API Special Summer Meeting - 2015

API 17TR8: High-pressure High-temperature (HPHT) Design Guidelines

Highlights on Working Items of 2

nd

Edition

• Design Verification workgroup – Extreme and Survival conditions – Fatigue input parameters - GoM – Hydrostatic pressure tests (Deepstar Project 12302) – Load-bearing design for HPHT: Load-bearing interface designs and allowables • Material workgroup – Material characterizations (Testing protocols)

Extreme and Survival Conditions

• Objectives: − Define design factors for extreme & survival events − Define the probability of occurrence or ‘buckets’ for extreme and survival conditions − Define function and/or performance post extreme and survival scenarios − Define potential impact on fatigue life for these events • Participations from API 17D, 17G, 16A, and ASME

Extreme and Survival Conditions

Conditions Normal Extreme Survival Conditions Normal Extreme Survival GLOBAL PLASTIC COLLAPSE

Linear-Elastic API

Elastic-Plastic (LRFD)

ASME Section VIII, 6A/6X/17D/17G Div. 2 0.67 x Sy 0.80 x Sy 1.00 x Sy 2.4 2.0 (10 -x ) 1.6 (10 -y )

LOCAL PLASTIC COLLAPSE

Linear-Elastic API 6A/6X/17D/17G

Elastic-Plastic (LRFD)

ASME Section VIII, Div. 2 N/A N/A N/A 1.70

1.42 (10 -x ) 1.13 (10 -y )

Elastic-Plastic (LRFD)

ASME Section VIII, Div. 3 1.8 1.5 (10 -x ) 1.2 (10 -y )

Elastic-Plastic (LRFD)

ASME Section VIII, Div. 3 1.28

1.07 (10 -x ) 1.00 (10 -y )

Fatigue Input Parameters

• Objectives: − To expedite the fatigue calculation process for Gulf of Mexico application − Identify and standardized input parameters • • Collect data Manufacturer can perform fatigue calculations based on standardized input parameters • Sensitivity checks of project-specific items, as necessary

Fatigue Input Parameters

1. Design Life 2. Water depth range 3. M etocean conditions 4. Soil model / data (P-y) 5. M anufacturer’s

• Factory Acceptance Testing (FAT) Pressure Test • System Integration Testing (SIT) Pressure Test

API 17TR8 Fatigue Input Parameters - GoM

25 years 6000’ - 9000’ Central GoM : Block 21 - 22 (API RP 2M ET) Central GoM : Block 21 - 22, Upper or Low er Bound [range, frequency] [range, frequency]

6. Fatigue Properties

[material characterizations]

7a. Drilling Operation Fatigue Loads 7b. Completion / Workover (Intervention) Fatigue Loads 7c. Production Fatigue Loads

a. Vessel RAO (response amplitude operator) • M ODU [magnitude] • Semi-Sub [magnitude] b. Pressure: • Tests  API Std 53 c. Temperature (250F - 350F) • Operation [range, frequency] c. Temperature (250F - 350F) • Operation [range, frequency] d. Cyclic External Load • Bending • Tension/Comp. • Shear e. Abnormal Loads • Extreme [range, frequency ] [magni, freq, Bin] [magni, freq, Bin] [magni, freq, Bin] [magni, freq, Bin] a. Vessel RAO • M ODU • Service Vessel (Intervention) b. Pressure: • Tests  API Std 53 d. Cyclic External Load • Bending • Tension/Comp. • Shear e. Abnormal Loads • Extreme [magnitude] [magnitude] [range, frequency] [magni, freq, Bin] [magni, freq, Bin] [magni, freq, Bin] a. Vessel RAO • TLP • Spar • FPSO b. Pressure: • Operation • Tests • Start-up • • Shut-in Pigging [magnitude] [magnitude] [magnitude] [range, frequency] [range, frequency] [range, frequency] [range, frequency] [range, frequency] c. Temperature (250F - 550F) • Operation [range, frequency] • Start-up [range, frequency] • Shut-in [range, frequency] d. Cyclic External Load • Bending • Tension/Comp. • Shear e. Abnormal Loads • Extreme [magni, freq, Bin] [magni, freq, Bin] [magni, freq, Bin] [magni, freq, Bin]

Fatigue Input Parameters

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 Deepstar’s Project 12302 – 20ksi Systems, incorporated 17TR8 objectives into their project work scope. − Project Champion: Chris Kocurek (COP)

Deepstar 12302 Executive Summary

20K 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” 20K TEE, per API SC17 TR8 along with a proposed validation program.  This exercise will provide an example analysis that provides independent usage of API SC 17 TR8.  Additionally, this CTR would have current 20K 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 TR8.

Deepstar 12302 Project Objectives and Key Deliverables

           Generation of a functional specification, FMECA Conduct pre-workshop to present proposed design methodology to DeepStar members and solicit input on gaps and path forward.

Design verification of 5” 20K 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

Material Characterizations

• Objectives: − To define material properties necessary for Design Verification and identify gaps in 17TR8 document for material requirements − With considerations to environmental effects, i.e. temperatures (min / max), H 2 S, CO 2 , Chloride, pH, etc.

Material Characterizations

• Testing Protocols for Properties Used in Design Verifications − Tensile properties • Modulus of elasticity • • • • Yield strength True-stress True-strain Reduction in area (%RA) Min specified elongation (%EL) − Fatigue properties • • da/dN: function of frequency / R ratio, ASTM E647 • • S/N: function of frequency / R ratio, ASTM E466/E468 or full scale K JIC / J  a: air and temperature K IEAC : environmental and/or temp

Material Characterizations

• − − Environmental Effects for Material Testing − Define environmental screening tests; SSRT, ripple SSRT, and/or ‘C’ Ring − Define K IEAC test and determine if this should be upper limit for da/dN vs ∆K curves Define test parameters for da/dN vs ∆K in environment The test environment and test temperature for LASs and CRAs

GoM Proposed Environments Cl (CO 2 )gas (H 2 S)gas pH Temp Gas Field

1,000-5,000 ppm 5-20 mole % 5-50 ppm 3-4 40 0 F (MDT)

Oil Field

50,000-100,000 ppm 5-20 mole % 5-50 ppm 5-6 40 0 F (MDT)