1. 1 HPHT Equipment Development Process Presented by Jim Raney Based on the work from 6HP

2. 2 For the Development of Safe, Reliable, Fit-for-Use Products Outside of the Scope of Existing International E&P Standards Outline a Detailed Methodology for the: Establishment of Product Essential Design Inputs (Basis of Design) Identification of: Pressure, Temperature, & Applied Loads From Systems Analysis Product Life Cycle Requirements Product Reliability Requirements & Potential Failure Modes Material Data for Exposed Environments Appropriate Product Design and Life Cycle Analysis Techniques Establishment of Product Design Validation Protocols and Qualification Criteria Identification of Essential: Manufacturing Process Control Inspection Requirements Establishment of the Essential Storage, Handling and Use Parameters Identification of Ongoing Data Collection and Product Performance Feedback API HPHT Sub-Committee Deliverables

3. 3 Drivers for API to Perform this Work: New product technology without significant industry experience Challenging physical and environmental conditions of new E&P developments, beyond the limits of traditional industry standards. Advanced design and analysis capabilities. Industry commitment to the technical integrity and HSE associated with industry challenges. Availability of significant historical experience and lessons-learned: 1980’s: 30,000 psi wellhead and Xmas tree equipment 1990’s: 300+ deg. F wellhead and Xmas tree equipment 2000’s: Advanced design analysis capabilities and design codes

4. 4 Project Basis of Design User’s Functional Design Spec Design Meets Spec Design Verification Analysis Design Validation Manufacture Equipment No Yes Product Development Process For Existing or New Design Equipment Fit for Purpose Qualification Process Both Legs Must Be Performed

5. 5 API Design Verification

6. 6 API Design Validation

7. 7 Project Basis of Design Operational Specific Basis of Design Reservoir Pressure Temperature Fluid Chemistry Mud Line Pressure Temperature at Various Flow Rates External Loads Surface Pressure Temperature at Various Flow Rates

8. 8 User’s Functional Design Specification Operational Statement of Requirements System Description Operating Conditions System Analysis to Obtain Component Loads Failure Modes & Effect Analysis of Components Life Cycle Operations for System/Components Materials Used in Construction of Equipment All Fluids/Environments in Contact with Wetted Surfaces Material Properties in the Environments/Temps Exposed

9. BOP or SS Tree System Analysis Spec Breaks Above Wellhead Casing Tubing Completion Equipment

10. 10 C/K Manifold & Rig Piping C/K Lines & Flex Pipe C/K Valves & Piping Ram BOP’s & Wellhead Connector Wellhead System Analysis Spec Breaks Well Construction Well Completion Well Intervention Surface Riser BOP & Wellhead

11. 11 Design Material Properties −Material Properties At Design Temperature (Inside & Out) −Material Properties In Service Environment (Inside & Out) −Determine Minimum Detectable Flaw Size (inspection) Comprehensive Design Conditions Analyses −Static, Dynamic, & Transient −Pressure (Inside and Out) −Thermal (Inside and Out) −Loads (Tension, Bending, & Torsion) Stress Analysis Using FEA −Comprehensive Design Conditions (Operating) −Hydrostatic Proof Test Life Cycle Fatigue Analysis −Fracture Mechanics/S-N Curves −Cycles to Failure Design Verification

12. 12 Design Test Program To Validate Verification Analysis −Insitu Temperature Requirements −Inside and Outside −Dynamic, Transient, and Steady-State −In-Service Load Conditions −Pressure & All Applied Loads (Tension, Bending, Etc) −Inside and Outside −Dynamic, Transient, and Steady-State −Measure and Monitor Peak Stresses −Establish Reliability Goals and Testing Methodology If Physical Tests are Impractical −Analytical Simulations −Scale Model Tests −Tests of Less Magnitude - Scale Design Validation

13. 13 API RECOMMENDED PRACTICE Re-certify Repair Design Validation Use Documentation Design Verification Functional Specification FAT Inspection QA/QC Materials Purchase Specs Manufacture Design Basis Elements Required to Complete The Manufacturing Process Design Manufacture

14. 14 Design Meets Specification Both Legs of the Flowchart Must be Performed The Design Verification Process Uses the Functional Specification as Inputs The Design Validation Process Confirms the Design Verification Results Both Legs Must Satisfy the Functional Specification

15. 15 Roadmap and next steps The committee will identify the functional requirements of the components in HP/HT environment and select the component product to be designed, the design and development verified (6 HP work) and the design and development validated (FEMA’s by TPEE) for use in the HP/HT environment. The product will be developed using current best practices. API subcommittee responsible for the component products requiring development verification and validation to meet HP/HT environments, will undertake: −A suitable design and development verification process like 6 HP. −FMEA on the component products using the methodology outlined including a review of the methodology and how it can be applied to the component products of the subcommittee; −a detailed evaluation of the development validation to meet HP/HT environments including identifing additional or unnecessary requirements associated with the committee’s specific products; −the development of the subcommittee plan to validate any amended methodology on one or more of the subcommittee’s products.

16. API ORGANIZATIONAL RECOMMENDATION Matrix Organization

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