API Standard 16AR
Standard for Repair and
Remanufacturing of Drill-through
Equipment
API Standard 16AR
First Edition, XXXX 2014
Draft – June 9 2014
SPECIAL NOTES
API publications necessarily address problems of a general nature. With respect to particular
circumstances, local, state, and federal laws and regulations should be reviewed.
API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and
properly train and equip their employees, and others exposed, concerning health and safety risks
and precautions, nor undertaking their obligations under local, state, or federal laws.
Information concerning safety and health risks and proper precautions with respect to particular
materials and conditions should be obtained from the employer, the manufacturer or supplier of
that material, or the material safety data sheet.
Nothing contained in any API publication is to be construed as granting any right, by implication
or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by
letters patent. Neither should anything contained in the publication be construed as insuring
anyone against liability for infringement of letters patent.
Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five
years. Sometimes a one-time extension of up to two years will be added to this review cycle. This
publication will no longer be in effect five years after its publication date as an operative API
standard or, where an extension has been granted, upon republication. Status of the publication
can be ascertained from the API Standards department telephone (202) 682-8000. A catalog of
API publications, programs and services is published annually and updated biannually by API,
and available through Global Engineering Documents, 15 Inverness Way East, M/S C303B,
Englewood, CO 80112-5776.
This document was produced under API standardization procedures that ensure appropriate
notification and participation in the developmental process and is designated as an API standard.
Questions concerning the interpretation of the content of this standard or comments and
questions concerning the procedures under which this standard was developed should be
directed in writing to the Director of the Standards department, American Petroleum Institute,
1220 L Street, N.W., Washington, D.C. 20005. standards@api.org Requests for permission to
reproduce or translate all or any part of the material published herein should be addressed to the
Director, Business Services.
API standards are published to facilitate the broad availability of proven, sound engineering and
operating practices. These standards are not intended to obviate the need for applying sound
engineering judgment regarding when and where these standards should be utilized. The
formulation and publication of API standards is not intended in any way to inhibit anyone from
using any other practices.
Any manufacturer marking equipment or materials in conformance with the marking requirements
of an API standard is solely responsible for complying with all the applicable requirements of that
standard. API does not represent, warrant, or guarantee that such products do in fact conform to
the applicable API standard.
All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or
transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without
prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220
L Street, N.W., Washington, D.C. 20005.
Copyright © 2014 American Petroleum Institute
FOREWORD
This standard shall become effective on the date printed on the cover but may be used
voluntarily from the date of distribution.
Standards referenced herein may be replaced by other international or national standards that
can be shown to meet or exceed the requirements of the referenced standard. Manufacturers
electing to use another standard in lieu of a referenced standard are responsible for
documenting equivalency.
This standard is under the jurisdiction of the API Subcommittee on Drilling Well Control
Systems.
This standard replaces the repair and remanufacturing chapter from API 16A.
API publications may be used by anyone desiring to do so. Every effort has been made by the
Institute to assure the accuracy and reliability of the data contained in them; however, the
Institute makes no representation, warranty, or guarantee in connection with this publication and
hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use
or for the violation of any federal state, or municipal regulation with which this publication may
conflict.
Suggested revisions are invited and should be submitted to the API, Standards Department,
1220 L Street, NW, Washington, DC 20005, or by email to standards@api.org.
iii
Table of Contents
Contents
1. Scope ........................................................................................................................... 1
2. Normative References ................................................................................................ 2
3 Terms, Definitions and Abbreviations ........................................................................ 4
3.2
Abbreviated terms ................................................................................................. 14
4. Quality Control Requirements .................................................................................. 15
4.1
General .............................................................................................................. 15
4.2
Measuring and testing equipment ..................................................................... 15
4.2.1 General .......................................................................................................... 15
4.2.2 Pressure-measuring devices .......................................................................... 15
4.3
Quality control personnel qualifications ........................................................... 16
4.3.1 Non-destructive examination (NDE) personnel............................................ 16
4.3.2 Visual examination personnel ....................................................................... 16
4.3.3 Welding inspectors........................................................................................ 16
4.3.4 Welder performance qualification ................................................................ 16
4.3.5 Third Party Inspection................................................................................... 17
4.3.6 Equipment certification ................................................................................. 17
4.3.7 Other personnel ............................................................................................. 17
4.4
Quality control requirements for equipment and parts ..................................... 17
4.4.1 General .......................................................................................................... 17
4.4.2 Material requirements ................................................................................... 17
4.4.3 Quality control instructions........................................................................... 18
4.4.4 Non-destructive examination (NDE) ............................................................ 18
4.4.5 Acceptance status .......................................................................................... 19
4.5
Quality control requirements for specific equipment and parts ........................ 19
4.6
Requirements for quality control records ......................................................... 25
4.6.1 General .......................................................................................................... 25
4.6.2 NACE records requirements ......................................................................... 25
4.6.3 Records control ............................................................................................. 25
4.6.4 Records to be maintained by remanufacturer ............................................... 26
5. Quality Management System Requirements ............................................................. 28
5.1
Control of Documents ....................................................................................... 28
5.2
Training and Awareness ................................................................................... 28
5.3
Control of testing, measuring, monitoring equipment ...................................... 28
5.4
Contract Review................................................................................................ 29
5.4.1 General .......................................................................................................... 29
5.4.2 Determination of Requirements .................................................................... 29
5.5
Purchasing Control............................................................................................ 29
5.6
Design and Development .................................................................................. 30
5.6.1 Design and Development Planning ............................................................... 30
5.6.2 Design documentation .................................................................................. 30
v
5.6.3 Design and Development Inputs ................................................................... 30
5.6.4 Design Verification ....................................................................................... 30
5.6.5 Design Validation ......................................................................................... 31
5.6.6 Control of design and development changes ................................................ 31
5.6.7 Control of nonconforming product ............................................................... 31
5.6.8 Field nonconformity analysis ........................................................................ 31
6. Responsibilities ......................................................................................................... 32
6.1
OEM .................................................................................................................. 32
6.2
Repairer / Remanufacturer ................................................................................ 32
6.3
Product Owner: ................................................................................................. 33
7. Repair / Remanufacturing Service Level Minimum Requirements .......................... 34
7.1
General .............................................................................................................. 34
7.2
Original Equipment Manufacturer (OEM) ....................................................... 34
7.3
Requirements for Pressure Testing ................................................................... 34
7.3.1 General .......................................................................................................... 34
7.3.2 Hydrostatic Proof/Shell Test ......................................................................... 34
7.3.3 Operating Chamber Pressure Test ................................................................ 35
7.3.4 Closed-preventer test .................................................................................... 35
7.3.5 Low Pressure Test ......................................................................................... 35
7.3.6 High Pressure Test ........................................................................................ 35
7.3.7 Acceptance Criteria ....................................................................................... 35
7.3.8 Annular packing unit tests ............................................................................ 36
7.3.9 Pipe, blind and variable-bore rams ............................................................... 36
7.3.10
Blind-shear rams ....................................................................................... 36
7.3.11
Rams lock test ........................................................................................... 37
7.3.12
Elastomeric Seal Requirements ................................................................ 37
7.3.13
Wellbore Sealing Components and Consumables .................................... 37
7.3.14
Operating Sealing Components and Consumables ................................... 37
7.4
Dimensional check ............................................................................................ 37
7.5
NDE – Initial Inspection ................................................................................... 38
7.6
Inspection on closure bolting (pressure retaining) ............................................ 38
7.7
Visual Inspection at disassembly ...................................................................... 39
7.8
Drift Test ........................................................................................................... 39
7.9
Replacement Parts – Qualifications .................................................................. 39
7.10 General Equipment Specifications .................................................................... 40
7.11 Documentation .................................................................................................. 40
7.12 Failure Reporting .............................................................................................. 40
8. Materials ................................................................................................................... 41
8.1
General .............................................................................................................. 41
8.2
Metallic Parts .................................................................................................... 41
8.3
Non-metallic parts ............................................................................................. 42
8.4
Base metal material Identification .................................................................... 42
8.4.1 General .......................................................................................................... 42
8.4.2 Original Material Test Records (MTRs). ...................................................... 42
8.4.3 Determining Hardness and approximate ultimate tensile values: ................. 42
8.4.4 Determining Chemical Composition: ........................................................... 43
8.5
Pressure-containing members ........................................................................... 43
8.5.1 Property requirements ................................................................................... 43
8.5.2 Heat treating .................................................................................................. 44
8.5.3 Chemical composition .................................................................................. 45
8.5.4 Material qualification .................................................................................... 45
8.5.5 Qualification test coupons (QTC) ................................................................. 47
8.5.6 Equivalent round (ER) .................................................................................. 47
8.5.7 Processing ..................................................................................................... 47
8.5.8 Tensile and impact testing ............................................................................ 48
8.5.9 Hardness testing ............................................................................................ 48
9. Welding requirements ............................................................................................... 49
9.1
General .............................................................................................................. 49
9.2
Weldment design and configuration ................................................................. 49
9.2.1 Pressure-containing fabrication weldments .................................................. 49
9.2.2 Load-bearing weldments ............................................................................... 49
9.2.3 Repair welds.................................................................................................. 49
9.2.4 Weld surfacing (overlay) for corrosion resistance and wear resistance for
material surface property controls ............................................................................ 50
9.3
Welding controls ............................................................................................... 53
9.3.1 Procedures ..................................................................................................... 53
9.3.2 Application .................................................................................................... 53
9.3.3 Designed welds ............................................................................................. 53
9.3.4 Preheating ..................................................................................................... 53
9.3.5 Instrument calibration ................................................................................... 53
9.3.6 Materials ....................................................................................................... 53
9.3.7 Post-weld heat treatment ............................................................................... 54
9.4
Welding procedure and performance qualifications ......................................... 55
9.4.1 General .......................................................................................................... 55
9.4.2 Base metals ................................................................................................... 55
9.4.3 Filler material qualification........................................................................... 55
9.4.4 Chemical Analysis ........................................................................................ 55
9.4.5 Heat-treat condition ...................................................................................... 55
9.4.6 Procedure qualification record ...................................................................... 55
9.5
Other Welding Qualification requirements ....................................................... 56
9.5.1 ASME Section IX, Article I — Welding general requirements ................... 56
9.5.2 ASME Section IX, Article II — Welding procedure qualifications ............. 58
9.5.3 ASME Section IX, Article III — Welding performance qualifications ....... 59
9.5.4 ASME Section IX, Article IV — Welding data ........................................... 59
9.6
Other requirements............................................................................................ 59
10.
Decommissioning ................................................................................................. 61
11.
Marking requirements ........................................................................................... 61
11.1 Low-stress-area marking ................................................................................... 61
11.2 High-stress-area marking .................................................................................. 61
11.3 Weld metal overlays ......................................................................................... 61
11.4 Wellbore non-metallic components .................................................................. 61
11.5 Non-wellbore non-metallic components ........................................................... 61
vii
11.6 Specific codification requirements of equipment ............................................. 62
11.7 Product description code (PDC) ....................................................................... 62
12.
Storing and shipping ............................................................................................. 63
12.1 Storing for periods greater than 30 days ........................................................... 63
12.1.1
Draining after testing ................................................................................ 63
12.1.2
Rust prevention ......................................................................................... 63
12.1.3
Connection-surface protection .................................................................. 63
12.1.4
Hydraulic operating system ...................................................................... 63
12.1.5
Elastomeric seals ....................................................................................... 63
12.1.6
Ring gaskets .............................................................................................. 63
12.2 Shipping ............................................................................................................ 63
13.
Certification .......................................................................................................... 64
13.1 Certificate of Conformance............................................................................... 64
13.2 Certificate of Usage Compatibility ................................................................... 64
13.3 Certificate of Service ........................................................................................ 64
13.4 Statement of Fact .............................................................................................. 64
Annex A (Normative) General Equipment Specifications ............................................... 66
Annex B (Normative) Manufacturing Data Book Requirements ..................................... 69
Annex C (Normative) Product History File Requirements .............................................. 71
Annex D (Normative) Failure reporting ........................................................................... 73
Annex E (Normative) OEM ownership ............................................................................ 74
Annex F (Informative) Minimum requirements for Certificate Of Conformance (COC) 75
Annex G (Informative) Recommended weld preparation design dimensions .................. 77
Annex H (Normative) Qualification of heat-treating equipment ...................................... 80
Annex I (Normative) Equivalent Rounds (ER) models .................................................... 83
Annex J (Normative) Replacement parts .......................................................................... 85
SPECIFICATION FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
1
1. Scope
This Standard specifies requirements for repair, remanufacturing, testing, inspection, welding, marking,
certification, recertification, handling, storing and shipping of drill-through equipment used for drilling for
oil and gas build under API 16A. When desired this standard can also be voluntary adopted for other well
control equipment build under a different specification, but this will not automatically make them API
products. This standard defines Repair Service Levels for the below listed equipment and the required
equipment traceability that is required to proof compliance. The repair and remanufacturing supported
under this standard requires that the associated service conditions of the equipment in terms of internal
pressure, temperature and wellbore fluids and ambient temperature limits for which the equipment is
designed remains unchanged and is supported by the Original Product Definition.
This standard is applicable to and establishes requirements for the following specific equipment:
1. ram blowout preventers;
2. ram blocks, operators, packers and top seals;
3. annular blowout preventers;
4. annular packing units;
5. hydraulic connectors;
6. drilling spools;
7. adapters;
8. loose connections;
9. clamps.
Dimensional interchangeability is limited to end and outlet connections. Simplified examples of surface
and subsea equipment defined by this standard are shown in Figures 1 and 2.
Requirements for failure reporting are outlined in Annex D.
This API standard supports the requirements of life cycle management for API 16A products.
1
2
API STANDARD 16AR
Key:
1. Ring gaskets – API 6A
2. Annular BOP
3. Clamp
4. Ram BOP
5. Drilling spool
6. Valve - API 6A
7. Wellhead
8. Casing
9. End and outlet connections
10. Drill-through equipment – API 16A
11. Wellhead equipment - API 6A
Figure 1 — Simplified example of surface drill-through equipment
2
API STANDARD 16AR
Key:
1. Riser connector
2. Flex/ball joint
3. Annular BOP
4. Hydraulic connector
5. Adapter
6. Ram BOP
7. Valve API 6A
8. Hydraulic connector
9. Wellhead
10. Riser equipment, including kill, choke,
booster and control fluid conduit lines.
11. Drill-through equipment - API 16A
12. Wellhead equipment - API 6A
Figure 2 — Simplified example of subsea drill-through equipment
2
API STANDARD 16AR
2. Normative References
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
API
API Specification 5DP, Specification for Steel pipes for Use as Drill Pipe
API Specification 6A, Specification for Wellhead and Christmas Tree Equipment
API Specification 16A, Specification for Drill-through Equipment
API Specification 20E, Specification for Alloy and Carbon Steel Bolting for Use in the Petroleum and
Natural Gas Industries
API Specification Q1: Specification for Quality Management System Requirements for Manufacturing
Organizations for the Petroleum, Petrochemical and Natural Gas Industry
ASME
ASME Boiler and Pressure Vessel Code Section V, Article 5, UT Examination Methods for Materials
and Fabrication
Article 4 is in Section 5.5 Table on 16A requirements
ASME Boiler and Pressure Vessel Code Section IX, Articles I, II, III and IV
ASME B40.100 Pressure Gauges and Gauge Attachments
ASNT
ASNT-SNT-TC-1A, Recommended Practice for Personnel Qualification and Certification in
Nondestructive Testing
ASTM
ASTM A370, Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM D395, Standard Test Methods for Rubber Property — Compression Set
ASTM D412, Test Methods for Vulcanized Rubber, Thermoplastic Rubbers and Thermoplastic
Elastomers
ASTM D471, Standard Test Method for Rubber Property — Effect of Liquids
ASTM D1414, Standard Test Methods for Rubber O-Rings
ASTM D1415, Standard Test Method for Rubber Property — International Hardness
ASTM D1418, Standard Practice for Rubber and Rubber Lattices — Nomenclature
ASTM D2240, Test Method for Rubber Property — Durometer Hardness
ASTM E10, Standard Test Method for Brinell Hardness of Metallic Materials
ASTM E18, Standard Test Methods for Rockwell Hardness of Metallic Materials
ASTM E94, Standard Guide for Radiographic Testing
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
ASTM E140, Hardness Conversion Tables for Metals
ASTM E165, Standard Test Method for Liquid Penetrant Examination
ASTM E384, Standard Test Method for Knoop and Vickers Hardness of Materials
ASTM E569, Standard Practice for Acoustic Emission Monitoring of Structures During Controlled
Simulation
ASTM E709, Standard Guide for Magnetic Particle Examination
ISO
ISO 2859-1:1989, Sampling procedures for inspection by attributes — Part 1: Sampling plans indexed
by acceptable quality level (AQL) for lot-by-lot inspection
ISO 6506-1, Metallic materials, Brinell hardness test, Part 1: Test method
ISO 6507-1, Metallic materials, Vickers hardness test, Part 1: Test method
ISO 6508-1, Metallic materials, Rockwell hardness test, Part 1: Test method (scales A, B, C, D, E, F,
G, H, K, N,T)
ISO 6892, Metallic materials , Tensile testing at ambient temperature
ISO 13665, Seamless and welded steel tubes for pressure purposes — Magnetic particle inspection of
the tube body for the detection of surface imperfections
ISO 9712, International Standard for Nondestructive Testing Personnel Qualification and Certification
CSWIP-WI-6-92, Requirements for the Certification of Visual Welding Inspectors (Level 1), Welding
Inspectors (Level 2) and Senior Welding Inspectors (Level 3) (fusion welding) in accordance with the
requirements of BS EN ISO 176371:2011
NACE
NACE MR0175, Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment
SAE
SAE AMS-H-6875A, Heat Treatment of Steel Raw Materials
3
4
3
3.1
API STANDARD 16AR
Terms, Definitions and Abbreviations
Terms and Definitions
For the purpose of this document, the following terms and definitions apply.
3.1.1
acceptance criteria
defined limits placed on characteristics of materials, products or service
3.1.2
adapter
pressure-containing piece of equipment having end connections of different nominal size designation
and/or pressure rating
3.1.3
annular blowout preventer
blowout preventer that uses a shaped elastomeric sealing element to seal the space between the
tubular and the wellbore or an open hole
3.1.4
blind-shear ram
BSR
closing and sealing component in a ram blowout preventer that first shears the tubular in the wellbore
and then seals off the bore or acts as a blind ram if there is no tubular in the wellbore
3.1.5
blind ram
closing and sealing component in a ram blowout preventer that seals the open wellbore API 16A
3.1.6
blowout preventer
BOP
equipment (or valve) installed at the wellhead to contain wellbore pressure either in the annular space
between the casing and the tubulars or in an open hole during drilling, completion, testing or workover
operations
3.1.7
body
any portion of equipment between end connections, with or without internal parts, which contains
wellbore pressure
3.1.8
bolting
threaded fasteners used to join end or outlet connections
3.1.9
calibration
comparison and adjustment to a standard of known accuracy
3.1.10
cast (verb)
pour molten metal into a mould to produce an object of desired shape
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
3.1.11
Current Equipment Manufacturer
Copy definition into this place, see below.
3.1.12
casting (noun)
object at or near finished shape obtained by solidification of a substance in a mould
3.1.13
Certificate of Statutory Compliance
document in which the Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the equipment and / or system meets the required standards or rules as depicted in the
relevant area of operations regulatory requirement
3.1.14
Certificate of Conformance
COC
document in which the Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the assembly or part has been manufactured / remanufactured in conformance to the
mentioned standard(s), specifications and guidelines in accordance with the product definition,
including design changes resulting from a malfunction or failure history of drill-through equipment
manufactured, remanufactured and / or repaired to the appropriate standard/specification
3.1.15
Certificate of Fit, Form and Function
document in which a Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the component or assembly meets or exceeds the product definition requirements.,
including design changes resulting from a malfunction or failure history of drill-through equipment
manufactured, remanufactured or repaired to the applicable Recognized International Standard /
Specification and is fully compatible with the product definition and can be integrated into other
systems guaranteeing the operations envelope.
3.1.16
Certificate of Service
COS
document in which the equipment Manufacturer, Repairer, Remanufacturer, recognized technical
authority / Owner or Operator certifies that the equipment has been inspected, properly maintained and
tested in accordance with the applicable Equipment Owner’s Quality Management System, Original
Equipment Manufacturer (OEM) or Current Equipment Manufacturer (CEM) specifications and meets
the API 16AR, RSL-1, 2 or 3 requirements.
3.1.17
chemical analysis
determination of the chemical composition of material
3.1.18
clamp (noun)
device with internal angled shoulders used to fasten mating hubs
3.1.19
clamping load
axial load applied to clamp hubs by the clamp due to bolt tightening
5
6
API STANDARD 16AR
3.1.20
closure bolting
threaded fasteners used to assemble pressure-containing parts other than end and outlet connections
3.1.21
conformance
compliance with specified requirements in every detail
3.1.22
corrosion-resistant ring groove
ring groove lined with metal resistant to metal-loss corrosion
3.1.23
design status
status of an API product managed under the requirements of this specification, with regard to changes
to elements of the Original Product Definition (OPD) as well as improvements to the OPD or
obsolescence of the product.
3.1.24
drilling spool
pressure-containing piece of equipment having end connections, used below or between drill-through
equipment, manufactured in conformance with API 16A
3.1.25
end connection
flange (studded or open-face), hub connection or other end connection (3.47) used to join together
equipment and integral to that equipment
3.1.26
equipment
any single completed unit that can be used for its intended purpose without further processing or
assembly
3.1.27
fabrication weld
weld that joins two or more pieces of metal
3.1.28
flange
protruding rim, with holes to accept bolts and having a sealing mechanism, used to join pressurecontaining equipment together by bolting to another flange
3.1.29
forge (verb)
lastically deform metal, usually hot, into desired shapes with compressive force, with open or closed
dies
3.1.30
forging (noun)
shaped metal part formed by the forging method
3.1.31
full-penetration weld
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
weld that extends throughout the complete wall section of the parts joined
3.1.32
heat
cast lot material originating from a final melt
NOTE For remelted alloys, a heat is defined as the raw material originating from a single remelted
ingot.
3.1.33
heat-affected zone
HAZ
portion of the base metal which has not been melted, but whose mechanical properties or
microstructure has been altered by the heat of welding or cutting
3.1.34
heat treatment
heat treating
alternate steps of controlled heating and cooling of materials for the purpose of changing physical or
mechanical properties
3.1.35
heat treatment load
material moved as a batch through one heat treatment cycle
3.1.36
hot-work (verb)
deform metal plastically at a temperature above the recrystallization temperature
3.1.37
hub
protruding rim with an external angled shoulder and a sealing mechanism used to join pressurecontaining equipment
3.1.38
hydraulic connector
hydraulically actuated drill-through equipment that locks and seals on end connections
3.1.39
indication
visual sign of cracks, pits or other abnormalities found during liquid penetrant and magnetic particle
examinations
3.1.40
integral (adjective)
parts joined by the forging, casting or welding process
3.1.41
leakage
visible passage of pressurized fluid from the inside to the outside of the pressure-containment area of
the equipment being tested
3.1.42
7
8
API STANDARD 16AR
loose connection
flange (studded or open-face), hub connection or other end connection (3.47) used to join together
equipment, but not integral to the equipment
3.1.43
maintenance
upkeep of the well control equipment which is performed in accordance with the equipment owner’s
PM program and the manufacturer’s guidelines.
NOTE These procedures may include but are not limited to, inspections, function testing, pressure testing, non-destructive
examination and change out of parts.
3.1.44
major repair weld
weld that is the greater in thickness of either 1 inch or 25 percent of the original base metal thickness
3.1.45
non-pressure-containing weld
weld whose failure will not reduce the pressure-containing integrity of the component
3.1.46
original equipment manufacturer
OEM
design owner or manufacturer of the traceable assembled equipment, single equipment unit, or
component part.
NOTE 1 If any alterations to the original design and/or assembled equipment or component part are made by anyone other
than the OEM, the assembly, part, or component is not considered an OEM product.
3.1.4x
current equipment manufacturer
CEM
design owner or remanufacturer of the current product definition of the assembled equipment, single
equipment unit, or component part.
3.1.47
original product definition
OPD
complete design verified and validated definition of the requirements for the original assembled
product, single equipment unit or component part, including specified limits and tolerances, health,
safety and environmental requirements, limitations of use, customer specific requirements, design
acceptance criteria, materials of construction, materials processing requirements and physical
properties, physical dimensions and requirements for manufacturing process controls, inspection,
assembly and testing, marking, handling, storage, maintenance, service and records requirements
3.1.4x
current product definition
CPD
complete design verified and validated definition of the requirements for the current assembled
product, single equipment unit or component part, including specified limits and tolerances, health,
safety and environmental requirements, limitations of use, customer specific requirements, design
acceptance criteria, materials of construction, materials processing requirements and physical
properties, physical dimensions and requirements for manufacturing process controls, inspection,
assembly and testing, marking, handling, storage, maintenance, service and records requirements.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
9
10
API STANDARD 16AR
3.1.48
other end connection
OEC
connection which is not specified in an API / ISO standard
NOTE This includes API ISO flanges and hubs with non-API/ISO gasket preparations and manufacturer's proprietary
connections.
3.1.49
part
individual piece used in the assembly of a single unit of equipment
3.1.50
post-weld heat treatment
PWHT
heating and cooling a weldment in a controlled manner to obtain desired properties
3.1.51
pressure-containing part
pressure-containing member part exposed to wellbore fluids whose failure to function as intended
would result in a release of wellbore fluid to the environment
NOTE
Examples include bodies, bonnets and connecting rods.
3.1.52
pressure-containing weld
weld whose failure will reduce the pressure-containing integrity of the component
3.1.53
pressure-controlling part
pressure-controlling member
parts intended to control or regulate the movement of wellbore fluids
NOTE
Examples include packing elements, rams, replaceable seats within a pressure-containing member or part.
3.1.54
pressure-retaining part
pressure-retaining member
part not exposed to wellbore fluids whose failure to function as intended will result in a release of
wellbore fluid to the environment
NOTE
Examples include closure bolts and clamps.
3.1.55
procedure qualification record
PQR
record of the welding data used to make the test weldment containing the actual values or ranges of
the essential and supplementary essential variables used in preparing the test weldments, including
the test results
3.1.56
product definition
design documentation of a particular product which includes the complete set of design validation and
verification files
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
11
3.1.57
product owner/operator
owner or operator of the product repaired or remanufactured in conformance with this document
3.1.58
product history file
PHF
composite file of records from a traceable API product which includes all records associated with the
original API product (including Monogram requirements) and those certification records required by this
document
3.1.59
ram blowout preventer
blowout preventer that uses metal blocks with integral elastomer seals to seal off pressure on a
wellbore with or without tubulars in the bore
3.1.60
rated working pressure
maximum internal pressure that the equipment is designed to contain and/or control
3.1.61
recognized technical authority
Manufacturer / Remanufacturer holding the manufacturing and quality licenses, or registered
professional engineer, or a technical classification society, or engineering firm in which its employees
hold appropriate licenses to perform the verification in the appropriate jurisdiction, and evidence to
demonstrate that the individual, society, or firm has the applicable expertise and experience necessary
to perform the required verifications.
3.1.62
record (noun)
retrievable information
3.1.63
remanufacture
process of disassembly, reassembly and testing of drill-through equipment, with or without the
replacement of parts, in which machining, welding, heat treatment or other manufacturing operation is
employed
3.1.64
repair
process disassembly, reassembly and testing of drill-through equipment, with or without the
replacement of parts
NOTE Repair does not include machining, welding, heat treating or other manufacturing operation of component parts and
does not include the replacement of pressure-containing part(s) or member(s). Repair may include replacement of parts other
than pressure-containing part(s) or member(s).
3.1.65
repair weld
welding performed subsequent to original heat treatment other than base weld repair
3.1.66
serialization
assignment of a unique code to individual parts and/or pieces of equipment to maintain records
12
API STANDARD 16AR
3.1.67
stabilized
pressure testing in a state in which the initial pressure-decline rate has decreased to within the
manufacturer's specified rate
NOTE Pressure decline can be caused by such things as changes in temperature, setting of elastomer seals or
compression of air trapped in the equipment being tested.
3.1.68
statement of fact
SOF
document in which the Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the maintenance / repair performed on a part or system is either not covered by a full
service history and required traceability, or the maintenance / repair was made with limited scope
defined by the Owner.
NOTE A Statement of Fact does not fulfil the requirements of a Certificate of Conformance or other certificates verifying
product design.
3.1.69
stress relief
controlled heating of material to a predetermined temperature for the purpose of reducing any residual
stresses
3.1.70
trepan (verb)
produce a hole through a part by boring a narrow band or groove around the circumference of the hole
and removing the solid central core of material
3.1.71
variable-bore ram
VBR
closing and sealing component in a ram blowout preventer that is capable of sealing on a range of
tubular sizes
3.1.72
visual examination
examination of parts and equipment for visible defects in material and workmanship
3.1.73
volumetric non-destructive examination
examination for internal material defects by radiography, acoustic emission or ultrasonic testing
3.1.74
weld (verb)
act of fusing materials, with or without the addition of filler materials
3.1.75
weld groove
area between two metals to be joined that has been prepared to receive weld filler metal
3.1.76
welding
application of any one of a group of welding processes, which applies heat energy sufficient to melt
and join one or more pieces of metal through localized fusion and coalescence
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
13
3.1.77
welding procedure specification
WPS
written welding procedure that is qualified to provide direction for welding in accordance with
requirements of this standard and describing the specific essential, nonessential, and supplementary
essential variables required for each welding process.
NOTE These variables and their meanings are defined, respectively, in Article II, QW-250 through QW-280 and Article IV of
the ASME Boiler & Pressure Vessel Code Section IX–Welding and Brazing Qualifications.
3.1.78
weldment
portion or area of a component on which welding has been performed. A weldment includes the weld
metal, the heat-affected zone (HAZ), and the base metal unaffected by the heat of welding
3.1.79
wrought structure
structure that contains no cast dendritic structure
3.1.80
yield strength
stress level, measured at room temperature, at which material plastically deforms and will not return to
its original dimensions when the stress is released
NOTE 1 The term is expressed in Newton’s per square millimeter (pounds per square inch) of loaded area.
NOTE 2 All yield strengths specified in this standard are considered as being the 0,2 % yield offset strength in accordance
with ISO 6892.
14
3.2
API STANDARD 16AR
Abbreviated terms
ANSI
Standards Institute
API
American Petroleum Institute
AQL
acceptance quality level
ASME
American Society of Mechanical Engineers
ASNT
American Society for Nondestructive Testing
ASTM
American Society for Testing and Materials
AWS
American Welding Society
BSR
blind shear ram
BOP
Blowout Preventer
CEM
Current Equipment Manufacturer
COC
Certificate of Conformance
COS
Certificate of Service
HAZ
heat-affected zone
ID
inside diameter
ITP
inspection test plan
LP
liquid penetrant
MP
magnetic particle
NACE
National Association of Corrosion Engineers
NDE
nondestructive examination
OD
outside diameter
OEC
other end connection
OEM
original equipment manufacturer
OPD
original product definition
OS
operating system
PHF
product history file
PQR
procedure qualification record
PWHT
post-weld heat treatment
RSL
remanufacturing service level
SOF
statement of fact
TPI
third party inspection
VBR
variable-bore ram
WPS
welding procedure specification
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
15
4. Quality Control Requirements
4.1
General
This clause specifies the quality control requirements and quality control requirements for equipment
and material manufactured to meet this standard.
The following subjects are covered:
― Measuring and testing equipment (see 4.2).
― Quality control personnel qualifications (see 4.3).
― Quality control requirements for equipment and parts (see 4.4).
― Quality control requirements for specific equipment and parts (see 4.5)
― Quality control records (see 4.6)
4.2
Measuring and testing equipment
4.2.1 General
Equipment used to inspect, test or examine material or other equipment shall be identified, controlled,
calibrated and adjusted at specified internals in accordance with documented manufacturer
instructions, and consistent with nationally or internationally recognized standards specified by the
manufacturer, to maintain the accuracy required by this specification.
4.2.2 Pressure-measuring devices
4.2.2.1 Type and Accuracy
Analog test pressure-measuring devices shall be accurate to at least 1% of full-scale range (grade 1A)
in conformance with ASME B40.100 and shall have a minimum face diameter of 100mm (4 in)
Digital pressure transducers shall be accurate to at least 1% of full scale in conformance.
If analog pressure gauges are used in lieu of pressure transducers, they shall be selected such that
the test pressure is indicated within 25% or more than 75% of full-pressure span of the gauge, in
conformance with ASME B40.100.
Pressure tests must be displayed as a chart in the Project History File (PHF) or Material Data Book
(MDB).
The record shall identify the recording device, calibration due date and shall be dated and signed.
4.2.2.2 Calibration procedure
Pressure-measuring devices shall be periodically calibrated with a master pressure-measuring device
or a deadweight tester to at least three equidistant points of full scale (excluding zero and full scale as
required points of calibration).
16
API STANDARD 16AR
4.2.2.3 Calibration Intervals
Intervals shall be established for calibrations based on repeatability and degree of usage.
Calibration intervals shall be a maximum of three months until recorded calibration history can be
established by the manufacturer and new intervals established, not exceeding ASTM minimum
requirements.
4.3
Quality control personnel qualifications
4.3.1 Non-destructive examination (NDE) personnel
Personnel performing NDE shall be qualified in accordance with the manufacturer's documented
training program that is based on the requirements specified in ISO 9712 or ASNT SNT-TC-1A.
4.3.2 Visual examination personnel
Personnel performing visual examinations, including welders, shall take and pass an annual vision
examination in accordance with the manufacturer's documented procedures that meet the applicable
requirements of ISO 9712 or ASNT SNT-TC-1A.
4.3.3 Welding inspectors
Personnel performing visual inspection of welding operations and completed welds shall be qualified to
one of the following:
1) AWS Senior Certified Welding Inspector (SCWI);
2) AWS Certified Welding Inspector (CWI);
3) AWS Certified Associate Welding Inspector (CAWI);
4) CSWIP Certified Visual Welding Inspectors (Level 1);
5) CSWIP Certified Welding Inspectors (Level 2);
6) CSWIP Certified Senior Welding Inspectors (Level 3)
7) Welding inspector certified by the manufacturer's documented training program
The manufacturer shall have written procedures:
1) Defining the In-house welding inspector certification program including training syllabus, Instructor
qualification requirements, length of certification and renewal requirements;.
2) Defining the roles, responsibilities, authority and accountability of a welding inspector;
3) Defining essential welding variables and equipment monitoring;
4) Defining Welding, Weld NDE and PWHT audits. Internal Audits shall be performed at least
annually, covering all on-site areas and shifts. Supplier Audits shall be performed in accordance
with the Manufacturers written procedure for Validation of Supplier Processes
4.3.4 Welder performance qualification
Welders and welding operators shall be qualified in accordance with ASME, BPVC, Section IX, Article
III.
Welders qualification for blind holes shall be in conformance with API 6A.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
17
4.3.5 Third Party Inspection
If Third Party Inspection is used, the following applies:
1) Third Party Inspectors (TPI) shall be competent based on the appropriate education, training, skills
and experience needed to perform the inspection service and certification related product
requirements defined in the inspection scope.
2) Evidence of the determination of competence of TPI personnel shall be recorded and maintained
by the TPI company in accordance with their QMS documented procedures and requirements for
competence.
3) The TPI scope shall be clearly defined in the purchase order by the client.
4) The TPI requirements defined in the purchase order shall be included in the Inspection Test Plan
for the product.
4.3.6 Equipment certification
Equipment certification shall be approved by a Recognized Technical Authority.
4.3.7 Other personnel
All other personnel performing measurements, inspections or tests for acceptance shall be qualified in
accordance with the manufacturer's Q1 or recognized Quality Management System documented
procedures and requirements for competence.
4.4
Quality control requirements for equipment and parts
4.4.1 General
All pressure-containing and pressure-controlling parts exposed to wellbore fluid shall be in
conformance with the requirements of NACE MR0175, ISO 15156 (all parts).
4.4.2 Material requirements
Material used for pressure-containing parts or members shall comply with API 16A.
4.4.2.1 Closure Bolting
Closure bolting and other parts shall conform to, or exceed, the manufacturer's written specification
and API 16A standard revision under which originally built. The manufacturer shall retain individualheat-traceability records for closure bolting, as required.
4.4.2.2 Studs and nuts other than closure bolting
Studs and nuts shall conform to the requirements of API 6A.
Carbon steel studs and nuts shall be in conformance with API 6A or API 20E, BSL-2 specifications.
Materials and consumables shall be fully traceable.
18
API STANDARD 16AR
4.4.2.3 Bolting environment
Bolting selection for surface and subsea pressure control equipment shall consider the maximum
hardness requirements, in relation to the operational environment and selected corrosion protection
system in order to prevent hydrogen embrittlement.
4.4.3 Quality control instructions
All quality control work shall be controlled by the manufacturer's documented instructions, which
includes an appropriate Inspection Test Plan (ITP) or other methodology that provides an auditable
tracking document with quantitative and qualitative acceptance criteria.
4.4.4 Non-destructive examination (NDE)
NDE instructions shall be detailed regarding the requirements of this International Standard and those
of all applicable nationally or internationally recognized standards specified by the manufacturer. All
NDE instructions shall be approved by a NDE Level III examiner.
4.4.4.1 NDE qualification levels
NDE level I:
a) The NDE Level I is qualified to perform system calibrations, Implement techniques and conduct
limited evaluation in the NDE method in which the individual is certified.
b) The NDE Level I does not Interpret test results for acceptance or rejection.
NDE Level II:
a) The NDE Level Il is qualified to setup and calibrate equipment, Interpret and evaluate results with
respect to applicable codes, standards, and specifications.
b) The NDT Level Il is familiar with the scope and limitations of the used methods for which qualified.
c) The NDE Level II can provide training of NDE Level I personnel.
d) The NDE Level II is qualified to prepare written Instructions, and report the NDE results.
NDE Level III:
a) The NDE Level III is qualified to select the appropriate NDE techniques based on knowledge of
materials, fabrication methods and product design for the part.
b) The NDE Level III is responsible to establish techniques and procedures for the examination of a
part.
c) The NDT Level III evaluates and interprets the results of the NDE method in conformance with the
codes, standards and specifications.
d) The NDE Level III establishes acceptance criteria where none are available.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
19
e) The NDE Level III is responsible for the training and certification examination of NDE Level I and II
personnel.
4.4.5 Acceptance status
The acceptance status of all equipment, parts and materials shall be indicated either on the equipment,
parts or materials or in the records traceable to the equipment, parts or materials.
4.5
Quality control requirements for specific equipment and parts
Unless specified differently in this standard, quality control requirements for specific equipment and
parts under API 16AR will be in conformance with API 16A.
All new manufactured or replacement parts shall be in full conformance to API 16A requirements,
including design verification and testing.
Quality control records and marking for specific equipment and parts shall be in conformance with API
16A.
4.5.1 Pressure-containing and pressure-controlling parts
Pressure-containing and pressure-controlling parts include those exposed to wellbore fluid (except for
studs and nuts, closure bolting, ring gaskets, non-metallic sealing materials, molded sealing
assemblies and metallic inserts in molded assemblies.
4.5.2 Hardness testing
a) Hardness testing methods shall be in accordance with ASTM E10, ASTM E18, ASTM E110,
ASTM E384, ISO 6506-1, ISO 6507-1 or ISO 6508-1, as appropriate.
b) At least one hardness test (two indentations) shall be performed on each part tested, at a location
determined by the manufacturer's specifications.
c) When equipment is a weldment composed of different material designations, hardness testing
shall be performed on each component part of the weldment after the final heat treatment
(including stress-relieving). The results of these hardness tests shall satisfy the hardness value
requirements for each respective part.
d) The hardness testing used to qualify each part shall be performed after the last heat-treatment
cycle (including all stress-relieving heat-treatment cycles) and after all exterior machining
operations.
e) The actual value of the hardness test shall be stamped on the part adjacent to the test location. It
is permissible for the hardness marking to be covered by other components after assembly.
f) Hardness measurements on wellbore-wetted parts manufactured from carbon low alloy and
martensitic stainless type steels shall exhibit maximum values in accordance with NACE MR0175
and minimum values equal to or greater than those specified in API 16A.
4.5.3 Critical dimensions
a) Critical dimensions, as defined by the Current Equipment Manufacturer or Remanufacturer shall
be documented for each part and such documentation shall be retained by the manufacturer in
accordance with the quality control requirements of 5.1.
b) The manufacturer shall define and document the extent to which dimensions shall be verified.
20
API STANDARD 16AR
4.5.4 Traceability
a) Parts and material shall be traceable to the individual heat and heat-treatment lot.
b) Identification shall be maintained on materials and parts, to facilitate traceability, as required by
documented manufacturer requirements.
c) Manufacturer-documented traceability requirements shall include provisions for maintenance or
replacement of identification marks and identification control records.
d) Welds without sufficient documentation / traceability in the PHF to meet the design specification of
the manufacturer / remanufacturer of the product shall be removed.
4.5.5 Chemical analysis
a) Chemical analysis shall be performed on a heat basis.
b) Chemical analysis shall be performed in accordance with the manufacturer's / remanufacturers
written procedure.
c) The chemical composition shall meet the requirements of API 16A.
4.5.6 Visual examination
a) Each part shall be visually examined.
b) Visual examination of castings and forgings shall be performed in accordance with the Current
Equipment Manufacturer's written specification.
c) Acceptance criteria shall be in accordance with Current Equipment Manufacturer's written
specifications.
d) Non-well fluid-wetted and non-sealing surfaces shall be examined in accordance with Current
Equipment Manufacturer's written specifications.
4.5.7 Surface NDE
a) For Surface NDE of ferromagnetic materials all accessible well fluid-wetted surfaces and all
accessible sealing surfaces of each finished part shall be inspected after final heat treatment and
after final machining operations by either magnetic particle (MP) or liquid penetrant (LP) methods.
b) For Surface NDE of non-ferromagnetic materials all accessible well fluid-wetted surfaces of each
finished part shall be inspected after final heat treatment and after final machining operations by
the LP method.
c) LP examination shall be in accordance with procedures specified in ASTM E 165.
d) MP examination shall be in accordance with procedures specified in ASTM E709. Prods are not
permitted on well fluid-wetted surfaces or sealing surfaces.
4.5.8 Acceptance criteria for MP and LP
a) Inherent indications not associated with a surface rupture (i.e. magnetic permeability variations,
non-metallic stringer, etc.) are not considered relevant indications.
4.5.8.1 Acceptance criteria for surfaces other than pressure-contact (metal-to-metal)
sealing surfaces
a) No relevant indication with a major dimension equal to or greater than 5 mm (0.2 in).
b) No more than ten relevant indications in any continuous 10 cm2 (2.5 in2) area.
c) Four or more relevant indications in a line separated by less than 1.5 mm (0.06 in) (edge to edge)
are unacceptable.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
4.5.8.2 Acceptance criteria for pressure contact (metal to metal) sealing surfaces
a) There shall be no relevant indications in the pressure-contact (metal-to-metal) sealing surfaces.
4.5.9 Weld NDE
a) When examination is required, essential welding variables and equipment shall be monitored and
completed weldments and the entire accessible weld shall be examined in accordance with the
methods and acceptance criteria of this specification.
b) 100 % of all surfaces prepared for welding shall be visually examined prior to initiating welding.
c) Examinations shall include a minimum of 12 mm (0,5 in) of adjacent base metal on both sides of
the weld.
d) Weld NDE surface preparation acceptance shall be in accordance with the Current Equipment
Manufacturer's written specification.
e) All welds shall be examined according to Current Equipment Manufacturer's written specification.
f) Any undercut detected by visual examination shall be evaluated in accordance with the Current
Equipment Manufacturer's written specification.
g) Surface porosity and exposed slag are not permitted on or within 3 mm (0,125 in) of sealing
surfaces.
4.5.10 Weld NDE - Surface examination (other than visual)
a) 100 % of all pressure-containing welds repair and weld metal overlay welds and repaired
fabrication welds shall be examined by either MP or LP methods after all welding, post-weld heat
treatment and machining operations are completed.
b) The examination shall include 13 mm (0.5 in) of adjacent base material on both sides of the weld.
c) Acceptance criteria for MP and LP shall be in conformance with API 16A.
4.5.11 Repair welds
a) All repair welds shall be examined using the same methods and acceptance criteria used in
examining the base metal.
b) The examination shall include 13 mm (0.5 in) of adjacent base material on both sides of the weld.
c) Surfaces of ground-out areas for repair welds shall be examined prior to welding to ensure defect
removal using the acceptance criteria for fabrication welds
4.5.12 Weld NDE — Volumetric examination of fabrication weld
a) 100 % of all pressure-containing welds shall be examined by either radiography, ultrasonic or
acoustic emission methods after all welding and post-weld heat treatment.
b) All repair welds for which the repair is greater than 25 % of the original wall thickness or 25 mm (1
inch) (whichever is less) shall be examined by either radiography, ultrasonic or acoustic emission
methods after all welding and post-weld heat treatment.
c) Examinations shall include at least 12 mm (0.5 in) of adjacent base metal on all sides of the weld.
4.5.13 Radiography examination
a) Radiographic examinations shall be performed in accordance with procedures specified in ASTM
E 94, to a minimum equivalent sensitivity of 2 %.
b) Both X ray and gamma ray radiation sources are acceptable within the inherent thickness range
limitation of each.
c) Real-time imaging and recording/enhancement methods may be used when the manufacturer has
documented proof that the methods will result in a minimum equivalent sensitivity of 2 %.
21
22
API STANDARD 16AR
d) Wire-type image quality indicators are acceptable for use in accordance with ASTM E 747.
e) Acceptance criteria for radiography in conformance with API 16A.
4.5.14 Ultrasonic examination
a) Ultrasonic examinations shall be performed in accordance with procedures specified in ASME
Boiler and Pressure Vessel Code, Section V, Article 4.
b) Acceptance criteria for Ultrasonic examination shall be in conformance with API 16A.
4.5.15 Acoustic emission examination
a) Acoustic emission (AE) examinations shall be performed in accordance with procedures specified
in ASTM E 569.
b) The acoustic emission examination shall be conducted throughout the duration of the hydrostatic
“in-plant” test.
c) Acceptance criteria for Acoustic emission examination shall be in conformance with API 16A.
4.5.16 Weld NDE — Hardness testing
a) All accessible pressure-containing, non-pressure-containing and major repair welds shall be
hardness tested.
b) At least one hardness test shall be performed in both the weld and in the adjacent unaffected base
metal after all heat treatment and machining operations.
c) The hardness recorded in the PQR shall be the basis for acceptance if the weld is not accessible
for hardness testing.
d) Hardness testing shall be performed in accordance with one of the following:
 those procedures specified in ASTM E18, ASTM E110 (Brinell) or ISO 6506-1;
 those procedures specified in ASTM E10, ASTM E110 (Rockwell) or ISO 6508-1;
 at least one hardness test shall be performed in both the weld and in the adjacent unaffected
base metal after all heat treatment and machining operations. . The actual value of the
hardness test shall be stamped on the part adjacent to the test location. It is permissible for
hardness marking to be covered by other components after assembly.
e) Acceptance criteria for hardness testing shall be in conformance with API 16A.
4.5.17 Volumetric NDE parts - Sampling
a) For quench-and-tempered replacement products, the volumetric inspection shall be performed
after heat treatment for mechanical properties exclusive of stress-relief treatments or re-tempering
to reduce hardness.
4.5.18 Volumetric NDE parts - Ultrasonic examination
a) Hot-worked parts: Ultrasonic examination of hot-worked parts shall be performed in accordance
with the flat-bottom-hole procedures specified in ASTM A 388 (except immersion method may be
used) and ASTM E 428.
b) Calibration: Distance amplitude curve (DAC) shall be based on 1,6 mm (1/16 in) flat-bottom hole
for metal thicknesses through 38 mm (11/2 in), on 3,2 mm (1/8 in) flat-bottom hole for metal
thicknesses from 38 mm (11/2 in) through 150 mm (6 in), and on 6,4 mm (1/4 in) flat-bottom hole
for metal thicknesses exceeding 150 mm (6 in).
c) Acceptance criteria for ultrasonic testing shall be in conformance with API 16A.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
4.5.19 Volumetric NDE parts - Radiographic examination
a) Radiographic examination of hot-worked parts shall be performed in accordance with API 16A.
b)
c) Acceptance criteria for radiographic testing shall be in conformance with API 16A
4.5.20 Non-Metallic parts
a) Inspection of Non-metallic parts shall be in accordance with API 16A
4.5.21 Annular packers when shipped separately from a BOP
a) When shipped separately (not part of an assembled BOP), annular packers shall be pressuretested and drift tested in accordance with API 16A.
4.5.22 Assembled equipment
a) The quality control requirements for assembled equipment shall include drift tests, pressure tests
and hydraulic operating system tests.
b) Serialization must be recorded on all assembled equipment and shall be carried out in accordance
with the CEM written specification.
c) A report shall be prepared in which all serialized and individual-heat-traceable parts are listed as
traceable to the assembly (e.g., assembly part number, serial number).
d) A drift test is required on ram BOP, annular BOP, hydraulic connectors, drilling spools and
adapters.
e) The hydrostatic proof or shell test pressure shall be determined by the rated working pressure for
the equipment and be in conformance with API 16A.
f) The hydraulic operating system test shall be tested on each assembled blowout preventer and
hydraulic connector.
4.5.23 Closed-preventer test
a) Each ram and annular blowout preventer shall be subjected to a closed-preventer test after the
hydrostatic proof test.
b) The hydraulic operating system pressure used shall be equal to or less than the manufacturer's
specified operating pressure.
c) Annular packing tests shall require pressure-testing on the appropriate size drill pipe and without
out drill pipe in accordance with API 16A.
d) VBRs shall be tested on the minimum and maximum sizes for their range.
e) Each preventer equipped with blind-shear rams shall be subjected to a shearing test.
f) The BOP closed-preventer test for each blowout preventer equipped with a hydraulic ram-locking
system shall be pressure tested with the locking system engaged and closing pressure bled off.
g) Loose operator assembly locking systems shall be tested in accordance with the CEM
requirements specified in the purchase order.
4.5.24 Hydraulic connector tests
a) Since there is no closure unit in a hydraulic connector, the hydrostatic proof test shall take the
place of any rated working pressure tests.
b) Check 16A new requirements
23
24
API STANDARD 16AR
4.5.25 Remanufacturing Service levels
Remanufacturing Service Levels (RSL) for remanufactured parts / assemblies indicate the level of
traceability and conformance of the API 16A (as summarized in Table 1 below).
Table 1 – Quality Control Requirements
A) Base Material:
Tensile testing
All pressure-containing parts material qualification tensile testing is in
conformance with API 16A.
Only the base material of pressure containing parts material qualification
tensile testing in conformance with API 16A.
No tensile testing is available for pressure containing parts. As a minimum
hardness testing required.
All pressure-controlling parts material qualification tensile testing in
conformance with API 16A.
Only the base material of pressure controlling parts material qualification
tensile testing in conformance with API 16A.
No tensile testing is available for wellbore wetted pressure controlling
parts. As a minimum hardness testing required.
No tensile testing is available for non-wellbore wetted pressure controlling
parts. As a minimum hardness testing required.
Impact testing
All pressure-containing parts material qualification impact testing is in
conformance with API 16A.
Only the base material of pressure containing parts material qualification
impact testing in conformance with API 16A.
No impact testing is available for pressure containing parts.
All pressure-controlling parts material qualification impact testing in
conformance with API 16A.
Only the base material of pressure controlling parts material qualification
impact testing in conformance with API 16A.
No impact testing is available for wellbore wetted pressure controlling
parts.
No impact testing is available for non-wellbore wetted pressure controlling
parts.
Hardness testing
Hardness measurements meet the current Product Definition allowables
but do not meet the 16A material designations hardness levels.
B) Weld Material:
Mechanical testing
Note: welding experts must fill out this section for differentiators.
PWHT traceability
RSL-1
RSL-2
RSL-3
X
X
X
X
X
X
X
RSL-1
RSL-2
RSL-3
X
X
X
X
X
X
X
RSL-1
X
RSL-2
X
RSL-3
RSL-1
RSL-2
RSL-3
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
4.5.3 Critical dimensions
Critical dimensions, as defined by the Current Equipment Manufacturer,
are within tolerances of as-new equipment.
Critical dimensions, as defined by the Current Equipment Manufacturer,
are out of tolerance for as-new equipment but meet the allowable wear
allowances.
4.5.4 Traceability
All pressure containing, pressure retaining, and pressure controlling
equipment is fully traceable in accordance with 16A standards as well as
the CEM standards and the history of the equipment is completely
documented.
RSL-1
X
RSL-2
X
X
X
RSL-1
RSL-2
4.6
Requirements for quality control records
4.6.1
General
RSL-3
X
RSL-3
X
X
All pressure containing, pressure retaining, and pressure
controlling equipment is traceable only back to heat lot but not in
accordance with both the 16A standards and the CEM standards.
There are gaps in the repair/remanufacture history of the equipment.
Traceability of at least one piece of pressure containing, pressure
retaining, or pressure controlling equipment has been lost.
In the event the original serialization is lost, the remanufacturer shall
designate a new unique identifier for the part or assembly.
Volumetric NDE parts - Sampling
When traceability has been lost for the part, the entire volume of each
part shall be volumetrically inspected (radiography or ultrasonic) after
heat treatment for mechanical properties and prior to machining
operations that limit effective interpretation of the results of the
examination
25
X
X
X
RSL-1
X
RSL-2
X
RSL-3
The quality control records required by this Standard are those documents and records necessary to
substantiate that all materials and equipment made to this Standard do conform to the specified
requirements.
4.6.2 NACE records requirements
Records required substantiating conformance of equipment to NACE requirements shall be in addition
to those described in other clauses of this Standard, unless the records required by this Standard also
satisfy the NACE MR0175 requirements.
4.6.3 Records control
The organization shall maintain a documented procedure to define the controls and responsibilities
needed for the initiation, identification, collection, storage, protection, retrieval, retention time, and
disposition of records.
Records, including those from outsourced activities, shall be established and controlled to provide
evidence of conformity to requirements and of the effective operation of the quality management
system.
Records shall be retained for a minimum of ten years following the date the equipment was received by
the service provider, or as required by customer, legal and other applicable requirements, whichever is
longer.
All records required by this Standard shall be signed and dated.
Records shall be legible, identifiable, retrievable and protected from damage, deterioration or loss.
26
API STANDARD 16AR
Records can be hard copies and/or computer-stored as defined in the organization records control
system procedure.
4.6.4 Records to be maintained by remanufacturer
4.6.4.1
General
The remanufacturer shall retain all documents and records as required in clause 5.6.4.1.
The remanufacturer shall provide a PHF and MDB in conformance with Annex B and Annex C to their
client in either electric format, hard copy or both, as specified in the purchase order by the client.
4.6.4.2
Parts or components covered in API 16A
The following records shall be retained:
1) weld procedure qualification record;
2) welder qualification record;
3) material test records:
― chemical analysis;
― tensile tests (QTC);
― impact tests (QTC, as required);
― hardness tests (QTC);
4) NDE personnel qualification records;
5) NDE records:
― surface NDE records;
― full penetration fabrication;
― weld volumetric NDE records;
― repair weld NDE records;
6) hardness test records;
7) welding process records:
― welder identification;
― weld procedures;
― filler material lot number;
― post-weld heat treatments and De-Hydrogen Treatments (DHT);
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
8) heat treatment records:
― actual temperature;
― actual times at temperature;
9) volumetric NDE records;
10) hydrostatic pressure test records;
11) critical dimensions as defined by the manufacturer.
27
28
API STANDARD 16AR
5. Quality Management System Requirements
5.1
Control of Documents
The quality management system documentation shall include:
1) Statements of quality policy and quality objectives;
2) A quality manual that addresses each requirement of this specification and includes:
― the scope of the quality management system, including justification for any exclusions to specific
quality management system elements;
― a description of the sequence and interaction between the processes of the quality management
system;
― identification of processes that require validation;
― reference to documented procedures that control the quality management system processes;
― documented procedures established for the quality management system;
― documents and records to ensure the effective planning, operation, and control of its processes
and compliance with specified requirements; and
― identification of legal and other applicable.
5.2
Training and Awareness
The organization shall:
1) Provide Quality Management System training to the organization’s personnel and contractors who
affect the execution of services or provision of service-related products;
2) Ensure that customer-specified training and/or customer-provided training, if required, is included in
the training program;
3) Maintain appropriate records on education, training, skills and experience.
5.3
Control of testing, measuring, monitoring equipment
The remanufacturer shall maintain a documented procedure which defines the required testing,
measurement, monitoring, and detection equipment to be controlled and necessary to provide
evidence that service or service-related product meets specified requirements.
The procedure shall address equipment traceability, frequency of calibration, calibration method,
acceptance criteria, suitable environmental conditions, storage and handling.
The procedure shall identify required assessments and maintain records when the validity of the
previous testing, measuring, monitoring, or detection results are found not to conform to calibration
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
29
requirements. The organization shall take appropriate action on the equipment and any service
affected.
Testing, measuring, monitoring and detection equipment shall have unique identification.
When the equipment is externally provided, the organization shall verify that the equipment is suitable
to provide evidence of conformity of service or service-related product to specified requirements.
5.4
Contract Review
5.4.1 General
The organization shall maintain a documented procedure for the review of contract requirements
related to the execution of services or provision of service-related products.
5.4.2 Determination of Requirements
The organization shall determine:
1) Requirements specified by the customer, including the requirements for service planning,
execution, and evaluation;
2) Legal and other applicable requirements;
3) Requirements not stated by the customer but considered necessary by the organization or
industry recognized Standards for the execution of service and provision of service related
product.
4) Documentation requirements pertaining to the certificate of compliance/conformance, MDB, PHF,
and any other required traceable documents.
Where the customer has provided incomplete, incorrect or unachievable requirements in the purchase
order, the customer requirements shall be informed by the remanufacturer and records maintained.
5.5
Purchasing Control
The organization shall maintain a documented procedure and qualification of outsourced services to
ensure that purchased or outsourced services and service-related products conform to specified
requirements.
Selection of outsourced service suppliers by the remanufacturer shall include the following prior to
initiation of the purchase agreement:
1) Assessment of the supplier at supplier’s facility to meet the organization’s purchasing
requirements, and
2) Verification that the supplier’s quality management system conforms to the quality system
requirements specified for suppliers by the organization.
30
5.6
API STANDARD 16AR
Design and Development
5.6.1 Design and Development Planning
The organization shall maintain a documented procedure to plan and control the design and
development of the product, including the use of service-related products.
The procedure shall identify:
1) the design and development stages;
2) the activities required for completion, review, and verification of each stage;
3) the interfaces between different groups involved in design and development; and
4) the responsibilities and authorities for the design and development activities.
The organization shall manage the interfaces between different groups involved in design and
development to ensure effective communication and clear assignment of responsibilities.
When design and development are outsourced, the organization shall ensure the supplier meets the
requirements of clause 6.6 and provide objective evidence that the supplier has met these
requirements.
5.6.2 Design documentation
Design documentation shall include the methods, assumptions, formulas and calculations.
5.6.3 Design and Development Inputs
Inputs relating to design of the product shall be determined and records maintained.
These inputs shall include:
1) customer-specified requirements
2) legal requirements; and
3) other applicable requirements including:
― requirements provided from an external source,
― requirements for products and service-related products, including its functional and technical
requirements,
― environmental and operational conditions
― historical performance and other information derived from previous similar product designs.
5.6.4 Design Verification
The design and development requirements are to be examined and confirmed to be in conformance
with specified requirements of the contract and relevant standards.
NOTE Design verification activities includes one or more of the following:
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
31
1) confirming the accuracy of design results through the performance of alternative calculations,
2) review of design output documents independent of activities of design and development,
3) comparing new designs to similar proven designs.
5.6.5 Design Validation
Design and development validation shall be performed in accordance with planned arrangements (see
clause 6.7.1) to ensure that the resulting product is capable of meeting the requirements for the
specified application or intended use, where known. Wherever practicable, validation shall be
completed prior to the delivery or implementation of the product. Records of the results of validation
and any necessary actions shall be maintained.
NOTE Design validation includes one or more of the following:
1) prototype tests;
2) functional and/or operational tests of production products;
3) tests specified by industry standards and/or regulatory requirements;
4) field performance tests and reviews.
5.6.6 Control of design and development changes
Design and development changes shall be identified and records maintained. The changes shall be
reviewed, verified and validated, as appropriate, and approved before implementation. The review of
design and development changes shall include evaluation of the effect of the changes on constituent
parts and product already delivered. Records of the results of the review of changes and any
necessary actions shall be maintained.
5.6.7 Control of nonconforming product
The organization shall ensure that product which does not conform to product requirements is
identified and controlled to prevent its unintended use or delivery. A documented procedure shall be
established to define the controls and related responsibilities and authorities for dealing with
nonconforming product.
When nonconforming product is corrected it shall be subject to re-verification to demonstrate
conformity to the requirements.
5.6.8 Field nonconformity analysis
The documented procedure for nonconforming product shall include requirements for identifying,
documenting and reporting incidents of field nonconformities or product failures. The documented
procedure shall ensure the analysis of field nonconformities, provided the product or documented
evidence supporting the nonconformity is available to facilitate the determination of the cause
32
API STANDARD 16AR
6. Responsibilities
6.1
OEM / CEM
1) The original product manufacturer (OEM) of the API product is responsible for compliance to the
standard in manufacturing / remanufacturing, documentation (Manufacturing Data Book (MDB) +
Project History File (PHF) and certification.
2) The OEM is responsible for the definition of the original product definition (OPD) and the ongoing
product design status.
3) The OEM is responsible for documenting design changes resulting from a malfunction or failure
history of drill-through equipment manufactured, remanufactured and / or repaired in the Original
Product Definition.
4) The OEM is responsible to audit OEM approved repair facilities in compliance with the
requirements of this product standard to assure compliance.
5) The OEM shall in accordance with the applicable API standard for manufacturing retain documents
required for repair and remanufacturing for ten years.
6) On request and in agreement with the equipment owner, the OEM will maintain the MDB and PHF
for periods exceeding the record keeping requirement of ten years as listed under this standard.
7) On request and in agreement with the equipment owner, the OEM will maintain the
decommissioning record for 5 years.
6.2
Repairer / Remanufacturer
1) The Repairer / Remanufacturer of the API product is responsible for compliance to the standard in
manufacturing, documentation (Manufacturing Data Book (MDB) + Project History File (PHF) and
certification.
2) The repairer / Remanufacturer shall provide the product owner with an overview of equipment
traceability and compliance to the OPD before selecting and agreeing the Remanufacturing Service
Level (RSL) in the purchase order.
3) The Repairer / Remanufacturer is responsible to audit Repairer / Remanufacturer approved repair
facilities in compliance with the requirements of this product standard to assure compliance.
4) The repairer / remanufacturer shall in accordance with the applicable API standard for
manufacturing retain documents required for repair and remanufacturing for ten years.
5) On request and in agreement with the equipment owner, the Repairer / Remanufacturer will
maintain the Manufacturing data book for periods exceeding the record keeping requirement of ten
years as listed under this standard.
6) On request and in agreement with the equipment owner, the Repairer / Remanufacturer will
maintain the decommissioning record for 5 years.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
6.3
Product Owner:
1) The product owner is responsible to keep an up to date MDB + PHF.
2) The product owner is responsible to keep the equipment in certification.
3) The product owner is responsible to document the requirements for the MDB + PHF in the
Purchase Order for repair and / or remanufacturing.
4) The product owner is responsible to document the required Remanufacturing Service Level for the
product in the Purchase Order for repair and / or remanufacturing.
5) The product owner is responsible to list the requirements for Third Party Inspection (TPI)
requirements in the Purchase Order for repair and / or remanufacturing.
6) The product owner is responsible to keep accurate records of product use and exposure to Sulfide
Stress Cracking environment.
7) The product owner is responsible for scheduling the required maintenance for the product,
including the recommendations from the OEM/CEM.
8) The product owner/operator is responsible for the product status verification and traceability, field
configuration assessment and service conditions, maintenance and service procedures, inspection
and test procedures, design status assessment and disposition, usage and performance history
evaluation, repair and selection of remanufacture procedures as described in this standard.
33
34
API STANDARD 16AR
7. Repair / Remanufacturing Service Level Minimum Requirements
7.1
General
Repair and remanufacturing under this standard excludes work performed on equipment under
maintenance.
Quality control requirements for specific equipment and parts as documented in clause 5.5 shall meet
or exceed the agreed Remanufacturing Service Level (RSL) as documented in the customer purchase
order.
The RSL for the entire system/assembly cannot be higher than the lowest RSL level of a part.
Parts that do not meet the minimum of RSL-1 quality requirements defined in clause 5.5 of this
standard are not considered suitable for service.
7.2
Original Equipment Manufacturer (OEM)
Throughout field life of an API 16A product the control of the design specification may change as result
of equipment being maintained / remanufactured by organizations other than those who own the
Original Product Definition (OPD).
The design owner or manufacturer of the traceable assembled equipment, single equipment unit, or
component part is the OEM.
NOTE: If any alterations to the original design and/or assembled equipment or component part are
made by anyone other than the OEM, the assembly, part, or component is not considered an OEM
product. The party that performs these alterations is then designated as the OEM as illustrated in
Annex E.
7.3
Requirements for Pressure Testing
7.3.1 General
All drill-through equipment shall be subjected to a hydrostatic proof test prior to shipment from the
service or repair facility. Water with soluble oil that also provides corrosion protection in the vapor
phase should be used as the testing fluid to avoid corrosion of the drill-through equipment. The type of
soluble oil and concentration used shall be documented in the test records. Water can be used in the
bore for pressure testing, but requires preservation of the drill-through equipment afterwards.
7.3.2 Hydrostatic Proof/Shell Test
Drill-through equipment shall be tested with its sealing mechanisms in the open position, if applicable.
Equipment repaired will require hydrostatic proof testing of the equipment to 1.0 x rated working
pressure.
Equipment remanufactured will require hydrostatic proof testing of the equipment to 1.5 x rated working
pressure.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
35
For equipment with end or outlet connections having different working pressures, the lowest rated
working pressure shall be used to determine the shell pressure test.
7.3.3 Operating Chamber Pressure Test
The hydraulic operating system test shall be tested on each assembled blowout preventer and
hydraulic connector.
The hydraulic operating chamber shall be tested at a minimum test pressure equal to 1.5 times the
operating chamber’s rated working pressure.
The hydrostatic proof test and the hydraulic operating chamber test shall consist of three steps:
― an initial pressure-holding period of not less than 3 min;
― reduction of the pressure to zero;
― a second pressure-holding period of not less than 15 min.
The timing of the test shall not start until the test pressure has been stabilized within the
manufacturer/remanufacturer specified range and the external surfaces have been thoroughly dried.
The acceptance criterion shall be zero leakage.
7.3.4 Closed-preventer test
Each ram and annular blowout preventer shall be subjected to a closed-preventer test after the
hydrostatic proof test. The hydraulic operating system pressure used shall be equal to or less than the
specified operating pressure.
The test fluids used for all closed preventer tests shall meet the requirements of 7.2.1.
The timing of all closed-preventer tests shall not start until the test pressure has stabilized.
Closed-preventer tests shall be performed at low and high pressures, with the low pressure test always
preceding the high pressure test.
7.3.5 Low Pressure Test
A pressure of 1.4 MPa to 2.1 MPa (200 psi to 300 psi) shall be applied and held below the closed ram
or annular packing unit for not less than 10 min after stabilization.
7.3.6 High Pressure Test
A pressure at least equal to the rated working pressure of the preventer shall be applied and held
below the closed ram or annular packing unit for not less than 10 min after stabilization (see exception
for annular packing units in section 7.2.8).
7.3.7 Acceptance Criteria
There shall be no visible leakage.
36
API STANDARD 16AR
7.3.8 Annular packing unit tests
Annular packing units shall be tested in two stages.
The stage one test shall require pressure-testing on the appropriate size drill pipe in accordance with
Table 2, unless otherwise specified by customer.
The stage two test shall require pressure-testing without drill pipe in the preventer, i.e. on the open
hole. The high pressure test for this stage shall be as specified in 7.2.6, except as a minimum it shall
be performed at 50% of the rated working pressure of the preventer.
Table 2 – Pipe Size Requirements
Bore Size
mm
179 and 228
279 and larger
Pipe Diameter
(in)
1
7 /16 and 9
11 and larger
mm
88.9
127.0
(in)
3½
5
7.3.9 Pipe, blind and variable-bore rams
These tests shall be performed with the appropriate size drill pipe for the rams being tested. VBRs
shall be tested on the minimum and maximum sizes for their range including pipe geometry changes
as defined in API 5DP.
7.3.10 Blind-shear rams
Each preventer equipped with blind-shear rams shall be subjected to a shearing test. The minimum
size shear pipe used shall conform to the requirements and reporting as listed in API-16A and Table 3
or unless otherwise specified by the customer.
Table 3 - Shear pipe requirements
BOP size
Shear pipe (minimum)
179 mm (7 1/16 in)
3 1/2 in 13.3 lb./ft Grade E-75
228 (9 in)
3 ½ inch 13.3 lb./ft Grade G105
279 mm (11 in)
5 in 19.5 lb./ft Grade G105
346 mm (13 5/8 in)
5 in 19.5 lb./ft Grade G-105
425 (16 ¾ in)
5 ½ inch 24.7 lb./ft Grade S135
476 (18 ¾ in)
5 ½ inch 24.7 lb./ft Grade S135
540 (21 ¼ In)
5 ½ inch 24,7 lb./ft Grade S135
Unless specified different by the customer, these tests shall as a minimum be performed without
tension in the pipe, in unconstrained condition in the BOP and with zero wellbore pressure.
We require qualification of the parts and system in conformance with API-16A. Would it then not
make sense to remove this requirement as the qualification is only required for a different
configuration of the BOP. Maybe when the BOP has received new bonnets from a different
manufacturer, this requirement is real.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
37
7.3.11 Rams lock test
This test determines the ability of the blowout preventer's ram-locking device to maintain a wellbore
pressure seal after removing the closing and/or locking pressure(s).
This test shall apply to each included ram that is designed to operate with the ram-locking system. The
preventer shall be tested after the rams are closed, the locks engage and then all operating
pressure(s) released.
7.3.12 Elastomeric Seal Requirements
All elastomer components used for FAT of units repaired or remanufactured in compliance with 16AR
must be fully design verified and validated in the BOP design in which they are being used.
7.3.13 Wellbore Sealing Components and Consumables
All BOP system elastomeric seal elements shall be addressed in the equipment owner’s PM program
for the system.
If the remanufacturer / manufacturer must provide components to allow for testing, those
parts/components will be removed after testing when conformance has been proven. Responsibility
will be with the equipment owner to add those components when putting the system into service.
Traceability must be maintained of the parts added to maintain compliance with the standard and to
maintain the equipment’s Operation Service Level.
Independent ram assemblies and operators will be treated as a separate component from the blowout
preventer.
7.3.14 Operating Sealing Components and Consumables
Identification of non-wellbore non-metallic components, such as elastomeric seals used in ram and
annular type BOP actuation systems, shall be in accordance with the manufacturer / remanufacturer
written specifications.
Markings and traceability must still be maintained and can be done through a traceable number by the
remanufacturer / manufacturer, permanently stamped or etched into the ram assembly.
Ram assemblies and operators will be provided with a separate certificate showing conformance or
compatibility (where applicable).
Specialized components, including proprietary design BOP seals and packing units, shall be stored in
accordance with the OEM recommendations.
7.4
Dimensional check
For recertification all API and sealing dimensions must be within product definition tolerances.
Corrosion must be removed and parts dimensional verified to have sufficient remaining strength in
conformance with the product definition.
38
API STANDARD 16AR
Wear tolerances defined in the product definition, must be used to verify if the part is suitable for
service.
Dimensional checks shall include at a minimum the following:
― Wear of all and sealing surfaces.
― Flange and Bore Dimensions
― Pressure Retaining Components
― Pressure controlling Components
― Any Critical Areas per the Product Definition
Dimensional must be documented and approved by a supervisor who is deemed competent and can
assure the technician is competent to record and take measurements in accordance with the
established QMS.
7.5
NDE – Initial Inspection
The following inspections shall be performed before proceeding with remanufacture of equipment.
― All well-fluid wetted surfaces shall be MPI or DPI inspected
― All welds shall be MPI or DPI inspected
― External surfaces shall be 100% visually inspected and any anomalies further investigated with
MPI or DPI
― Unacceptable indications found with MPI or DPI shall be removed.
If full weld records are not available it is advisable to acid etch the BOP to determine any previous
weld.
7.6
Inspection on closure bolting (pressure retaining)
If closure bolting identification is lost, it shall be replaced.
If closure bolting or other closing devices are intended for reuse, they shall undergo a thorough
inspection which includes:
― Wet particle MPI or DPI
― Hardness measurements on bolts & nuts
― Threads (internal / external) must be inspected for wear and stretch
― Bolt holes threads must be inspected for wear and confirmed to be within specification
― Bolt holes must be checked to verify if weld repairs have been made. Bolt hole surfaces should
be etched when traceability of repairs has been lost
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
39
― Full dimensional inspection of pressure retaining of non-threaded devices
7.7
Visual Inspection at disassembly
All parts shall be 100% visually inspected and includes but is not limited to:
― Critical wear areas and body structure
― All threaded lifting bolt holes
― Sealing surfaces
― Door/Bonnet assembly alignment
― Straightness of parts
― Flatness of seal areas
― Damage to running surfaces
― Corrosion / pitting
7.8
Drift Test
A drift test is required on ram BOP, annular BOP, hydraulic connectors, drilling spools and adapters.
Pass a drift mandrel through the bore of the assembly after all pressure testing.
Drift mandrel diameter shall be 1/32” (0.79mm) smaller than the bore diameter with a tolerance of
+0.01” / -0” (+0.25mm / - 0 mm).
Drift mandrel gauge length shall be at least 51 mm (2 in) longer than any cavity that intersects the
bore, but not less than 305 mm (12.0 in).
The taper on the drift should be 1/8” x 45 deg (3mm x 45 deg).
Time and temperature shall be recorded for the drift to pass the BOP.
7.9
Replacement Parts – Qualifications
All replacement parts shall be designed to meet or exceed the requirements of API-16A specification.
Replacement parts shall be fully design verified and design validated in conformance with Annex J.
Reused parts shall be fully traceable, design verified and design validated in conformance Annex J.
An assembly shall meet or exceed minimum API 16A performance criteria with the replacement part
fitted.
A Certificate of Usage Compatibility shall be provided with a replacement part which does meet or
exceed the full OEM or OPD specification, including all design verification and validation. Revise
wording in the definitions.
40
API STANDARD 16AR
Replacement parts must be documented in the PHF. Unique markings of the part shall provide the
traceability that allows verification of the part design status.
Equipment shall be reassembled in accordance with documented specifications of the repairer /
remanufacturer.
Parts shall not be reused if the serial markings are no longer legible or otherwise traceable to the part.
7.10
General Equipment Specifications
Equipment repaired and / or remanufactured under API 16AR shall general equipment specification in
conformance with Annex A.
7.11
Documentation
Repair and remanufacturing activities performed on the product shall be fully documented, supported
by the required certification and added to the PHF as defined in Annex-C. Annex-B must be added we
need it MDB is part of the the complete set of documentation.
Documentation must provide traceability as required under API 16A.
7.12
Failure Reporting
The equipment owner of blowout prevention equipment shall provide a written failure report to the
equipment manufacturer / of any malfunction or failure that occurs. Guidelines for failure reporting can
be found in Annex D.
.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
41
8. Materials
8.1
General
Unless specified differently in this standard, material requirements for API 16A equipment will be in
conformance with API 16A, clause 6.
This clause describes the material performance, processing and compositional requirements for
pressure-containing or pressure containing parts and all other parts which shall as a minimum satisfy
the OPD design requirements for the product repaired and /or remanufactured under this standard.
Metallic materials exposed to well bore fluids and gasses shall meet the design requirements of NACE
MR0175 / ISO 15156 does allow shear blades not to be Sulfide Stress Cracking (SSC) resistant.
Suitability of the shear blades that do not comply with the hardness limitations and its potential
influence on the sealing capability in SSC environment is the responsibility of the user.
Meeting NACE MR0175 / ISO 15156 for prevention of Sulfide Stress Cracking (SSC) can be achieved
by:
― Deployment of the Well Control Equipment in a non-SSC environment
― The use of the WCE in an inhibited fluid environment
― Material hardness shall not exceed 22HRC and care must be taken when hardness exceeds 26
HRC (rams only)
― The use of Corrosion Resistant Alloy (CRA) and its application that is SSC resistant.
8.2
Metallic Parts
A written material specification shall be required for all manufacturing / remanufacturing of metallic
pressure-containing, pressure-controlling and all other parts. The remanufacturer shall be capable to
meet or exceed the material specifications for the product as listed in the OPD, which shall contain the
following information:
― acceptance and/or rejection criteria;
― material composition with tolerance;
― material qualification;
― allowable melting practice(s);
― forming practice(s);
― heat treatment procedure, including cycle time and temperature with tolerances, heat treating
equipment and cooling media;
― NDE requirements;
― mechanical property requirements.
42
8.3
API STANDARD 16AR
Non-metallic parts
Each manufacturer shall have written specifications for all elastomeric materials used in the production
of drill-through equipment.
These specifications shall include the following physical tests and limits for acceptance and control:
― acceptance and/or rejection criteria
― physical property requirements.
― material qualification, which shall meet the equipment temperature and pressure class requirement.
― storage and age-control requirements.
― Hardness in accordance with ASTM D 2240 or ASTM D 1415;
― Normal stress-strain properties in accordance with ASTM D 412 or ASTM D 1414;
― Compression set in accordance with ASTM D 395 or ASTM D 1414;
― Immersion testing in accordance with ASTM D 471 or ASTM D 1414;
― Generic base polymer testing in accordance with ASTM D1418
8.4
Base metal material Identification
8.4.1 General
In order to start the repair and remanufacturing process control must also be established over the
material properties.
8.4.2 Original Material Test Records (MTRs).
If no original Material Tests Records are available, the following must be tested and documented to
establish material property requirements for pressure-containing members to meeting RSL-1:
― Determining hardness and approximant tensile values
― Determining Chemical composition
In order to meet the requirements of RSL-2 or 3, all the material property requirements for pressurecontaining members must be available or be re-established in conformance with section 9.5.
Pressure-containing members manufactured under API 6A and from only which the impact strength is
not available meets the requirements of RSL-2.
8.4.3 Determining Hardness and approximate ultimate tensile values:
Determining Hardness and approximate tensile values shall be done in accordance with
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
Brinell:
ASTM E10 (Brinell) or ASTM E110 (portable testing)
ISO 6506-1, Metallic materials, Brinell hardness test, Part 1
Rockwell:
ASTM E18 for Rockwell
ISO 6508-1, Metallic materials, Rockwell hardness test, Part 1: Test method (scales A, B, C, D, E, F,
G, H, K, N,T)
Vickers:
ASTM E384 for Vickers
ISO 6507-1, Metallic materials, Vickers hardness test, Part 1
Harness conversion shall be done in accordance with ASTM E 140, Hardness Conversion Tables for
Metals
The hardness of a material is in principle related to the UTS and not to the YS. Yield Strength and
Ultimate Tensile Strength show a linear correlation with hardness for most steels. However, for steel
that shows evidence of strain hardening, a lower strength can be measured for a given hardness.
There can be a non-linear relation between strength and hardness.
If uncertainty exists with respect to the material specification, it is required to validate the material
properties as per the RSL, clause 5.5.
8.4.4 Determining Chemical Composition:
In absence of material specifications for the parts of the system, PMI shall be used to confirm that the
material from the pressure containing and pressure controlling parts meets the requirements of the
product definition.
The material identification shall be done using an industry recognized process that is capable of:
― Determining carbon content
― Determining all alloying elements such that the material can be matched to a base material
specification.
― Determining Nickel and sulfur content for NACE MR0175 applications.
― Determining other types of non iron-based materials (i.e. type of overlay materials).
Prior to welding of carbon and low alloy steel, all elements in the carbon equivalency formula shall be
adequately identified as per ASME, QW-403.26 Section IX:
C.E. = C% + Mn%/6 + (Cr%+Mo%+V%)/5 + (Ni%+Cu%)/15
8.5 Pressure-containing members
8.5.1 Property requirements
Pressure-containing members shall be manufactured from materials as specified by the manufacturer
that meet the requirements of API16 and are listed in Table 4 and Table 5 below.
43
44
API STANDARD 16AR
Charpy V-notch impact testing shall conform to clause 9.4.5.2.
Table 4 — Material property requirements for pressure-containing members
Material
designation
36K
45K
60K
75K
Yield strength
2 % offset
min.
MPa
(psi)
248
36 000
310
45 000
414
60 000
517
75 000
Tensile strength
min.
MPa
483
483
586
655
(psi)
70 000
70 000
85 000
95 000
Elongation
in 50 mm
min.
%
21
19
18
18
Reduction
of area
min.
%
none specified
32
35
35
Non-standard materials yield as specified, Tensile as specified, elongation 15 % reduction in area 20%
Table 5 — Material applications for pressure-containing members
Rated working pressure
Part
Body
13.8 MPa
(2 000 psi)
20.7 MPa
(3 000 psi)
34.5 MPa
69.0 MPa
(5 000 psi) (10 000 psi)
36K, 45K, 60K, 75K
103.5 MPa
(15 000 psi)
45K
60K, 75K
138.0 MPa
(20 000 psi)
End connections
60K
75K
Blind flanges
60K
75K
Blind hubs
60K
75K
60K, 75K
Non-standard materials may be used that have a design stress intensity that is not less than that of the
lowest strength standard material permitted for the applications above.
8.5.2 Heat treating
In principle parts in the remanufacturing process can be fully normalized or annealed and again heat
treaded (quenched and tempered) with the aim to restore the material properties that meet the
minimum requirements of API 16A.
Normalized or annealed parts including any existing welds shall meet the base material chemical
composition requirements; if not, weld material shall be tested after full heat treatment.
A full QTC is required after the full heat treatment (normalized or annealed + Q&T) is completed.
Although normalizing or annealing may lead to distortion of dimensions, surfaces and tolerances of the
part, it may in some occasions be economical to do so.
All heat-treatment operations shall be performed utilizing equipment qualified in accordance with the
requirements specified by the manufacturer / remanufacturer (see Annex H for a recommended
practice).
Care should be taken in loading of material within furnaces such that the presence of one part does not
adversely affect the heat-treating response of any other part.
Temperature and times for heat treatment shall be determined in accordance with the manufacturer's /
remanufacturers written specification.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
45
Quenching shall be performed in accordance with the manufacturer's / remanufacturers written
specifications.
a) Water quenching
The temperature of the water or water-based quenching medium shall not exceed 38 °C (100 °F) at the
start of the quench, nor exceed 49 °C (120 °F) at the completion of the quench.
b) Oil quenching / Polymer
The temperature of any oil/polymer-quenching medium shall be greater than 38 °C (100 °F) at the start
of the quench.
8.5.3 Chemical composition
8.5.3.1 General
The remanufacturer shall specify the range of chemical composition of the material used to
remanufacture pressure-containing members.
Material composition shall be determined on a heat basis (or a remelt ingot basis for remelt grade
materials) in accordance with the manufacturer's written specification.
8.5.3.2 Composition limits
The chemical composition limits of pressure-containing members manufactured from carbon and low
alloy steels or martensitic stainless steels shall comply with API 16A.
8.5.4 Material qualification
8.5.4.1 Tensile testing
If yield strength 0.2% offset, tensile strength, elongation and reduction area must be reestablished for
the remanufacturing in order to meet RSL-2 and/or RSL-3 requirements, removing a test specimen
from the part is required.
Tensile test specimens shall be removed from a part and must meet dimensions as described in
section 8.5.8.
Tensile tests shall be performed at room temperature in accordance with the procedures specified in
ISO 6892 or ASTM A 370
A minimum of one tensile test shall be performed. The results of the tensile test(s) shall satisfy the
applicable requirements of API 16A. If the results of the first tensile tests do not satisfy the applicable
requirements, two additional tensile tests may be performed in an effort to qualify the material. The
results of each of these additional tests shall satisfy the requirements of API 16A.
8.5.4.2 Impact testing
If impact strength must be reestablished for the remanufacturing in order to meet RSL-2 and/or RSL-3
requirements, removing a test specimen from the part is required.
46
API STANDARD 16AR
Impact testing shall be performed on parts used for pressure-containing members.
Impact test specimens shall be removed from a part and must meet dimensions as described in
section 8.5.8.
Standard-size specimens of cross-section 10 mm  10 mm shall be used, except where there is
insufficient material, in which case the next smaller standard-size specimen obtainable shall be used.
When it is necessary to prepare sub-size specimens, the reduced dimension shall be in the direction
parallel to the base of the V-notch.
Impact tests shall be performed in accordance with ASTM A 370 using the Charpy V-notch technique.
In order to qualify material for an ISO temperature rating T-0, T-20 or T-75, T 350 the impact tests shall
be performed at or below the test temperature shown in Table 5.
Pressure containing members from which the impact strength is unknown shall not be higher classed
than T-0.
A minimum of three impact specimens shall be tested to qualify a part. The average of the impact
property value shall be at least the minimum value shown in Table 5. In no case shall an individual
impact value fall below 2/3 the required minimum average. No more than one of the three test results
shall be below the required minimum average.
If a test fails, then one retest of three additional specimens (removed from the same part may be
made. The retest shall exhibit an impact value for each specimen equal to or exceeding the required
minimum average.
The values listed in Table 6 are the minimum acceptable values for forgings and wrought products
tested in the transverse direction and for castings and weld qualifications.
Forgings and wrought products may be tested in the longitudinal direction instead of the transverse
direction, in which case they shall exhibit 27 J (20 ft-lb) minimum average value.
For equipment rated for 20,000 psi and higher pressure , the Charpy V –notch impact values shall be
in accordance with the class T-HP or table 23 or 68J (50ft-lb) minimum average in the longitudinal
direction
Table 6 — Acceptance criteria for Charpy V-notch impact tests
Temperat
ure rating
T-0,
T-20 T350
T-75
T-HP
Test temperature
°C
 18
 29
 59
-29
(°F)
0
 20
 75
-20
Minimum impact value
required for average of
each set of three
specimens
J
(ft-lb)
20
15
20
15
20
15
41
30
Minimum impact value
permitted for one specimen
only per set
J
14
14
14
33
(ft-lb)
10
10
10
24
Rated pressure can be de-rated for elevated temperature service over 250 degrees F per annex G of
API-6A.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
47
8.5.5 Qualification test coupons (QTC)
In remanufacturing the QTC used for reestablishing the material properties is removed from the part
requiring weld repair.
A QTC may be taken from an equal size part from the same heat number as the part requiring weld
repair to represent the impact and/or tensile properties, provided it satisfies the requirements of this
standard.
The properties exhibited by the QTC shall represent the properties of the material comprising the
equipment it qualifies.
When the QTC is a trepanned core or a prolongation removed from a production part, the QTC shall
only qualify parts having the same or smaller equivalent round (ER).
A QTC may only qualify material and parts produced from the same heat.
8.5.6 Equivalent round (ER)
8.5.6.1 General
The dimensions of a QTC for a part shall be determined using the following ER method.
8.5.6.2 ER methods
Annex-I illustrates the basic models for determining the ER of simple solid and hollowed parts and
more complicated equipment. The ER of a part shall be determined using the actual dimensions of the
part in the “as-heat-treated” condition.
8.5.6.3 Required dimensions
The ER of the QTC shall be equal to or greater than the dimensions of the part it qualifies, except the
size of the QTC is required not to exceed 125 mm (5 in) ER.
8.5.7 Processing
8.5.7.1 Melting practices
In no case shall the QTC be processed using a melting practice(s) cleaner than that of the material it
qualifies [e.g. a QTC made from a remelt grade or vacuum-degassed material may not qualify material
from the same primary melt which has not experienced the identical melting practice(s)].
Remelt grade material removed from a single remelt ingot may be used to qualify other remelt grade
material which has been processed in like manner and is from the same primary melt. No additional
alloying shall be performed on these individual remelt ingots.
8.5.7.2 Welding
Welding on the QTC is prohibited, except for attachment-type welds.
48
API STANDARD 16AR
8.5.7.3 Heat treating
All heat-treatment operations shall be performed utilizing “production type” equipment certified in
accordance with the manufacturer/remanufacturer written specification. “Production type” heattreatment equipment shall be considered equipment that is routinely used to process parts.
Qualification of heat treatment equipment shall be in conformance with Annex H.
The QTC shall experience the same specified heat-treatment processing as the parts it qualifies.
The QTC shall be heat-treated using the manufacturer/remanufacturer specified heat-treatment
procedures.
When the QTC is not heat-treated as part of the same heat treatment load as the parts it qualifies, the
austenitizing (or solution heat-treat) temperatures for the QTC shall be within 14 °C (25 °F) of those for
the parts.
The tempering temperature for the part shall be no lower than 14 °C (25 °F) below that of the QTC.
The upper limit shall be no higher than permitted by the heat-treatment procedure for that material. The
cycle time of the QTC at each temperature shall not exceed that for the parts.
8.5.8 Tensile and impact testing
It is allowable to remove tensile and impact specimens from multiple QTCs as long as the multiple
QTCs have had the same heat-treatment cycle(s).
Tensile and impact specimens shall be removed from the part such that their longitudinal centerline
axis is wholly within the center core ¼T envelope for a solid QTC or within 1 mm (¼ in) of the midthickness of the thickest section of a hollow QTC (see Annex-I).
For QTCs larger than the dimensions specified in Annex I, the test specimens need not be removed
from a location farther from the QTC surface than would be required if the specified QTC dimensions
were used.
When a sacrificial production part is used as the QTC, the test specimens shall be removed from a
section of the part meeting the dimensional requirements of the QTC for that production part.
8.5.9 Hardness testing
A hardness test shall be performed on the QTC after the final heat-treatment cycle.
Hardness testing shall be performed in accordance with procedures specified in ISO 6892 or
ISO 6506-1 as appropriate.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
49
9. Welding requirements
9.1 General
The welding specification of this standard defines the minimum requirements for joining and repairing
pressure containing and load bearing parts by fusion welding and for qualification of fusion-welding
procedures.
All welding of components exposed to wellbore fluid shall comply with the welding requirements of
NACE MR0175. Verification of compliance shall be established through implementation of the
manufacturer's written welding procedure specification (WPS) and the supporting procedure
qualification record (PQR).
When material specifications for pressure-containing and pressure-retaining components require
impact testing, verification of compliance shall be established through implementation of the
manufacturer's WPS and supporting PQR.
Welding shall be performed in accordance with welding procedure specifications (WPS), written and
qualified in accordance with ASME, BPVC:2004, Section IX, Article II. The WPS shall describe all the
essential, non-essential and supplementary essential (if required, see ASME, BPVC:2004, Section IX)
variables.
The PQR shall record the essential, and supplementary essential (if required) variables of the weld
procedure used for the qualification test(s). Both the WPS and PQR shall be maintained as records in
accordance with the quality control record requirements from section 5.6.3 and 5.6.4.
Welds from previous remanufacturing without sufficient documentation / traceability in the PHF to meet
the design specification of the manufacturer / remanufacturer of the product shall be removed.
9.2 Weldment design and configuration
9.2.1 Pressure-containing fabrication weldments
Pressure-containing fabrication weldments contain and are wetted by wellbore fluid.
Only full-penetration welds fabricated in accordance with the manufacturer's written specification shall
be used. Figures G.1 through G.3 in Annex-G are provided for reference.
Welding and completed welds shall meet the quality control requirements of clause 5.5.
9.2.2 Load-bearing weldments
Load-bearing weldments are those subject to external loads and not exposed to wellbore fluids.
Joint design shall be in accordance with the manufacturer's written procedures.
Welding and completed welds shall meet the quality control requirements of clause 5.5.
9.2.3 Repair welds
All repair welding shall be carried out in accordance with the manufacturer's written specification. All
repair welds to pressure-containing members performed subsequent to original heat treatment shall be
mapped.
50
API STANDARD 16AR
Welding and completed welds shall meet the quality control requirements of clause 5.5.
9.2.4 Weld surfacing (overlay) for corrosion resistance and wear resistance for material
surface property controls
9.2.4.1
9.2.4.1.1
Corrosion-resistant ring grooves
General
Standard dimensions for the preparation of type SR ring grooves for overlays are specified in API 6A,
section 10.
If equipment has metal-overlaid, corrosion-resistant ring grooves, the ring gasket type and number
shall be followed by “CRA” to designate a corrosion-resistant alloy, or “SST” to designate an austenitic
stainless steel.
9.2.4.1.2
Chemical analysis
Chemical analysis on the weld metal shall be performed in accordance with the requirements of ASME.
BPVC:2004, Section IX, at a location 3 mm (0.125 in) or less from the original base metal surface. The
chemical composition of the deposited base metal at the location shall be as specified by the
remanufacturer, OEM or OPD holder.
For austenitic or 300 series stainless steels, the chemical composition shall be given in Table 7.
Table 7 —Chemical composition of austenitic or 300 series stainless steels
For the nickel-based alloy UNS N06625, the chemical composition shall meet one of the classes given
in table 8
Table 8 —Chemical composition of the nickel-based alloy UNS06625
For the nickel-based alloy UNS N06625, the chemical composition Fe 5 specification should be
considered for equipment that remains subsea for prolonged times.
Welds for use in hydrogen sulphide service shall conform to the requirements of ISO 15156 (all parts),
NACE MR 0175.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
9.2.4.1.3
51
Application
― Post weld heat treatment:
End and outlet connections with corrosion-resistant weld-overlaid ring grooves shall be subjected to
post weld heat treatment in accordance with the WPS.
― Ring joint grooves for welding:
Ring grooves for welding shall be prepared in accordance with API 6A, table 52.
― Other weld preparations:
Other weld preparations may be used if the mechanical properties of the deposited weld metal equal or
exceed those of the base metal.
9.2.4.2 Other corrosion-resistant overlays other than ring grooves
The provisions of section 10.2.4.2 apply to the use of corrosion-resistant weld overlay for bodies,
bonnets, clamp hub end connectors, and end outlet connectors for the purposes other than API 6A
standard ring grooves.
The manufacturer shall use a written procedure that provides controls for consistently meeting the
manufacturer-specified material surface properties in the final machined condition. As a minimum, this
shall include inspection methods and acceptance criteria.
Qualification shall be in accordance with Articles II and III of ASME Boiler and Pressure Vessel Code
Section IX for corrosion-resistant weld metal overlay or hard facing weld metal overlay as applicable.
9.2.4.3 Chemical analysis
Chemical analysis of the weld metal shall be performed in accordance with the requirements of ASME.
BPVC:2004, Section IX, at the minimum overlay thickness as specified by the remanufacturer, OEM or
OPD holder for the finished component.
Provisions for the chemical analysis of section 9.2.4.1.2 apply.
9.2.4.4 Mechanical properties overlays
Base metal shall retain the minimum mechanical property requirements after post-weld heat treatment.
The manufacturer shall specify the methods to assure that these mechanical properties and record the
results as part of the PQR.
If the overlay material is considered part of the remanufacturer, OEM or OPD holder or API 16A design
criteria, mechanical testing of the overlay is required as part of the weld qualification.
9.2.4.5 Guided-bend tests
Guided-bend tests and acceptance criteria shall be in accordance with ASME, BPVC:2004, Section IX,
to confirm weld-overlay material bond integrity.
52
API STANDARD 16AR
9.2.4.6 Mechanical properties base material
Mechanical properties of the base material shall retain the minimum mechanical property requirements
after thermal treatment. The manufacturer shall specify the methods to ensure these mechanical
properties, and shall record the results as a part of the PQR.
9.2.4.7 Weld conformance overlays
Hardness test shall be performed at a minimum of three test locations in each base material, the heat
affected zone and in each layer of the overlay up to a maximum of two layers. See figure 3 required
hardness test locations.
Key
1
2
Weld
HAZ
3
Base
Dimensions in millimetres (inches)
Figure 3 —Hardness test locations for weld overlays
For corrosion-resistant ring groove overlay, chemical analysis shall be performed in the weld metal in
accordance with the requirements of ASME Section IX at a location of 3 mm (0.125 in) or less from the
original base metal surface.
The average of three or more test results shall be equal or greater than 83 HRB and recorded as part
of the PQR. The chemical composition of the deposited weld metal at that location shall be as specified
by the remanufacturer, OEM or OPD holder.
9.2.4.8 Quality control requirements
The remanufacturer, OEM or OPD holder shall use a written procedure that provides controls for
consistency meeting the specified material surface properties in final machined condition.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
53
9.3 Welding controls
9.3.1 Procedures
The manufacturer's system for controlling welding shall include procedures for monitoring, updating
and controlling the qualification of welders, welding operators and the use of welding-procedure
specifications.
9.3.2 Application
Welding shall be performed by personnel qualified in accordance with the requirements of clause 4.3.
Welding shall be performed in accordance with written WPS and qualified in accordance with Article II
of ASME Section IX. The WPS shall describe all the essential, non-essential and supplementary
essential (in accordance with ASME Section IX) variables. Welders and welding operators shall have
access to, and shall comply with, the welding parameters as defined in the WPS.
9.3.3 Designed welds
For all welds that are considered part of the design of a production part, the manufacturer shall specify
the requirements for the intended weld.
Dimensions of groove and fillet welds with tolerances shall be documented in the manufacturer's
specification. Figures 9 through 12 depict some typical joint designs.
9.3.4 Preheating
Preheating of assemblies or parts, when required, shall be performed in accordance with the
remanufacturer, OEM or OPD holder written procedures.
9.3.5 Instrument calibration
Instruments to verify temperature, voltage and amperage shall be serviced and calibrated in
accordance with the written specification of the manufacturer performing the welding.
9.3.6 Materials
9.3.6.1 Welding consumables
Welding consumables shall conform to American Welding Society (AWS) or the consumable
manufacturer's approved specifications.
The manufacturer shall have a written procedure for storage and control of welding consumables.
Materials of low-hydrogen type shall be stored and used as recommended by the consumable
manufacturer to retain their original low-hydrogen properties.
9.3.6.2 Deposited weld metal properties
The deposited weld metal mechanical properties shall meet or exceed the minimum specified
mechanical properties of the base material. Verification of properties shall be established through the
implementation of the manufacturer's WPS and supporting PQR. When materials of differing strength
are joined, the weld metal shall meet the minimum requirements of the lesser material.
54
API STANDARD 16AR
9.3.7 Post-weld heat treatment
Post-weld heat treatment of components shall be in accordance with the remanufacturer, OEM or OPD
holder written procedures.
Furnace post-weld heat treatment shall be performed in equipment meeting the requirements specified
by in Annex H and performed in accordance with the remanufacturer, OEM, or OPD holder procedure.
Local post-weld heat treatment may be performed with a qualified written procedure.
Local post-weld heat treatment shall consist of heating a band around the weld at a temperature within
the range specified in the qualified WPS. The minimum width of the controlled band adjacent to the
weld, on the face of the greatest weld width, shall be the thickness of the weld. Localized flame-heating
is permitted provided the flame is baffled to prevent direct impingement on the weld and base material.
When PWHT is required, all-weld-metal test coupons shall be PWHT’d with the nominal temperature
and maximum time to be used in production. The tensile strength, yield strength and elongation shall
meet the base metal properties.
Additional heat treatments that affect base metal and weld mechanical properties shall be included in
the qualification of the WPS.
Additional heat treatment procedures like de-hydration and Intermediate stress relief shall be
documented.
All WPS’s shall specify the following if PWHT or additional heat treatment is required:
― Holding temperature range
― Holding time
― Heating method
― Insulation
― Temperature control devices
― Recording equipment
In addition, the WPS should specify the following if PWHT or additional heat treatment is required:
― Maximum heating rate
― Maximum cooling rate
― Temperature gradients
If not specified on the WPS, the heating and cooling rates shall be identified in a in a documented
PWHT procedure, In accordance with ASME BPVC section VIII, DIV1, UCS-56 and B31.1 section
132.5.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
55
9.4 Welding procedure and performance qualifications
9.4.1 General
All weld procedures, welders and welding operators shall be qualified in accordance with the
qualification and test methods of Section IX, ASME Boiler and Pressure Vessel Code, as amended
below.
9.4.2 Base metals
The manufacturer may use ASME Section IX P number materials. In principle, materials not listed in
ASME BPCV Section IX must have their own WPS.
The manufacturer may establish an equivalent P number (EP) grouping for low alloy steels not listed in
ASME Section IX with nominal carbon content equal to or less than 0.35 %.
Low alloy steels not listed in ASME Section IX with nominal carbon content greater than 0.35 % shall
be specifically qualified for the manufacturer's specified base material.
Qualification of a base material at a specified strength level also qualifies that base material at all lower
strength levels.
9.4.3 Filler material qualification
Filler metals shall be specified in each WPS by ASME II, Part C/AWS specification and classification or
other recognized international standard.
Welding consumables shall be clearly identified by trade name, as applicable, and the identity
maintained until consumed.
9.4.4 Chemical Analysis
Chemical analysis of the base materials and filler metal for the test weldment shall be obtained from
the supplier or by testing, and shall be part of the PQR.
9.4.5 Heat-treat condition
All testing shall be done with the test weldment in the post-weld heat-treated condition. Post-weld heat
treatment of the test weldment shall be according to the remanufacturer, OEM or OPD holder written
specifications.
9.4.6 Procedure qualification record
The PQR shall record all essential and supplementary essential (when required by ASME) variables of
the weld procedure used for the qualification test(s). Both the WPS and the PQR shall be maintained
as records in accordance with the requirements of Clause 4.
56
API STANDARD 16AR
9.5 Other Welding Qualification requirements
9.5.1 ASME Section IX, Article I — Welding general requirements
9.5.1.1 General
Article I of ASME Section IX shall apply with additions as given below.
9.5.1.2 Hardness testing
9.5.1.2.1 General
Hardness testing shall be conducted across the weld and base material heat-affected zone (HAZ)
cross-section and shall be recorded as part of the PQR.
Results on all pressure-containing and pressure-controlling parts exposed to wellbore fluid shall be in
conformance with NACE MR0175 requirements.
The remanufacturer, OEM or OPD holder shall specify the hardness testing locations in order to
determine maximum hardness.
Testing shall be performed on the weld and base-material HAZ cross-section in accordance with ISO
6508 (all parts) or ASTM E18, Rockwell method; or ISO 6507 (all parts), using the 98 N method or
ASTM E384, Vickers 10 kgf method.
Results shall be converted to Rockwell C, as applicable. ISO 18265 or ASTM E140 shall be used for
the conversion of hardness readings for materials within the scope of their application.
Other conversion tables also exist. Users may establish correlations for individual materials outside the
scope of ISO 18265 or ASTM E140.
9.5.1.2.2 Rockwell method (ISO 6508-1)
If the Rockwell method is selected by the manufacturer, the following procedure shall be used:
a) for a weld cross-section thickness less than 12 mm (1/2 in), four hardness tests each shall be
made in the base material(s), the weld and the HAZ;
b) for a weld cross-section thickness equal to or greater than 12 mm (1/2 in), six hardness tests each
shall be made in the base material(s), the weld and the HAZ;
c) HAZ hardness tests shall be performed in the base material within 1.5 mm (0.06 in) of the weld
interface and at least one each within 3 mm (0.125 in) from top and bottom of the weld. See
Figure 4 for test locations.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
Key
1
Weld
2
3
HAZ
Base
a
Typical
57
Dimensions in millimetres (inches)
Figure 4 — Rockwell hardness test locations
9.5.1.2.3 Vickers method (ISO 6507-1)
If the Vickers method is selected by the manufacturer, the following procedure shall be used:
a) for a weld cross-section thickness less than 12 mm (1/2 in), four hardness tests each shall be
made in the base materials and the weld;
b) for a weld cross-section thickness equal to or greater than 12 mm( ½ in), six hardness tests each
shall be made in the base material(s) and the weld;
c) multiple HAZ hardness tests equally spaced 3 mm (0.125 in) apart shall be performed in each of
the base materials within 0.25 mm (0.01 in) of the weld interface and at least one within 1.5 mm
(0.06 in) from the top and the bottom of the weld. See Figure 5 for test locations.
Dimensions in millimetres (inches)
Key
1
Weld
58
API STANDARD 16AR
2
HAZ
3
Base
a
Typical
Figure 5 — Vickers hardness test locations
9.5.1.2.4 Hardness testing (optional) — Minimum mechanical properties
For the purpose of hardness inspection and qualifying production weldments, a minimum of three
hardness tests in the weld metal shall be made and recorded as part of the PQR. These tests shall be
made by the same methods used to inspect production weldments. These tests may be used to qualify
weld metal with hardness less than shown in 8.5.1.4 by the method shown in the same subsection.
9.5.1.3 Impact testing
When impact testing is required by the base material specification, the testing shall be performed in
accordance with ASTM A 370 using the Charpy V-notch technique. Results of testing in the weld and
base material HAZ shall meet the minimum requirements of the base material. Records of results
shall become part of the PQR.
When impact testing is required of the base material, one set of three test specimens each shall be
removed at the 1/4 thickness location of the test weldment for each of the weld metal and base
material HAZ. The root of the notch shall be oriented normal to the surface of the test weldment and
located as follows:
a) weld metal specimens (three each) 100 % weld metal;
b) HAZ specimens (three each) shall include HAZ material as specified in the manufacturer's written
procedure;
c) when weld thickness of the product is equal to or greater than 50 mm (2 in), impact testing shall
be performed on weld metal and HAZ material removed within 1/4 thickness.
9.5.2 ASME Section IX, Article II — Welding procedure qualifications
9.5.2.1 General
Article II of ASME Section IX shall apply with additions as shown in this section.
9.5.2.2 Heat treatment
The Post-Weld Heat Treatment (PWHT) of the test weldment and the production weldment shall be in
the same range as that specified on the WPS. Allowable range for the post-weld heat treatment on the
WPS shall be a nominal temperature of  14 °C ( 25 °F). The stress-relieving heat-treatment(s)
time(s) at temperature(s) of production parts shall be equal to or less than that of the test weldment.
For Quenched & Tempered and Normalized & Tempered materials, the PWHT holding temperature
shall be at least 25 deg F below the original tempering temperature of the base material.
Weld qualifications must be designed
If weld procedures do not allow additional PWHT cycles after repair, then the client shall be notified.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
59
9.5.2.3 Bolt tapped and blind hole repair procedure qualification
Dan text on this from the paper.
9.5.3 ASME Section IX, Article III — Welding performance qualifications
9.5.3.1 General
Article III of ASME Section IX shall apply with additions as shown in this subsection.
9.5.3.2 Bolt, tapped and blind hole repair performance qualification
The welder or welding operator shall perform an additional repair welding performance qualification
test using a mock-up hole (refer to Annex G, Figure G.2).
The repair welding qualification test hole shall be qualified by radiography according to clause 5, or
shall be cross-sectioned through the centerline of the hole and both faces shall be examined by NDE
in accordance with clause 5. This evaluation shall include the total depth of the hole.
The repair weld qualification shall be restricted by the following essential variables for performance
controls.
a) The hole diameter used for the performance qualification test is the minimum diameter qualified.
Any hole with a diameter greater than that used for the test shall be considered qualified.
b) The depth-to-diameter ratio of the test hole shall qualify all repairs to holes with the same or
smaller depth-to-diameter ratio.
c) The performance qualification test shall have straight parallel walls. If any taper, counter-bore or
other aid is used to enhance the hole configuration of the performance test, that configuration shall
be considered an essential variable.
For welder performance qualification, ASME Section IX P-1 base metals may be used for the test
coupon in place of the low alloy steels covered by this standard (Table 20).
9.5.4 ASME Section IX, Article IV — Welding data
Article IV of ASME Section IX shall apply as written.
9.6 Other requirements
Where metallic permanent backing material is permitted, the P-number or its nominal chemical
composition shall be specified in the WPS and/or the applicable fabrication drawing. For joints between
similar materials, the chemical composition of backing materials shall match the nominal base metal
chemical composition.
Temporary attachments welded to the base metal shall be compatible with the base metal and welded
in accordance with a qualified weld procedure.
60
API STANDARD 16AR
Temporary attachments shall be removed by gouging or grinding and the base metal restored to its
original condition before final heat treatment (if required), pressure testing, and final acceptance. The
base metal shall be inspected with MT or PT upon removal of the attachment.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
10.
61
Decommissioning
The Repairer / Remanufacturer is responsible for determining, documenting and executing
requirements for the decommissioning of API 16A products. The equipment owner shall be informed
when API 16A products cannot (economically) meet the minimum requirements of this standard.
At the end of the decommissioning process, a report shall be written capturing the date and location of
the decommissioning.
All documentation shall be retained and available for a minimum of five years past the date of
decommissioning of the equipment.
The decommissioning report shall be approved by the owner/operator and included in the PHF.
11.
Marking requirements
All equipment, as listed in Section 1, manufactured in accordance with this standard shall be marked in
accordance with the procedure and requirements API 16A.
11.1
Low-stress-area marking
For identification on low-stress areas (such as nameplates, outside diameters of flanges, etc.), the use
of sharp “V” stamping is acceptable.
11.2
High-stress-area marking
For identification on high-stress areas, dot, vibration or round “V” stamping is acceptable. Sharp “V”
stamping is allowed in high-stress areas only if subsequent stress-relieving is performed to the
component.
11.3
Weld metal overlays
When equipment has weld metal-overlaid ring grooves, the ring gasket type and number shall be
followed by “CRA” to designate a corrosion-resistant alloy or “SST” to designate an austenitic stainless
steel.
11.4
Wellbore non-metallic components
For identification of wellbore non-metallic components, such as ram and annular-type BOP packers
and seals, the manufacturer shall have a written procedure for affixing the required codification to the
product or its package.
The remanufacturer / manufacturer shall retain a certificate of compliance for non-metallic sealing
materials and molded sealing assemblies to manufacturer's written requirements.
11.5
Non-wellbore non-metallic components
Identification of non-wellbore non-metallic components, such as elastomeric seals used in ram and
annular type BOP actuation systems, shall be in accordance with the manufacturer's written
specification.
62
11.6
API STANDARD 16AR
Specific codification requirements of equipment
Ring gaskets shall be marked in accordance with API 6A.
Studs and nuts shall be marked in accordance with API 20E.
Closure bolting shall be marked in accordance with API 20E.
Wellbore non-metallic components shall be marked with an alphanumeric code system in the
sequence denoted in API 16A.
In addition, the manufacturer's part number shall be marked on the component.
11.7
Product description code (PDC)
The product description code (PDC) is used as an aid in describing equipment manufactured to this
standard. The PDC is a twelve digit number that can be used to fully describe the equipment to which it
is applied. The location and meaning of the digits that make up the PDC are described in API 16A.
Equipment shall be stamped on the product with the product description code (PDC) or alphanumeric
code, followed by API 16A.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
63
12. Storing and shipping
12.1 Storing for periods greater than 30 days
12.1.1 Draining after testing
All equipment shall be drained after testing and prior to storage.
12.1.2 Rust prevention
Prior to storage, parts and equipment shall have exposed metallic surfaces protected with a rust
preventative which will not become fluid at temperatures below 50 °C (125 °F).
12.1.3 Connection-surface protection
All connection faces and ring gasket grooves shall be protected with durable covers.
12.1.4 Hydraulic operating system
The hydraulic operating system shall be flushed with a non-freezing, corrosion-inhibiting fluid in
accordance with the equipment manufacturer's written procedures.
Ports shall be plugged prior to storing.
Equipment may be stored with customer specified control fluid to avoid contamination with corrosion
inhibiting fluid.”
It is recommended to paint stencil on the outside of the connector near the operating control ports
“Shipped with fluid xxxxx.”
CAUTION
Mixing of OEM control fluids may create highly caustic compounds. These compounds
can cause extreme damage to lip seal elastomers.
12.1.5 Elastomeric seals
Elastomeric seals shall be stored in accordance with the manufacturer's written procedures.
12.1.6 Ring gaskets
Loose ring gaskets shall be wrapped or boxed for storage and shipping.
12.2 Shipping
All equipment shall be shipped in accordance with the manufacturer's written procedures.
64
API STANDARD 16AR
13.
Certification
13.1
Certificate of Conformance
Minimum requirements for the Certificate of Conformance (COC) shall be used to certify repairs and
remanufacturing under this standard. The minimum requirements for the COC are listed in Annex F.
13.2
Certificate of Fit, Form and Function
Replacement parts other than those supported by the OEM product definition shall be supported by a
Certificate of Fit, Form and Function in the PHF.
13.3
Certificate of Service
Equipment inspection, service and maintenance performed should be documented by Certificate of
Service in the PHF.
13.4
Statement of Fact
Maintenance / repair performed on a part or system which is either not covered by a full service history
and required traceability, or the maintenance / repair was made with limited scope defined by the
Owner, should be documented by a Statement of Fact in the PHF.
13.5
Certificate of Statutory Compliance
Other equipment conformance requirements in addition to those covered under Section 13.1, 13.2,
13.3 and 13.4 should be the Certificate of Conformance, Certificate of Fit, Form and Function,
Equipment Requirements Where required the Manufacturer, Repairer, Remanufacturer, or recognized
technical authority certifies that the equipment and / or system meets the required standards or rules
as depicted in the relevant area of operations regulatory requirement
document in which the Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the equipment and / or system meets the required standards or rules as depicted in the
relevant area of operations regulatory requirement
3.1.14
Certificate of Conformance
COC
document in which the Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the assembly or part has been manufactured / remanufactured in conformance to the
mentioned standard(s), specifications and guidelines in accordance with the product definition,
including design changes resulting from a malfunction or failure history of drill-through equipment
manufactured, remanufactured and / or repaired to the appropriate standard/specification
3.1.15
Certificate of Fit, Form and Function
document in which a Manufacturer, Repairer, Remanufacturer, or recognized technical authority
certifies that the component or assembly meets or exceeds the product definition requirements.,
including design changes resulting from a malfunction or failure history of drill-through equipment
manufactured, remanufactured or repaired to the applicable Recognized International Standard /
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
65
Specification and is fully compatible with the product definition and can be integrated into other
systems guaranteeing the operations envelope.
3.1.16
Certificate of Service
COS
document in which the equipment Manufacturer, Repairer, Remanufacturer, recognized technical
authority / Owner or Operator certifies that the equipment has been inspected, properly maintained and
tested in accordance with the applicable Equipment Owner’s Quality Management System, Original
Equipment Manufacturer (OEM) or Current Equipment Manufacturer (CEM) specifications and meets
the API 16AR, RSL-1, 2 or 3 requirements.
66
API STANDARD 16AR
Annex A
(Normative)
General Equipment Specifications
A.1
General
This annex provides specifications for repair and remanufacturing of equipment covered by the scope of API
16AR.
A.2
Blowout preventers and drilling spools
A.2.1
Size designation
Equipment to which this standard is applicable shall have a vertical through-bore dimension (drift diameter)
corresponding with the size designation as shown in Table A1.
Table A1 — Equipment size
Nominal size designation
mm
(in)
179
7 1/16
228
9
279
11
346
13 5/8
425
16 3/4
476
18 3/4
527
20 3/4
540
21 1/4
680
26 3/4
762
30
A.2.2
Service conditions
A.2.2.1
Rated working pressure
Drift diameter
mm
(in)
178.61
7.032
227.84
8.970
278.64
10.970
345.31
13.595
424.69
16.720
475.49
18.720
526.29
20.720
538.99
21.220
678.69
26.720
761.24
29.970
The rated working pressure is determined by the lowest pressure rating of all integral end or outlet connections.
Equipment to which this standard is applicable shall be rated in only the rated working pressures shown in
Table A2.
Table A2 — Equipment rated working pressures
MPa
6.9
13.8
20.7
34.5
69.0
103.5
138.0
(psi)
1 000
2 000
3 000
5 000
10 000
15 000
20 000
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
A.2.2.2
67
Temperature ratings
Minimum temperature is the lowest ambient temperature to which the equipment may be subjected. Maximum
temperature is the highest temperature of the fluid that may flow through the equipment.
A.2.2.2.1 Temperature ratings for metallic materials
Equipment shall be repaired or remanufactured for metallic parts to operate within the temperature ranges shown
in Table A3. Equipment from which traceability is lost or from which material properties cannot be reconstructed,
will be temperature classified to T-0.
Table A3 — Temperature ratings for metallic materials
Operating range
°C
°F
 59 to 121
 75 to 250
 29 to 121
 20 to 250
0 to 250
 18 to 121
-29 to 177
-20 to 350
Classification
T-75
T-20
T-0
T 350
Note: Information on strength of materials at elevated temperatures is found in annex G of API 6A and TR 6MET
A.2.2.2.2 Temperature ratings for non-metallic sealing materials
Equipment shall be repaired or remanufactured for wellbore elastomeric materials to operate within the
temperature classifications of Table A4.
Table A4 — Temperature ratings for non-metallic sealing materials
Upper
Operating
Limit
(second
digit)
Lower
Limit
(first
digit)
Code
Temperature
F
C
A
-15
-26
B
0
-18
C
10
D
Code
Upper
extreme
limit
(third
digit)
Temperature
F
C
A
150
66
B
180
82
-12
C
210
20
-14
D
E
30
-1
F
40
G
Other
Code
Temperature
F
C
A
180
82
B
200
93
99
C
220
104
240
116
D
250
121
E
270
132
E
300
149
4
F
300
149
F
350
177
Other
G
Other
Other
G
Other
Other
Example: Material "FDE" has a lower temperature rating of 40 degrees F , a continuous
elevated temperature rating of 240 degrees F and an extreme temperature limit of 300 degrees F
All other elastomeric seals shall be designed to operate within the temperature ranges specified in the OEMs
written specifications or OPD.
A.2.2.2.3 Wellbore elastomeric materials
The purchaser shall provide the temperature range for which wellbore elastomeric materials must operate.
68
A.2.3
API STANDARD 16AR
Outlet connections
The purchaser shall determine the number, location, size, pressure and temperature ratings for all outlet
connections. It should be noted that the pressure rating for the BOP or drilling spool is determined by the lowest
pressure rating of all end or outlet connections.
Flanged end and outlet connections shall be in conformance to the dimensional requirements of API
Specification 6A and API Specification 16A, section 5.3 prior to assembly and testing.
A.2.4
Equipment details/data book
On request of the purchaser, and when specified in the contract, a data book shall be supplied, which shall meet
or exceed the requirements for the Manufacturing Data Book (MDB) and / or Project History File (PHF), as listed
in Annex B and Annex C.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
69
Annex B
(Normative)
Manufacturing Data Book Requirements
The below mentioned document contents for the construction of the Material Data Book (MDB) shall be provided
and recorded in order to provide the minimum traceability requirements for maintenance and remanufacturing of
pressure control equipment manufactured under API 16A.
Manufacturing Data Book (MDB)
Delivered to Client
Maintained by
Manufacturer
√
√
√
√
√
√
√
√
√
√
b) Chemical Analysis
√
√
c) Tensile tests (QTC) or prolongation
√
√
d) Impact tests (QTC as required) or
prolongation as required
e) Hardness tests (QTC) or prolongation.
√
√
√
√
May be difficult to get for older products,
can be retrieved if brought in for repair at
original facility
√
Document Contents
Purchase order number/sales order number
Date of Manufacturing
Serial Numbers of equipment and location
Assembly drawings showing:
 Actual overall package dimensions
 Pressure rating
 End connection/outlet description
 Mass,
 Centre of gravity,
 List of materials for components defined
in API Specification 16A, section 8.5.1
and the location of their use.
Manufacturer's statement of compliance to
current edition of API Specification 16A.
Design Verification Report
 Rated Working Pressure
 Temperature ratings
 SMYS
 UTS
 NACE
 Other specific customer requirements
Material Test Records (including the following):
a) Certified Material test reports
f) NDE Personnel qualification records
70
API STANDARD 16AR
Manufacturing Data Book (MDB) continued.
Delivered to Client
Maintained by
Manufacturer
√
√
√
Most OEM's give a Weld Data Sheet
which includes:
- Welder ID
- Filler Metal
- Heat and/or batch number
- WPS #
- Stress Charts
- PWHT
√
All remaining
documentation
required as defined
in API 16A are kept
at OEM facility for
required length of
time
a) Surface NDE Records
√
√
b) Full penetration fabrication
√
√
c) Weld volumetric NDE records
√
√
d) Repair weld NDE records
√
√
√
√
√
√
√
√
√
√
√
Limited scope and pressure test only
√
Document Contents
Material Specification Number
Welding Process Records
NDE Records:
Heat Treatment Records
a) Actual Temperature
b) Actual times at temperature
Third Party or Class Society Inspection Reports
Test Report(s), Pressure Testing and FAT
a) Volumetric NDE Records / radiographic UT
Records
b) Hydrostatic pressure test records
c) Critical dimensions (as defined by OEM)
Certificate of Conformance
a) include standard to which equipment is
certified to
√
√
Limited scope and basic dimensions only Critical dimensions
(height, weight, etc…)
kept by OEM.
√
√
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
71
Annex C
(Normative)
Product History File Requirements
The below mentioned document contents for the construction of the Product History File (PHF) shall be provided
and recorded in order to provide the minimum traceability requirements for maintenance and remanufacturing of
pressure control equipment manufactured under API 16A.
Traceability shall be provided by the repairer / remanufacturer in the PHF for the parts being either original parts
or non-original parts.
Product History File (PHF) Repair with Original Parts Only
Document Contents
Manufacturing Data Book
Serial Numbers of equipment and location
Design Verification Report
Third Party or Class Society Inspection Reports
Test Report(s), Pressure Testing and FAT
Delivered to Client
√
√
Still covered by original design
verification , however design
verification reports remain proprietary
to OEM
√
Maintained by
Manufacturer
N/A
N/A
N/A
N/A
N/A
√
N/A
b) Hydrostatic pressure test records
√
Limited scope and pressure test only
N/A
c) Critical dimensions (as defined by OEM)
√
Limited scope and basic dimensions
only (height, weight, etc…)
√
N/A
a) Volumetric NDE Records / radiographic
UT Records
Certificate of Conformance
a) include standard to which equipment is
certified to.
N/A
72
API STANDARD 16AR
Product History File (PHF) Repair with NON-OEM Parts Only
Manufacturing Data Book
(if available)
√
N/A
Serial Numbers of equipment and location
√
N/A
Repair facility will be required to
ensure that all design verification is
compliant with API 16A.
N/A
PMI Test
√
N/A
Material Specification Number
√
N/A
√
Most OEM's give a Weld Data Sheet
which includes:
- Welder ID
- Filler Metal
- Heat and/or batch number
- WPS #
- Stress Charts
- PWHT
√
N/A
√
N/A
√
N/A
√
N/A
√
N/A
b) Hydrostatic pressure test records
√
Limited scope and pressure test only
N/A
c) Critical dimensions (as defined by OEM)
√
Limited scope and basic dimensions
only (height, weight, etc…)
N/A
√
N/A
Design Verification Report
(if available)
Welding Process Records
(if applicable)
NDE Records
Heat Treatment Records (if applicable)
Third Party or Class Society Inspection Reports
Test Report(s), Pressure Testing and FAT
a) Volumetric NDE Records / radiographic
UT Records
Certificate of Compatibility
a) include standard to which equipment is
certified to.
N/A
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
73
Annex D
(Normative)
Failure reporting
D.1
User Recommendations
The equipment owner of blowout prevention equipment shall provide a written failure report to the equipment
manufacturer of any malfunction or failure that occurs.
The failure report shall include the following:
― as much information as possible on the operating conditions that existed at the time of the malfunction or
failure;
― an accurate a description as possible of the malfunction or failure;
― any operating history of the blowout prevention equipment leading up to the malfunction or failure (e.g. field
repair, modifications made to the blowout prevention equipment, etc.).
The manufacturer shall respond to receiving the failure report and provide a timeline to provide failure resolution.
D.2
Manufacturer’s Recommendations
D.2.1
Manufacturer’s Internal Recommendations
All significant problems experienced with blowout prevention equipment noted during its manufacture, testing or
use shall be formally communicated to the individual or group within the manufacturer's organization responsible
for the design and specification documents.
The manufacturer shall have a written procedure that describes forms and procedures for making this type of
communication, and shall maintain records of progressive design, material changes, or other corrective actions
taken for each model and size of blowout prevention equipment.
D.2.2
Manufacturer’s External Recommendations
All significant problems experienced with blowout prevention equipment shall be reported in writing to each and
every equipment owner of the blowout prevention equipment within three weeks after the occurrence.
The manufacturer shall communicate any design changes resulting from a malfunction or failure history to every
equipment owner using the affected equipment. That notice shall be within 14 days after the design change.
74
API STANDARD 16AR
Annex E
(Normative)
Design ownership
If any alterations to the original design and/or assembled equipment or component part are made by anyone
other than the OEM, the assembly, part, or component is not considered an OEM product. The party that
performs these alterations is then designated as the Current Equipment Manufacturer (CEM).
Used pressure
control equipment
Remanufacture
(hot work and / or
machining)
Repair / replacement
parts
Yes
Current Verified and
validated product
definition
No
Yes
All Parts in assembly are in
conformance with product
definition for the assembled
system, subassembly or
product.
Yes
OEM/CEM controls the specification
for the assembled system,
subassembly or product after repair
and will provide a COC
Part in conformance
with remanufacturers
verified and validated
product definition
No
Owner / User controls the specification of
the hybrid system, unless one of the
suppliers of parts adopts the assembled
system, subassembly or product as CEM
and will provide a COC.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
75
Annex F
(Informative)
Minimum requirements for Certificate Of Conformance (COC)
Example
Company Name
Company Address
Company telephone number
Company Registration No.: 16AR-0000
Certificate No.: ABC-14-0001
CERTIFICATE OF CONFORMANCE
Certificate No. :
Customer :
Customer Reference No.:
Date of Remanufacture:
Customer Purchase Order:
Work Order No.:
A. Assurance:
This is to confirm that the drill through equipment remanufactured per the above purchase order and as listed
below have been inspected and/or remanufactured and maintained in accordance with the following:
1. API Spec.16AR “Specification for Drill-through Equipment Repair and Remanufacture”, 1st Edition
2. Companies current understanding of implementation and interpretation of Jurisdictional
regulations listed here:
a. …………..
b. …………..
In addition, the following additional standard(s) have been used in support of the repair and remanufacture of the
equipment listed on this certificate:
 API Spec16A “Specification for Drill-through Equipment”, 3rd Edition
 ……………
 ……………
Controlled Document No.
Revision Date/Level
Page 1 of 2
76
API STANDARD 16AR
B. The certification is related to the following operational limitation:
Maximum Working Pressure:
Design Temperature (minimum to maximum):
Sour Service according to NACE MR0175 / ISO 15156:
Yes / No
Other limitation:
C. List of inspected equipment:
Item
Assembly or Part No.
Qty.
Description
Serial Number(s)
1
2
3
D. Comments:
 It is the responsibility of the owner to ensure that risk analysis is considered and carried out prior to every
operation including subject equipment when evaluating the risk situation.
 All documentation in support of the above listed products is retained on file by the Company for a
minimum of 10 years for repair / remanufacture.
 All documents and inspection reports to support this certificate of conformance have been verified to the
best of my knowledge to be true and correct.
 All documents and inspection reports to support this certificate of conformance have been added to the
Project History File.
E. Conditions
 Non-metallic sealing material shall be capable of functioning at specified design temperature and at
retained fluid rating, Sour Service, NACE MR0175 / ISO 15156.
Certificate of Conformance Approval
Signature
Signature
Name:
Title:
16AR-0000
Name:
Title:
Company disclaimer or Quality disclaimer if so desired by the organization.
Controlled Document No.
Revision Date/Level
Page 2 of 2
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
Annex G
(Informative)
Recommended weld preparation design dimensions
Dimensions in millimetres (inches) unless otherwise indicated
a) V-groove
b) U-groove
c) Heavy-wall V-groove
a
Maximum misalignment.
Figure G.1 — Typical weld grooves for pipe butt joints
77
78
API STANDARD 16AR
Dimensions in millimetres (inches) unless otherwise indicated
a
Maximum misalignment (unless removed by machining).
b
c
Remove to sound metal by machining.
Maximum misalignment.
d
Backing shall be removed. Material shall be compatible with base material.
Figure F.2 — Typical attachment welds
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
79
Dimensions in millimetres (inches) unless otherwise indicated
a
b
Ratio of d1 to D2 shall not exceed 1,5:1.
Depth required to maintain a maximum of 1,5:1 depth, d1, to diameter, D2, ratio.
Figure F.3 — Typical repair welds
Key
1 side
2 end
a
Original area.
Figure F.3 — Repairs
80
API STANDARD 16AR
Annex H
(Normative)
Qualification of heat-treating equipment
H.1
General
All heat treatment of parts and QTCs shall be performed with equipment meeting the requirements of this annex.
H.2
Temperature tolerance
The temperature at any point in the working zone shall not vary by more than  13
 25 °F) from the furnace
set-point temperature after the furnace working zone has been brought up to temperature. Furnaces which are
used for tempering, aging and/or stress-relieving shall not vary by more than  8 °C ( 15 °F) from the furnace
set-point temperature after the furnace working zone has been brought up to temperature.
H.3
Furnace calibration
H.3.1
General
Heat treatment of production parts shall be performed with heat-treating equipment that has been calibrated and
surveyed.
H.3.2
Records
Records of furnace calibration and surveys shall be maintained for a period not less than two years.
H.3.3
Temperature survey method for calibration of batch-type furnaces
A temperature survey within the furnace working zone(s) shall be performed on each furnace at the maximum
and minimum temperatures for which each furnace is to be used.
A minimum of nine thermocouple test locations shall be used for all furnaces having a working zone greater than
0.3 m3 (10 ft3).
For each 3,5 m3 (125 ft3) of furnace working zone surveyed, at least one thermocouple test location shall be
used, up to a maximum of 40 thermocouples. See Figures H.1 and H.2 for examples of thermocouple locations.
For furnaces having a working zone less than 0.3 m3 (10 ft3), the temperature survey may be made with a
minimum of three thermocouples located either at the front, centre and rear, or at the top, centre and bottom of
the furnace working zone.
After insertion of the temperature-sensing devices, readings shall be taken at least once every 3 min to determine
when the temperature of the furnace working zone approaches the bottom of the temperature range being
surveyed.
Once the furnace temperature has reached the set-point temperature, the temperature of all test locations shall
be recorded at 2-min intervals, maximum, for at least 10 min. Then readings shall be taken at 5-min intervals,
maximum, for sufficient time (at least 30 min) to determine the recurrent temperature pattern of the furnace
working zone.
Before the furnace set-point temperature is reached, none of the temperature readings shall exceed the set-point
temperature by more than 13
After the furnace control set-point temperature is reached, no temperature reading shall vary beyond the limits
specified. The temperatures within each furnace shall be surveyed within one year prior to use of the furnace for
heat treatment.
When a furnace is repaired or rebuilt, a new temperature survey shall be carried out before the furnace is used
for heat treatment.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
a)
Top view
b)
Side view
Figure H.1 — Thermocouple locations — Rectangular furnace (working zone)
a)
Side view
b)
Top view
Figure H.2 — Thermocouple locations — Cylindrical furnace (working zone)
H.3.4
Continuous-type furnaces method
Furnaces used for continuous heat treatment shall be calibrated in accordance with procedures specified in
SAE AMS-H-6875F.
81
82
API STANDARD 16AR
H.4
Instruments
H.4.1
General
Automatic controlling and recording instruments shall be used.
Thermocouples shall be located in the furnace working zone(s) and protected from furnace atmospheres by
means of suitable protective devices.
H.4.2
Accuracy
The controlling and recording instruments used for the heat-treatment processes shall be accurate to  1 % of
their full-scale range.
H.4.3
Calibration
Temperature-controlling and -recording instruments shall be calibrated at least once every three months.
Equipment used to calibrate the production equipment shall be accurate to  0.25 % of full-scale range.
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
83
Annex I
(Normative)
Equivalent Rounds (ER) models
When L is less than T, consider section as a plate of L thickness. Area inside dashed lines is 1/4 T envelope for
test specimen removal.
When L is less than D, consider as a plate of T thickness
Figure I.1—Simple geometric equivalent rounds (ER) sections/shapes having length L
a. Where T is the thickness when the component is heat-treated, use the larger of the two
indicated dimensions.
When all internal and external surfaces during heat treatment are within 13 mm (1/2 in) of the final
surfaces, ER  1-1/4 T. (must this not be ¼ T ?, see API 16A 2004 Also check conformance with
9.5.8.)
When all internal and external surfaces during heat treatment are not within 13 mm (1/2 in) of the final
surfaces, then ER  2 T. On multi-flanged components, T shall be the thickness of the thickest flange.
Figure I.2 — Complex-shaped components
84
API STANDARD 16AR
b. Envelope for test specimen removal.
.
Figure I.3 — Equivalent round models
STANDARD FOR REPAIR AND REMANUFACTURING OF W ELL CONTROL EQUIPMENT
Annex J
(Normative)
Replacement parts
Remanufactured / replacement parts
All parts shall meet or exceed the
requirements of API-16A specification.
API 16A + QMS Requirements in 16AR
1) Design documentation (verification)
2) Design review
3) Design validation
Design verification and
validation completed
No
Part is not in
conformance with
the requirements
of the API 16AR
standard.
Yes
Replacement or Remanufactured parts
meet or exceed the full API 16A
specification, including all design
verification and validation, and may be
used in an assembly repaired as per 16AR.
All parts meet a
current product
definition
RSL-3
Not all parts meet
current product
definition. All parts
have full traceability
RSL-2
Not all parts meet
current product
definition. Parts have
partial traceability
RSL-1
85
86
API STANDARD 16AR
Bibliography
[1]
API Bulletin 6AF, Capabilities of API flanges under combinations of load
[2]
API Specification Q2: Specification for Quality Management System Requirements for Service
Supply Organizations for the Petroleum, Petrochemical and Natural Gas Industry
[3]
ASME Boiler and Pressure Vessel Code Section VIII, Division 1, Appendix 4, Rounded
Indication Charts Acceptance Standard for Radiographically Determined Rounded Indications
in Welds
[4]
ASME Boiler and Pressure Vessel Code Section VIII, Division 2, Pressure Vessel — Alternate
Rules, Appendix 4, Design Based on Stress Analysis
[5]
ASME Boiler and Pressure Vessel Code Section VIII, Division 2, Pressure Vessel — Alternate
Rules, Appendix 6, Experimental Stress Analysis
[6]
ASTM A 193, Specification for Alloy Steel and Stainless Steel Bolting Materials for High
Temperature Service
[7]
ASTM A 320, Specification for Alloy Steel Bolting Materials for Low Temperature Service
[8]
ASTM A 453, Specification for Bolting Materials, High Temperature, 50 to 120 ksi Yield
Strength, with Expansion Coefficients Comparable to Austenitic Steels
[9]
ASTM E 747, Standard Practice for Design, Manufacture, and Material Grouping Classification
of Wire Image
[10]
AWS QC1 Standard for AWS Certification of Welding Inspectors
Additional copies are available through Global Engineering
Documents at (800) 854-7179 or (303) 397-7956
Information about API Publications, Programs and Services is
available on the World Wide Web at http://www.api.org
Product No: G6HT01