API Ballot Summary Sheet 10/29/2011

Transcription

1 Ballot: API Ballot Summary Sheet 10/29/2011 Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting Ballot ID: 2422 Start Date: 9/11/11 Closing Date: 10/28/11 Associate: Roland Goodman Coordinator: Roland Goodman VotingCategory Results r Interest Category Company s Affirmative Negative Abstain Did t James Buchanan Steve Cabral John Elwell Tom Goin Tim Haeberle Jimmy Hashem Per Kristianson Fang Li Theodore Mitchell Joel Russo Eric Wehner Operator-User Contractor Contractor Operator-User Chevron Lone Star Howco Group TSP GE Oil & Gas Inc Halliburton Technip USA Aker Solutions Hess Corporation FMC Technologies Inc. NOV Yes Yes Yes Yes Yes Affirmative Negative Abstain Did t Balloting Totals: Total Responses: Total Ballots: Response Rate ((Affirmative + Negative + Abstain) / Total Ballots): Approval Rate (Affirmative / [Affirmative + Negative] ): Consensus: % 91% YES Must be > 50% Must be > 67% 1

2 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution 1 Farstad, Ola Guest General Technical Statoil has experienced failure of fasteners installed at subsea equipment. Failures are experience at topside installation as well, but not with the same consequences or cost implications. Our following comments are therefore related to fasteners to be installed at subsea equipment. The reasons for failure subsea are mainly caused by installation of too high strength fasteners. This has happened because the equipment manufacturers have not respected to limit the SMYS and maximum hardness specified by NORSOK M-001 or ISO (max 32 or 35 HRC). Other reasons have been - mix-up of material grades by equipment manuf.; - incorrect certificates or the certified products do not conform to the material certificate; - all failures have been related to headed fasteners and nuts. Due to these experiences Statoil have audited several manufacturer of wellhead equipment and have seen that fasteners have been treated as commodity items. The suppliers have been selected based upon cost and not on quality. Due to this fasteners have often been supplied by traders and quality requirements have often not been understood or neglected. Product certificates have not been representative for the products delivered. Improvements are made the over the last years and the number of suppliers are reduced to a few. The Draft API 20E specification establish three quality levels mainly addressing metallurgical issues such as steel refining practise, inclusion content, grain size, micro structure, banding, forging ratio and sulphur/phosphorous content. All these requirements are additional to the ASTM product standards such as A193, A194 and A320 and not even specified as supplementary requirements. Page 1 of 9

3 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution The failures Statoil has experience have not been linked to metallurgical reasons, but to reason given above. Since fasteners are procured and installed by a vast number of equipment manufacturers we have requested our suppliers to procure fasteners as other quality forgings and not as commodity items. In our opinion the quality and extent of testing specified by the ASTM product standard are a good basis, but the main issue has been to add the following requirements for fasteners to be installed subsea: - Quality assurance provisions per Category 2 of ASME B shall apply - establish Manufacturing Process Plans or ITP s for each type of fastener to define each step in the production route - clarify understanding of ASTM product standards including A962 - to clarify product testing requirement dependent of production method (headed fasteners) - introduce traceability marking to each item - 100% hardness measurement - clarify extent of dimensional control testing - Include acceptance criteria for visual inspection - Specify SR S4 and S5 for nuts to A Increase minimum hardness of nuts in Grade 7M and 2HM to 200 HB. - Max. actual yield stress of low alloyed steel fasteners to 950MPa, Rp0.2/Rm-ratio not exceed 0.90 and max hardness 35HRC. The approach Statoil has taken for fasteners to be installed subsea is to ensure traceability of each installed fastener to the product certificate and to improve and build confidence in the actual certification issued by the fastener manufacturer. A summary of additional requirements are given above. By this approach we do not introduce new testing methods or requirement, but use the supplementary requirements already given in product standards known by the fastener manufacturers. Based on our experience the main effort should be made to headed fasteners and nuts, and issue of material certificates of such products. Page 2 of 9

4 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution The approach proposed in the draft API 20E introduce a new set of requirement, which will improve product quality, but also limit availability, increase cost not necessarily ensure installed quality. Neither do the proposed requirements address the reasons for - incorrect installed fastener material grade - mix-up of grades - incorrect product testing - lack of traceability 2 Popielarczyk, Karl Guest All s General In general, paragraph numbers referred at different places need to be corrected. For example, paragraph numbers referred in, and 4.1.2, 5.7.2, etc. are not correct. 3 Popielarczyk, Karl Guest Intro General Overall, we think it will be a real challenge for our current supply chain to try and fulfill these requirements. Correct 4 Haeberle, Tim Negative / 1 These paragraphs say "standard", but the cover page Use the same terminology throughout. says "specification". Which term is correct? 5 Farstad, Ola Guest / 1.2 Technical Add definition of for primary load bearing equipment. 6 Popielarczyk, Karl Guest / 1.4 Technical 1.4 Bolting s It seems there is some Committee to review ambiguity in the different types. Are these types referring to material before threading, or after threading, or both. For example, in the case of type (d), is this referring to hot formed bolts with threads or without threads? Typically, threads are formed by machining (type (b)) or rolled (type (f) or (g)). 7 Haeberle, Tim Negative / 1.4 Does API policy require both English and metric units? Add metric units. ne 8 Goodman, Roland Guest / 2 Technical The last sentence in the beginning paragraph is not correct and does not conform to the standard text in the API Style Guide. This statement is only applicable to Monogram licensees and is not appropriate for a standard since this is covered in the license agreement. Delete the second sentence 9 Goodman, Roland Guest / The second sentence is a requirement and cannot be Move this requirement to 5. part of a definition. 10 Haeberle, Tim Negative / In the "NOTE", the word "distributer" is a misspelling. Revise "distributer" to "distributor". 11 Li, Fang Affirmative / 3.2 General Miss "NDE" Add "NDE", non destructive examination Add new suggested change text here. 12 Popielarczyk, Karl Guest / Technical Only bolting types and BSL are considered in the qualification. Material grade is not addressed in the qualification of bolting. For example, for a given type and spec level, if we qualify B7M, it will automatically qualify L7M, which requires additional impact tests. We think, qualification should include different material grades for different bolting types. Committee to review Page 3 of 9

5 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution 13 Haeberle, Tim Negative / This section incorrectly indicates bolting grades are listed Revise to read, "Qualification bolts and nuts in 4.4. Bolting grades are actually listed in shall be produced from raw material procured from an approved supplier as defined in 5.1 and manufactured in accordance with an applicable Manufacturing Procedure Specification (MPS) from a bolting grade listed in Hashem, Jimmy Affirmative / General "bolting grade" is not used in this document Change the phrase to "bolting material grade" which is covered in Hashem, Jimmy Affirmative / General 4.4 should be 4.3. The numbering is off in various parts of Fix the numbering throughout the document this document; some other examples are: (a) is followed by (b) In , reference to should actually be to Hashem, Jimmy Affirmative / Technical Qualification is to a Bolting Specification Level and not to Bolting Change the phrase "bolting types listed in 1.4" to bolting specification levels" listed in table 1 17 Haeberle, Tim Negative Table Haeberle, Tim Negative Table Haeberle, Tim Negative Table Haeberle, Tim Negative Table Haeberle, Tim Negative Table Haeberle, Tim Negative Table The section numbers listed under "Material" are Revise "5.5.1" to "5.4.1". Revise "5.5.2" to "5.4.2". Revise "5.5.3" to "5.4.3". The section numbers listed under "Heat Treat" are Revise "5.4.3" to "5.3.4". Revise "5.4.4" to "5.3.5". Revise "5.4.5" to "5.3.6". The section numbers listed under "Chemistry" are Revise "5.6" to "5.5". The section numbers listed under "Mechanical" are Revise "5.7" to "5.6". Revise "5.7.1" to " 5.6.2". The section numbers listed under "Metallurgical" are Revise "5.8.1" to "5.7.2". Revise "5.8.2" to "5.7.3". Revise "5.8.3" to "5.7.4". The section numbers listed under "Hardness" are Revise " " to " ". Revise " " to " ". Revise " " to " ". 23 Haeberle, Tim Negative Table The section numbers listed under "NDE Surface" are Revise "5.10.1" to "5.9.1". Revise "5.10.2" to "5.9.2". Revise "5.10.3" to "5.9.3". 24 Haeberle, Tim Negative Table The section numbers listed under "NDE Volumetric" are Revise "5.10.3" to "5.9.3". 25 Hashem, Jimmy Affirmative Table General The numbering is off in the table: for example, Fix the numbering throughout the document should be 5.4.1, should be etc 26 Popielarczyk, Karl Guest / Technical & For a given bolting type and spec level, Committee to review the number of samples required for qualification is not clear.is it one sample or more than one? 27 Hashem, Jimmy Affirmative / General steel producer is not defined in clause 3 change "steel producer" to "raw material supplier", which is defined in clause 3 28 Popielarczyk, Karl Guest / Technical & For a given bolting type and spec level, the number of samples required for qualification is not clear.is it one sample or more than one? 29 Haeberle, Tim Negative / The term "roll threads" does not seem to fit in with the other terms. 30 Hashem, Jimmy Affirmative / General The list of items that must be documented in the last sentence is redundant to clause 5.3 which states what Similarly in , change "mill" to "raw material supplier" Committee to review Revise to read, "thread rolling (if performed)". delete the entire last sentence and bullets since MPS is already referred to in the first sentence of this clause must be in an MPS 31 Haeberle, Tim Negative / The term "Grades" is missing from the first bullet. Revise to read, "ASTM A193 Grades B7 and B7M". Page 4 of 9

6 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution Change the last sentence to say: Results shall documentation requirements are stated in 4.5 be documented per 4.5 Revise to read, "re-evaluation". improperly here. 32 Hashem, Jimmy Affirmative / General In it is stated that results shall be documented. The 33 Haeberle, Tim Negative / The term "revaluation" refers to currency and is used 34 Hashem, Jimmy Affirmative / General The phrase "..processes and procedures.." is referring to the MPS reword to state: Samples failing to meet acceptance criteria shall be cause for revaluation of the MPS used and requalification is required. 35 Haeberle, Tim Negative / This sentence says a production lot is defined in Delete ", as defined in 4.2.3" , but it is not. 36 Hashem, Jimmy Affirmative / General in and , reprocessing is allowed in the event the qualification fails. If reprocessing is done using a changed process, it means the MPS has changed and this should be documented. Add clause : If reprocessing results in any changes to the MPS, the MPS shall be revised to reflect the new process control variables. 37 Haeberle, Tim Negative / 4.5 Bullet "a" is missing the ASTM edition. Revise to read, "ASTM specification number, edition, and grade;" 38 Haeberle, Tim Negative / 4.5 Bullet "a" has too many non-related issues in one bullet. Revise "a" to become three bullets that read, "a) "ASTM specification number, edition, and grade; b) heat number; c) size;" and re-label the subsequent bullets in this section. 39 Farstad, Ola Guest / 4.5 a) Technical Add steel manufacturer, steel refining method 40 Farstad, Ola Guest / 4.5 b) Technical process control variables is considered to be a broad term. Should at least be related to defined processes as forging and heat treatment. 41 Haeberle, Tim Negative / The first sentence does not read properly. Revise to read, "Limits of bolting qualification for BSL-1 are required for BSL-2 and BSL-3. Additionally, the following changes apply:" 42 Li, Fang Affirmative / General modify the sentence...are required for BSL-2 and BSL-3 with the addition of the following changes 43 Popielarczyk, Karl Guest / General (b) This may be over the top.threading can be Committee to review verified. 44 Goodman, Roland Guest / a) Modify list item. Change "required" to "requiring". 45 Haeberle, Tim Negative / b) In bullet b, the concept of machining or threading method Define machining and threading method control control is used, but is not defined. here. 46 Haeberle, Tim Negative / c) In bullet c, the concept of hot forming practice temperature control method is used but is not defined. Define hot forming practice temperature control method here. 47 Buchanan, James Affirmative / 5 there are references to section 4.5.1; however, no such update references. section exists. 48 Hashem, Jimmy Affirmative / 5.2 General section 5.2 lists the material specifications to be sent to Should the two sections be combined? the raw material supplier. 5.4 lists the properties for Raw Material. 49 Goodman, Roland Guest / Second sentence; text readability suggestion. Change sentence to read: "The bolting manufacturer shall have a documented procedure and fully implemented procedure for qualifying raw material suppliers for each grade and heat treat condition of material." 50 Haeberle, Tim Negative / The last sentence reads, "Options for the technical Reword the last sentence to read as follows: approval of a raw material supplier are the following:", but "The methods for technical approval of a raw items a), b), and c) are not necessarily options. They are material supplier for the various BSL's are as requirements for the applicable BSL. follows:" Page 5 of 9

7 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution 51 Popielarczyk, Karl Guest / Technical a) 1): Remove on a routine basis or revise Committee to review sentence to include a more definitive requirement for when material inspection is performed per this requirement. 52 Popielarczyk, Karl Guest / Technical a) 3): The word extended is used in the sentence. Committee to review What is an extended period of time? One year, five years or five days? 53 Russo, Joel Affirmative / a) 4) General should be more specific about who can perform a technical audit "physical on-site technical audits performed by applicable subject matter experts, at scheduled 3 year intervals" 54 Haeberle, Tim Negative / c) There is no section " ". Revise from " " to "5.1.2.a)". 55 Li, Fang Affirmative / c) General mistake, should not be a) shall be used 56 Buchanan, James Affirmative / a.2 Technical What does this clause mean - the fastener manufacturer must test a sample (not related to a specific qualification) of the steel suppliers material? Also, this is the first reference to 'first article' and so should probably be defined. 57 Hashem, Jimmy Affirmative / Technical BSL requirements state that the ASTM specification may Add 5.2.1g) Mechanical properties be used to document raw material requirements while for BSL-2 and BSL-3, requirements (a) to (f) should be used as a minimum. ASTM specifications have requirements for Mechanical Properties which is not listed in (a) through (f) so the requirements for higher BSL levels may actually be less than for BSL1. 58 Li, Fang Affirmative / f) General suggestion add "as applicable per BSL" at the end 59 Haeberle, Tim Negative / Grammar and punctuation errors. Add an "a" between "as" and "minimum". Add a comma after minimum. 60 Buchanan, James Affirmative / the subsections are incorrectly numbered e.g is update section numbering under Goodman, Roland Guest / Text clarification. Change sentence to read: "ASTM A320 Grade L43 and ASTM A540, Grade B23 material shall be double tempered." 62 Farstad, Ola Guest / Technical Why requesting stress relieving of cold rolled threads? To improve fatigue resistance cold rolled threads may be a design requirement. 63 Haeberle, Tim Negative / The reference to is wrong. Revise from "4.5.1" to "4.3.1" Goodman, Roland Guest / Misspelled word. Change "manufacture's" to "manufacturer's". 65 Li, Fang Affirmative / General should be "manufacturer's" Add "r" in the word 66 Farstad, Ola Guest / Technical Add reference to ASTM A Farstad, Ola Guest / Technical We support the idea to limit the S and P content, but why be more restrictive than specified by API 6A PSL3? 68 Haeberle, Tim Negative / This section needs an introductory sentence before the Add an introductory sentence that reads, "The sentence on what to do if the raw material supplier did not following tests shall be performed, as perform all the tests required. applicable to the specified BSL." Then change from "following" in the next sentence to "specified". Page 6 of 9

8 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution 69 Li, Fang Affirmative / General section 4.5.1? 70 Farstad, Ola Guest / Technical Requirement: Grain size to be determined once per heat. : Grain size should be taken from actual product since grain size is dependent of the production route; forging and heat treatments. Several type and size of products can be made from same heat of steel. 71 Buchanan, James Affirmative / Technical Please add "of questionable acceptability" after " structure is observed". Please add "of questionable acceptability" after " structure is observed". 72 Hashem, Jimmy Affirmative / The wrong figure in ASTM E1268 is referenced. It should change to Figure A1.20 be figure A1.20 and not A Haeberle, Tim Negative / Technical First, this section does not provide any information regarding what parts of ASTM E381 and ASTM A962 This section needs to be re-written to provide the following: (1) A clear statement as to what apply. Second, this section does not provide any specific parts of ASTM E381 and ASTM A962 are inspection criteria to insure that hot formed and cold formed bolts and nuts have the desired grain flow patterns, but do not have any of the defects that can result from these operations. For example, induction required, (2) requirements for inspection of the grain flow patterns and general structure of hot formed or cold formed bolts, screws, and nuts, and (3) requirements for inspection of rolled heated and hot forged bolt heads can have forging bursts threads. due to over heating in a poorly controlled induction heating process. Third, this section does not address any inspection criteria to insure that thread rolling processes result in a thread that is free from detrimental laps. 74 Farstad, Ola Guest Table Table 2 Technical Severity level number to be added to columns 2 and 3. Add to abbreviation list: SLN = severity level number To read in column 2/3 second line: SLN 2 for thin, SLN 1.5 for thick, all categories 75 Farstad, Ola Guest / 5.8 Technical Reference is made to ASTM A194 and the specified requirement for proof load testing. Proof load testing is verifying the strength of the nut and the minimum hardness levels are not corresponding to the level of strength to pass the proof load, ref. Grade 7M. Please also observe the proof load requirement to B8M nuts. These are roughly the half of Grade 7M even if these are to be mounted on studs in Grade B8M Class 2. Therefore, please review the proof load requirements and the requirements for which grade of nut to be mounted on high strength bolts/studs. 76 Hashem, Jimmy Affirmative / Change the word 'must' to 'shall'. The foreword of this document states that 'shall' will be used; using 'shall' also results in an auditable statement. Search for the word 'must' throughout the document and change to 'shall' 77 Buchanan, James Affirmative / Technical where is a hardness traverse for induction or resistance heated bar required? 78 Haeberle, Tim Negative / The reference to paragraph is wrong. Revise from " " to " ". 79 Buchanan, James Affirmative / there is a reference to section ; however, no such section exists. update references. Page 7 of 9

9 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution 80 Farstad, Ola Guest / Technical Supplementary requirement S4 of A194 to be made mandatory. ASTM F606 specifies surface hardness. Hardness indentations taken at a cross section of a nut to be specified, see below, or axial tensile testing to be taken from nuts M72 or greater. 81 Buchanan, James Affirmative / Technical BSL should require 100% indentation hardness testing. revise to address comment. 82 Li, Fang Affirmative / General In section , it stated "each piece shall be inspected", why it still mentioned the electromagnetic sorting is not permitted 83 Hashem, Jimmy Affirmative / 5.9 Technical NDE personnel should be qualified per an industry accepted practice. delete this section Suggest using requirements and of API 6A in clause 5.9: 7.3 Quality-control personnel qualifications n-destructive examination personnel Personnel performing NDE shall be qualified in accordance with the manufacturer's documented training programme that is based on the requirements specified in ISO 9712, EN 473 or ASNT SNT-TC-1A Other personnel All other personnel performing measurements, inspections or tests for acceptance shall be qualified in accordance with the manufacturer's documented procedures and requirements. 84 Haeberle, Tim Negative / Punctuation error. Delete the comma after API 6A. 85 Haeberle, Tim Negative / Technical As written, the wording in the ballot version has been interpreted by a reviewer at a bolting supplier to mean that oversizing of nuts is permissible to facilitate the use of thick coatings on theads. The wording in the ballot Revise to read as follows: "All dimensions shall meet the equirements of the applicable ASTM specification. oversizing of nut threads or undersizing of bolt threads is version says, "All dimensions shall meet the requirements permissible, even if addressed in an ASTM of the applicable ASTM specification", but ASTM A194 Supplementary Requirement S7 cites "modification to spec to facilitate the use of thick coatings. Results shall be documented on an inspection dimensions" as an example of information that is required report." The use of ASTM bolting for API for coating. equipment is based on designs that have been validated using the ASTM bolting dimensions. Thus, oversizing of nuts or undersizing of bolts must not be permitted. 86 Li, Fang Affirmative / General missing "with" shall be in accordance with Table 3 Page 8 of 9

10 Ballot: 2422 : Spec 20E, 1st Ed. Ballot - Alloy and Carbon Steel Bolting of Proposed Change Resolution 87 Hashem, Jimmy Affirmative / 8 Technical Is there a need to have a clause on Marking method similar to API 6A clause which states? Marking Method Marking using low-stress (dot, vibration or rounded V) stamps is acceptable. Conventional sharp V-stamping is acceptable in low-stress areas, such as the outside diameter of flanges. Sharp V-stamping is not permitted in high-stress areas unless subsequently stress-relieved at 590 C (1 100 F) minimum. The method of marking on nameplates is optional. 88 Goodman, Roland Guest / 8.2 Second paragraph, second sentence; incorrect word. Change "that" to "than". 89 Haeberle, Tim Negative Annex Annex B Technical Even if this is the standard API statement regarding the monogram, it needs to be revised. Bolting does not have a nameplate. 90 Farstad, Ola Guest / New Technical A new section for visual inspection to be added. Acceptance criteria to be specified: Stud and bolts to: ASTM F788 Nuts to: ASTM F Farstad, Ola Guest / New Technical A concern within Statoil is related to the requirement of API 6A Table 62 allowing use of Grade 2HM and 7M nuts in combination with high strength bolts/studs in Grade B7/L7 and L43, ref. attached Technical te and NWIP to ISO To ensure nut strength properties the minimum hardness should match the strength of the mating bolt/stud. This means that the minimum hardness of Grade 7M and 2HM should be increased from 159 HB to 200 HB. Use the marking procedure from 8. Page 9 of 9