. . . . . . . . . . . . . . . . . . . . . . . 266 Typical Protocols for Property Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Summary of Test Protocols for Nonmetallic Materials in M-710 . . . . . . . . . . . . . . . . . . . . . .
45、. . . . . . . . . . . 388 Cross References of Industry Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 Reference Industry Standards for Design Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46、. . . . 4110 Reference Industry Standards for Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46A.1 Example of Thermal Decay of API 5CT Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
47、A.2 Recommended Yield Strength Reduction Ratios in Percent by Temperature for Low-alloy Steels . . . . 55A.3 Example of Composition of 4130M7 Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56A.4 Example of Hot Tensile Testing of 4130M7 Tubin
48、g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57A.5 Recommended Yield Strength Reduction Ratios in Percent by Temperature for Stainless Steels and CRA Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49、. . . . . . . . . . . . . . . . . . 58A.6 Example of Mechanical Properties of Alloy 825 (Cold Worked) from 4 in. Diameter Tube. . . . . . . . . . . . 61A.7 Example of Chemical Composition of Heats Tested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63A.8 Example of Tensile Properties as a Function of Temperature for INCONELAlloy 725. . . . . . . . . . . . . . 63A.9 Example of Composition of Alloy Tested in the Accompanying Tensile Data . . . . . . . . . . . . . . . . . . . . . . 66A.10 Example of Tensile Properties of Titanium 6-2-4-6 (UNS R5626
