api 7k 5th edition item 2201 (reballot) non-metallic...

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API 7K 5th Edition Item 2201 (Reballot)

Non-metallic Tongs

6 Materials Requirements

6.1 General

This clause describes the various material qualification, property, and processing requirements for primary load-carrying and pressure-containing components, unless otherwise specified.

6.2 Written Specifications

Materials used in the manufacture of primary load-carrying components of equipment to which this specification is applicable shall conform to a written specification that meets or exceeds the design requirements.

6.3 Mechanical Properties

6.3.1 Impact Toughness (Metallic Components Only)

Impact testing shall be in accordance with ISO 148 (V-notch Charpy) or ASTM A 370 (V-notch Charpy).

When it is necessary for subsize impact test pieces to be used, the acceptance criteria shall be multiplied by the appropriate adjustment factor listed in Table 3. Subsize test pieces of width less than 5 mm (3/16 in.) are not permitted.

For design temperatures below those specified in 4.1, supplementary impact toughness requirements may apply. See Annex A, Supplementary Requirements SR2 and SR2A.

Table 3 — Adjustment Factors for Subsize Impact Specimens

Specimen dimensions mm × mm

Adjustment factor

10.0 × 7.5 0.833

10.0 × 5.0 0.667

6.3.2 Through-thickness Properties (Metallic Components Only)

Where the design requires through-thickness properties, materials shall be tested for reduction of area in the through-thickness direction in accordance with ASTM A 770. The minimum reduction shall be 25%.

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6.4 Material Qualification

6.4.1 General

The mechanical tests required by this specification shall be performed on qualification test coupons representing the heat and heat treatment lot used in the manufacture of the component. For non-metallic components, a batch from the same manufacturing lot, with the same chemistry, shall be considered as a heat. Tests shall be performed in accordance with the requirements of ISO 6892, ISO 148 or ASTM A 370, or equivalent national standards, where possible, using material in the final heat-treated condition. For the purposes of material qualification testing, stress relief following welding is not considered heat treatment., provided that the PWHT temperature is below that which changes the heat-treated condition of the base material. Material qualification tests may be performed before the stress-relieving process, provided that the stress-relieving temperature is below that which changes the heat-treatment condition.

6.4.2 Equivalent Rounds (Metallic Components Only)

The size of the qualification test coupon for a part shall be determined the size of the qualification test coupon for a part using the equivalent-round (ER) method. Figure 1 and Figure 2 illustrate the basic models for determining the equivalent round of simple solid and hollow parts. Any of the shapes shown may be used for the qualification test coupon. Figure 3 describes the steps for determining the governing equivalent-roundER for more complex sections.

The ER of a part shall be determined the equivalent round of a part using the actual dimensions of the part in the “as-heat-treated” condition. The equivalent roundER of the qualification test coupon shall be equal to or greater than the equivalent-round dimensions of the part it qualifies, except that the equivalent round is not required to exceed 125 mm (5 in). Figure 4 and Figure 5 illustrate the procedure for determining the required dimensions of an ASTM A 370 keel block.

Figure 1 — Equivalent round models — Solids of length L

Figure 2 — Equivalent round models — Tube (any section)

Figure 3 — Equivalent round models — Complex shapes

Figure 4 — Equivalent round models — Keel block configuration

Figure 5 — Development of keel block dimensions

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6.4.3 Material Test Coupons

6.4.3.1 Qualification test coupons shall either be integral with the components they represent, or be separate from the components, or be taken from sacrificed production part(s). In all cases, test coupons shall be from the same heat as the components they qualify, shall be subjected to the same working operations, and shall be heat-treated together with the components.

6.4.43.2 Test specimens shall be removed from integral or separate qualification test coupons so that their longitudinal centerline axis is entirely within the center core 1/4-thickness envelope for a solid test coupon, or within 3 mm (1/8 in) of the mid-thickness of the thickest section of a hollow test coupon. The gauge length of a tensile specimen or the notch of an impact specimen shall be at least 1/4-thickness from the ends of the test coupon.

6.4.53.3 Test specimens taken from sacrificed production parts shall be removed from the center core 1/4-thickness envelope location of the thickest section of the part.

6.4.63.4 For components to be machined entirely from wrought material which has been fully heat treated as a solid or tubular bar, whereby the standard ¼ T envelope is either wholly or partly outside the volume of the critical and/or non-critical areas of the finished component, the test specimens, cut from the bar, may alternatively be taken from a more representative volume as defined by:

Volume OD defined by a 1/3 T envelope determined by using the maximum finished OD and the minimum finished ID of the final component.

The volume ID shall be equal to, or greater than, the minimum finished ID of the component.

EXAMPLE

6 in. OD 4340 mod bar, non-quenched tempered (NQT);

Part final dimensions have maximum OD of 5.5 in., minimum ID of 2.5 in.;

T = (5.5 – 2.5)/2 = 1.5 in. 1/3 T = 0.5 in.;

The 1/3 T envelope of the finished part would have a 4.5 in. OD;

Therefore, the specimens could be removed from anywhere within the volume defined by 4.5 in. OD × 2.5 in. ID; (the 1/3 T outer envelope and the finished ID of the component).

6.5 Manufacture

6.5.1 The manufacturing processes shall ensure repeatability in producing components that meet all the requirements of this specification.

6.5.2 All wrought materials shall be manufactured using processes that produce a wrought structure throughout the component.

6.5.3 All heat-treatment operations shall be performed utilizing equipment qualified in accordance with the requirements specified by the manufacturer or processor. The loading of the material within heat-treatment furnaces shall be such that the presence of any one part does not adversely affect the heat-treating response of any other part within the heat-treatment lot. The temperature and time requirements for heat-treatment cycles shall be determined in accordance with the manufacturer's or processor's written specification. Actual heat-treatment temperatures and times shall be recorded, and heat-treatment records shall be traceable to relevant components.

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NOTE See Annex B for recommendations on qualification of heat-treating equipment.

6.6 Chemical Composition (Metallic Components Only)

The material composition of each heat shall be analyzed in accordance with the requirements of ASTM A 751 (see ISO TR 9769 for further information), or equivalent national standard, for all elements specified in the manufacturer's written material specification.

6.7 Non-metallic Components

6.7.1 General

The use of non-metallic materials to manufacture primary load carrying components shall be permitted provided that the materials meet the mechanical properties required for the design.

The mechanical property requirements for all non-metallic materials shall be specified with appropriate limits for properties critical to the function of the equipment. The material properties shall be qualified at a minimum temperature of -4°F (-20°C) unless otherwise specified in section 9, and at a specified maximum temperature corresponding to the maximum recommended operating temperature. Material for which the rate of loading affects the mechanical properties, the qualification tests shall be performed at the most severe rate of loading that may be encountered in service.

For materials that do not exhibit yield strength, the value of the ultimate strength multiplied by 0.80 shall be used as the equivalent yield strength.

The manufacturer shall provide specific procedures for the inspection of all non-metallic materials incuding frequency, methods, equipment, and acceptance and rejection criteria to the user/owner in an inspection and maintenance manual upon delivery of the equipment under a purchase agreement. These procedures shall also include recommendations for maximum intervals for replacement due to aging and shelf life of replacement components. The manufacturer shall also provide instructions and information regarding the material’s resistance to chemical attack, along with a list of what types of chemicals will affect the serviceability of the equipment or its ability to be used at its designated rated load. In addition, the manufacturer shall provide the minimum and maximum temperatures that the equipment can be used at its designated rated load, plus any other ambient conditions that could adversely affect the ability of the equipment to be operated at its designated rated load.

6.7.2 Aramid Fiber Cordage with Unbonded Elastomeric Coating Loaded in Simple Tension

The material shall be qualified and controlled for conformance to the manufacturer’s written specification. The material specification shall contain, as a minimum with appropriate limits, the uncoated cordage diameter, the denier of the cordage, the coated cord diameter, the twist density, and the tensile strength. The tensile strength shall be tested in accordance with ASTM D4268 or other international standards.

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8 Quality Control

8.4 Quality Control for Specific Equipment and Components

8.4.7 Surface NDE

8.4.7.4 Acceptance Criteria

8.4.7.5 Non-metallic Components

The manufacturer shall have written specifications defining the maximum defect size, orientation, grouping, etc. for each type of defect expected. The defect types considered are to be at a minimum, voids, cuts, cracks, and/or tears.

The methods for detection and measurement of the expected defects are to be specified and proven effective in detecting defects no larger than 75% of the maximum allowable size or severity. All primary load carrying components are to be examined in both critical and non-critical areas.

ANNEX F

(informative)

Load Limiting Design of Manual Tongs

F.1 Purpose

F.1.1 General

The purpose of this annex is to provide standards for certifying a design as load limiting. A load limiting design is one that in the event of an overload, the primary load will be either prevented from increasing or released in a controlled manner without unlatching and with no fragments expelled. Clauses 4.2.4, 4.2.5, 4.6, 5.4, 5.5, and 5.6 regarding the design and design verification testing of manual tongs does not apply to load limiting tongs designed, qualified, and tested in accordance with this annex.

Load limiting designs may be accomplished by the use of materials, components, or mechanisms to release or limit the primary load in an overload condition. The limiting component shall be an integral part of the tool, impossible to be removed, bypassed, or adjusted in the field.

F.1.2 Equipment covered

This specification covers the design, manufacture and testing of load limiting manual tongs.

F.2 Definitions

For the purpose of this appendix, the following definitions apply:

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F.2.1 average limit load The numerical average of primary load which causes the limiting component to release the primary load.

F.2.2 limiting component A component, material or mechanism which will release the primary load in the event of an overload

F.2.3 load variance A measure of how widely values are dispersed from the average value

F.2.4 secondary load The minimum load capacity of all components in the tool except for the limiting component.

F.2.5 secondary component All components with the exception of the limiting component.

F.3 Design

F.3.1 Average Limit Load

The average limit load shall be determined by testing the limiting component. A minimum sample size of fifty (50) tests of the same size and type of component shall be used. The primary load to the tool required to cause a limit of the load shall be measured or calculated using the mechanical relationship of the measured load to the primary load. The average limit load shall be documented in terms of the output.

Testing shall be performed at the worst case(s) of temperature and rate of loading that may be encountered in service.

Testing of reduced sized specimens is permitted provided that a minimum of two full size tests are conducted to verify the relationship with the specimens.

F.3.2 Load Variance

The load variance of the limit load shall be calculated from the test data used to determine the average limit load. The load variance shall be the greater of the standard deviation (determined from the equation below) or one seventh (1/7) of the average limit load:

2

1

)()1(

1 LLn

Dn

ii∑

=

−−

=

where

L is the load corresponding to each sample in measuring the average limit load;

n is the number of samples and is the average limit load.

L is the average limit load.

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F.3.3 Rated Load

The rated load shall be a maximum of two load variations below the average limit load. The rated load is given by the equation:

DLR 2−=

F.3.4 Secondary Load

The secondary load shall be a minimum of three load variations above the average limit load. The secondary load is given by the equation:

DLS 3+=

F.3.5 Design of Secondary Components

All components in the primary load path except the limiting component shall be designed such that the minimum material yield strength is equal to or greater than the stresses created by the secondary load.

F.4 Design Verification Load Test

The test procedure is as follows.

a) An assembled production unit shall be loaded to the maximum rated load. After this load has been released, the unit shall be checked for its intended design functions. The function of all of the equipment’s parts shall not be impaired by this loading.

b) The equipment shall be mounted in a test fixture capable of loading the equipment in a similar manner as found in typical field use. This may include, but is not limited to, the use of springs to simulate the compliance of the expected field loading equipment.

c) Strain gauges shall be applied to the unit at all places where high stresses are anticipated in all secondary components, provided that the configuration of the unit permits such techniques. The use of finite-element analysis, models, brittle lacquer, and so forth, is recommended to confirm the proper location of the strain gauges. Three-element strain gauges are recommended in critical areas to permit determination of the shear stresses and to eliminate the need for exact orientation of the gauges.

d) The design verification test load shall be applied to the unit at a rate expected in field use or, such that the limiting load shall be obtained in a maximum of ten (10) seconds, whichever is the greater rate of loading.

e) The unit shall be loaded at the rate determined in F.4b) until an indication that the load is being limited. The application of the load is then to be stopped manually and held in position for a minimum of 5 minutes. With the application of the load stopped, the measured load on the test unit may decrease in value indicating a release of stored energy. The test unit shall not unlatch and no components, or portions of components, shall become separated from the test unit assembly. This test shall be video recorded.

f) The peak load and the peak stresses computed from the strain gauges shall be recorded. The peak stresses computed shall not be greater than the equivalent stress from the following equation:

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SFS ty

e

×=σ

where

Sy is the specified minimum yield strength for the component;

Ft is the peak load recorded in testing;

S is the secondary load from clause F.3.4.

The stress values computed from the strain gauge readings shall not exceed the values obtained from design calculations (based on the design verification test load) by more than the uncertainty of the testing apparatus specified in 5.7.

g) Failure of the test unit to meet the above requirements or failure in a secondary component shall be cause for complete reassessment of the design, followed by additional testing of an identical number of production units as originally required, including a unit of the same load rating as the one that failed.

h) Upon completion of the design verification load test, the test unit shall be disassembled and the dimensions of all secondary load-carrying components shall be checked for evidence of permanent deformation. Evidence of permanent deformation shall be compared to expected results in the design analysis. All permanent deformation shall not affect the serviceability of the components.

F.5 Proof Load Testing

The test procedure is as follows:

a) Each production unit or primary load-carrying component shall be load tested in accordance with the requirements of this section.

b) The equipment shall be mounted in a test fixture capable of loading the equipment in the same manner as in actual service and with the same areas of contact on the load bearing surfaces unless design verification testing indicates that the contact area is not the location of maximum stress and that the stresses produced by the alternate loading are not less than the maximum stresses expected from the design analysis and the design verification testing.

c) A test load equal to 1.5 times rated load shall be applied to all secondary components and held for a period of not less than five minutes. Load limiting components are to be tested at a load equal to the rated load and held for a period of not less than five minutes.

d) Following the load test, the design functions of the equipment shall be checked, as applicable. Proper functioning of the equipment shall not be impaired by the load test.

e) Assembled equipment shall be subsequently stripped down to a level that will permit full surface NDE of all primary load-bearing parts (excluding bearings and non-metallic components).

f) All critical areas of the primary load bearing parts shall be subjected to magnetic particle examination in conformance with 8.4.7.1 with the exception of bearings and nonmetallic components. Nonmetallic components shall be visually inspected for cracks, delamination, or other physical damage.

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F.6 Quality Control of Limiting Components

Limiting components are to be controlled for a load equal to the average limit load plus or minus two load variations.

NOTE Nonconformance of the limiting component to control within the minimum and maximum loads will necessitate corrective action so that loss of load limiting, and an undesirable failure mode will not occur.

F.7 Product Marking

Manual tongs furnished in conformance with this specification shall be marked with the manufacturer’s name or mark, rated load, and API 7K-LL.

9.7 Manual tongs

9.7.5 Design verification load tests

The design verification load test, as described in Clause 5, shall apply except for load limiting manual tongs.

9.7.6 Proof load testing

Proof load testing, as described in 8.6, shall apply except for load limiting manual tongs. Load limiting manual tongs shall be proof tested in accordance with Annex F.5. Jaw hinge pins of wrought material shall be exempt from this requirement.

9.7.7 Load limiting manual tongs

Load limiting manual tongs shall be designed, and design verification load tested in accordance with Annex F.

11/10/2009API Ballot Summary Sheet

7K 5th Ed Item 2201 - Nonmetallic Tongs (Reballot) Ballot ID: 1846

Roland GoodmanAssociate:10/30/09Closing Date:9/16/09Start Date:

Ballot:

Coordinator: Roland Goodman

Proposal:

VotingCategory

Did Not VoteAbstainNegativeAffirmativeCommentsCompanyVoter

Vote Results

Interest CategoryEngineering Design & TestingGlenn Armstrong XYesConsultantNoble Drilling ServicesDave Beard XNoOperator-UserNational Oilwell Varco/Orange FacilityThomas Becker XNoManufacturerBusse Engineering IncRalph Busse XNoContractorDen-Con Tool CompanyLarry Denny XNoManufacturerDet Norske VeritasNorman Dyer XNoManufacturerWireCo WorldGroupJ. Dennis Fetter XNoManufacturerFoley Engineering, LLCLarry Foley XNoManufacturerGearenchPat Johnson XYesManufacturerBlohm and Voss Repair GmbHJens Lutzhoeft XNoManufacturerCONTITECH RUBBER Industrial Ltd.Tibor Nagy XNoManufacturerPride International, Inc.Vincent Nicolini XNoOperator-UserBP America Inc.David Pattillo XNoOperator-UserForum Oilfield Technologies Inc. Drilling PMark Pierce XYesManufacturerTransoceanJeff Shepard XNoOperator-UserFrank's Casing Crew & Rental ToolsMark Sibille XYesManufacturerDiamond Offshore Drilling IncorporatedDuane Snyder XNoOperator-UserRowan Companies, Inc.Ronnie Sralla XNoOperator-User

Howard Stapleton XNoConsultantT & T Engineering Services, Inc.Mark Trevithick XNoContractorGates CorporationR. Trujillo XNoManufacturerPrecision Drilling Oilfield Services CorporRobert Urbanowski XYesOperator-UserCanrig Drilling Technology Ltd.Faisal Yousef XNoManufacturer

1

11/10/2009API Ballot Summary Sheet

7K 5th Ed Item 2201 - Nonmetallic Tongs (Reballot) Ballot ID: 1846

Roland GoodmanAssociate:10/30/09Closing Date:9/16/09Start Date:

Ballot:

Coordinator: Roland Goodman

Proposal:

VotingCategory

Balloting Totals: 1 5

Affirmative Negative Abstain Did Not Vote

16 1

Total Responses:

Total Ballots:

Response Rate ((Affirmative + Negative + Abstain) / Total Ballots):

Approval Rate (Affirmative / [Affirmative + Negative] ):

23

18

Consensus:

%78

%94

Must be > 50%

Must be > 67%

YES

2

Ballot Comments and Resolution

Ballot: 1846 Name: Report Date: 11/10/2009 Closing Date: 10/30/2009

Proposal:

Sort Key Name Vote Section

Type

ClauseSubclause

Number

Type ofComment Comment Proposed Change Comment Resolution

1 Sibille, Mark Negative Section/Clause 6.6 General No method/standard provided for analysis of non-metallics

List applicable standard(s).

2 Sibille, Mark Negative Section/Clause 6.4.1 Technical "Tests shall be performed in accordance with the requirements of ISO 6892, ISO 148 or ASTM A 370, or equivalent national standards, where possible" implies that the tests are not required if the listed standards are not applicable or "possible".

Define applicable test stds for non-metallics and eliminate the loop-hole.

3 Sibille, Mark Negative Section/Clause 6.4.1 General Should be divided into 2 separate sections for metallic and non-metallic mat'ls. Ref applicable stds for testing non-metallics.

Write separate section for non-metallics.

4 Sibille, Mark Negative Section/Clause 6.4.1 Technical Batch is not defined. Effects of processing of non-metallics not given consideration.

Define "batch" in terms of the issues noted and those processes that are not listed but may also affect properties -therefore should define the batch/lot size that is qualified by a single set of tests.

5 Sibille, Mark Negative Section/Clause 6.4.2 Editorial Sentence has been changed from "active voice" to "passive voice".

Unless there is good reason for changing to passive voice, return to original text (ISO editors will change to active voice wherever they find passive.)

6 Sibille, Mark Negative Section/Clause 6.4.3 Technical The details of this section don't apply to non-metallic materials -you can not simply use a section of a composite if it is not complete - the results would not be the same (the whole is greater than the sum of its parts).

A new section is needed to define, for nonmetallics,how/where/etc the specimens are to be taken.

7 Sibille, Mark Negative Section/Clause 6.7.1 Technical Insufficient definition of the lot size or "batch" that is qualified by a given specimen. No direction as to how the specimen(s) is taken.

Provide better definition of the lot size or "batch" that is qualified by a given specimen, and direction as to how the specimen(s) are taken.

8 Sibille, Mark Negative Section/Clause 6.7.1 General 2nd paragraph does not address glass transition temperature of polymers.

Insert at end of 2nd sentence of 2nd paragraph: "Polymers and polymer composites with a glass transition temperature above the design/operating temperature shall not be used."

9 Sibille, Mark Negative Section/Clause 6.7.1 Technical 3rd paragraph- Equiv Yield should also be limited in terms of modulus.

after "0.80", insert: "or 5% of the elastic modulus, whichever is less".

10 Sibille, Mark Negative Section/Clause 6.7.1 Editorial 4th paragraph could be clarified. In 1st sentence of 4th paragraph, insert the phrase "incuding frequency, methods, equipment, and acceptance and rejection criteria" into parentheses.

7K 5th Ed Item 2201 - Nonmetallic Tongs (Reballot)

Page 1 of 3



Proposal:


Type

ClauseSubclause

Number



11 Sibille, Mark Negative Section/Clause 6.7.2 Editorial Section title seems unnecessarily specific, omitting other composites that should be addressed similarly.

Change the portion of the title "Aramid Fiber Cordage with Unbonded Elastomeric Coating Loaded in Simple Tension" to "Composite of Fiber Cord Reinforcement in Elastomer".

12 Sibille, Mark Negative Section/Clause 8.4.7.5 Technical "Delaminations" should be included in list of defects in 1st paragraph.

Insert "delaminations, " after "cracks".

13 Urbanowski, Robert Affirmative Section/Clause 8.4.7.5 Technical “The methods for detection and measurement of the expected defects are to be specified and proven effective in detecting defects no larger than 75% of the maximum allowable size or severity.”

As stated, these methods could not be effective in finding defects 76% or larger than the maximum allowable size or severity. I do not think this is the intent.

Change: “The methods for detection and measurement of the expected defects are to be specified and proven effective in detecting defects no larger than 75% of the maximum allowable size or severity”

To: “The methods for detection and measurement of the expected defects are to be specified and proven effective in detecting defects that are 75% or smaller than the maximum allowable size or severity.”

14 Sibille, Mark Negative Section/Clause 9.7.5 General The exception should be clarified. add "which shall comply with the requirements of Annex F." to the end of the sentence.

15 Johnson, Pat Affirmative Section/Clause Annex F General Annex F is normative, not informative. Change category of Annex F to normative.

16 Urbanowski, Robert Affirmative Section/Clause Annex F Editorial Why is Annex F considered "Informative". If part of this ballot item is adding a section 9.7.7 - which is outside this annex - that makes use of the annex mandatory for load limiting tongs, then should the annex be "normative" instead?

Change: “ANNEX F (Informative)”

To: “ANNEX F (Normative)”

17 Sibille, Mark Negative Section/Clause F.2 Editorial All definitions should be in Clause 3 (Definitions). Move all of the definitions listed in F.2 to clause 3.0 Definitions, and insert "in Load Limiting Designs (ref Annex F)" at the end of each def.

18 Sibille, Mark Negative Section/Clause F.2.5 General Clarify definition to apply to PLC components of load limited designs.

Change to: "All primary load carrying components of a load limited design with the exception of the limiting component.

Page 2 of 3



Proposal:


Type

ClauseSubclause

Number



19 Armstrong, Glenn Affirmative Section/Clause F.3.1 Editorial Last sentence ending in "... relationship with the specimens." is ambiguous.

"...full size tests are conducted to determine the relationship between the two sizes of test specimens."

20 Sibille, Mark Negative Section/Clause F.3.2 Editorial Typos in the description of variable, n. Delete "and is the average limit load" from the end of the description of "n"

21 Sibille, Mark Negative Section/Clause F.3.3 Editorial "Load Variance" term, previously defined, should be used where "Load Variation" and "D" are being used in the text and equations.

replace "two load variations below the average limit load" w/ "the Average Limit Load - two times the Load Variance." Replace "2D" with "2 x Load Variance"

22 Sibille, Mark Negative Section/Clause F.3.4 Editorial "D" is being used where "Load Variance" should be used.

Replace "3D" with "3 x Load Variance"

23 Armstrong, Glenn Affirmative Section/Clause F.4(e) Editorial reference to rate of loading in F.4(b) is not correct Should be to F.4(d)

24 Pierce, Mark Abstain Section/Clause General not enough knowledge of the product to vote none

25 Sibille, Mark Negative Section/Clause General (marked up copy of PDF provided) Refer to uploaded PDF containing mark-ups of the original doc.

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August 2009

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API 7K 5th Edition Item 2201 (Reballot)

Non-metallic Tongs

6 Materials Requirements

6.1 General

This clause describes the various material qualification, property, and processing requirements for primary load-carrying and pressure-containing components, unless otherwise specified.

6.2 Written Specifications

Materials used in the manufacture of primary load-carrying components of equipment to which this specification is applicable shall conform to a written specification that meets or exceeds the design requirements.

6.3 Mechanical Properties

6.3.1 Impact Toughness (Metallic Components Only)

Impact testing shall be in accordance with ISO 148 (V-notch Charpy) or ASTM A 370 (V-notch Charpy).

When it is necessary for subsize impact test pieces to be used, the acceptance criteria shall be multiplied by the appropriate adjustment factor listed in Table 3. Subsize test pieces of width less than 5 mm (3/16 in.) are not permitted.

For design temperatures below those specified in 4.1, supplementary impact toughness requirements may apply. See Annex A, Supplementary Requirements SR2 and SR2A.

Table 3 — Adjustment Factors for Subsize Impact Specimens

Specimen dimensions mm � mm

Adjustment factor

10.0 � 7.5 0.833

10.0 � 5.0 0.667

6.3.2 Through-thickness Properties (Metallic Components Only)

Where the design requires through-thickness properties, materials shall be tested for reduction of area in the through-thickness direction in accordance with ASTM A 770. The minimum reduction shall be 25%.

Oct 2009 Ballot Comments from Mark Sibille, FRANK'S Casing

August 2009

Page 2 of 9


6.4.1 General

The mechanical tests required by this specification shall be performed on qualification test coupons representing the heat and heat treatment lot used in the manufacture of the component. For non-metallic components, a batch from the same manufacturing lot, with the same chemistry, shall be considered as a heat. Tests shall be performed in accordance with the requirements of ISO 6892, ISO 148 or ASTM A 370, or equivalent national standards, where possible, using material in the final heat-treated condition. For the purposes of material qualification testing, stress relief following welding is not considered heat treatment., provided that the PWHT temperature is below that which changes the heat-treated condition of the base material. Material qualification tests may be performed before the stress-relieving process, provided that the stress-relieving temperature is below that which changes the heat-treatment condition.

6.4.2 Equivalent Rounds (Metallic Components Only)

The size of the qualification test coupon for a part shall be determined the size of the qualification test coupon for a part using the equivalent-round (ER) method. Figure 1 and Figure 2 illustrate the basic models for determining the equivalent round of simple solid and hollow parts. Any of the shapes shown may be used for the qualification test coupon. Figure 3 describes the steps for determining the governing equivalent-roundER for more complex sections.

The ER of a part shall be determined the equivalent round of a part using the actual dimensions of the part in the “as-heat-treated” condition. The equivalent roundER of the qualification test coupon shall be equal to or greater than the equivalent-round dimensions of the part it qualifies, except that the equivalent round is not required to exceed 125 mm (5 in). Figure 4 and Figure 5 illustrate the procedure for determining the required dimensions of an ASTM A 370 keel block.

Figure 1 — Equivalent round models — Solids of length L

Figure 2 — Equivalent round models — Tube (any section)

Figure 3 — Equivalent round models — Complex shapes

Figure 4 — Equivalent round models — Keel block configuration

Figure 5 — Development of keel block dimensions


AND processing?

pbatch from the same manufacturing lot, with the same chemistry, shall be considered as a p

heat.

Define "batch"?where possible,

Implies tests aren't requiredif the ref stds don't apply (orif "not possible").

I don't know if ER methods(intended to address HTmass-effects, as well assize effects) can apply tonon-metallics, but theactive-voice was used byISO in preference topassive-voice.

Should be divided into 2 separate sections formetallic and non-metallic mat'ls. Ref applicable stdsfor testing non-metallics.

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6.4.3 Material Test Coupons

6.4.3.1 Qualification test coupons shall either be integral with the components they represent, or be separate from the components, or be taken from sacrificed production part(s). In all cases, test coupons shall be from the same heat as the components they qualify, shall be subjected to the same working operations, and shall be heat-treated together with the components.

6.4.43.2 Test specimens shall be removed from integral or separate qualification test coupons so that their longitudinal centerline axis is entirely within the center core 1/4-thickness envelope for a solid test coupon, or within 3 mm (1/8 in) of the mid-thickness of the thickest section of a hollow test coupon. The gauge length of a tensile specimen or the notch of an impact specimen shall be at least 1/4-thickness from the ends of the test coupon.

6.4.53.3 Test specimens taken from sacrificed production parts shall be removed from the center core 1/4-thickness envelope location of the thickest section of the part.

6.4.63.4 For components to be machined entirely from wrought material which has been fully heat treated as a solid or tubular bar, whereby the standard ¼ T envelope is either wholly or partly outside the volume of the critical and/or non-critical areas of the finished component, the test specimens, cut from the bar, may alternatively be taken from a more representative volume as defined by:

Volume OD defined by a 1/3 T envelope determined by using the maximum finished OD and the minimum finished ID of the final component.

The volume ID shall be equal to, or greater than, the minimum finished ID of the component.

EXAMPLE

6 in. OD 4340 mod bar, non-quenched tempered (NQT);

Part final dimensions have maximum OD of 5.5 in., minimum ID of 2.5 in.;

T = (5.5 – 2.5)/2 = 1.5 in. 1/3 T = 0.5 in.;

The 1/3 T envelope of the finished part would have a 4.5 in. OD;

Therefore, the specimens could be removed from anywhere within the volume defined by 4.5 in. OD � 2.5 in. ID; (the 1/3 T outer envelope and the finished ID of the component).

6.5 Manufacture

6.5.1 The manufacturing processes shall ensure repeatability in producing components that meet all the requirements of this specification.

6.5.2 All wrought materials shall be manufactured using processes that produce a wrought structure throughout the component.

6.5.3 All heat-treatment operations shall be performed utilizing equipment qualified in accordance with the requirements specified by the manufacturer or processor. The loading of the material within heat-treatment furnaces shall be such that the presence of any one part does not adversely affect the heat-treating response of any other part within the heat-treatment lot. The temperature and time requirements for heat-treatment cycles shall be determined in accordance with the manufacturer's or processor's written specification. Actual heat-treatment temperatures and times shall be recorded, and heat-treatment records shall be traceable to relevant components.

The details of this section don't apply tonon-metallic materials -you can take asection of a composite if it is not complete -the results would not be the same (thewhole is greater than the sum of its parts).A new section is needed to define, for non-metallics, how/where/etc the specimens areto be taken.

l Test Coupons

August 2009

Page 4 of 9

NOTE See Annex B for recommendations on qualification of heat-treating equipment.

6.6 Chemical Composition (Metallic Components Only)

The material composition of each heat shall be analyzed in accordance with the requirements of ASTM A 751 (see ISO TR 9769 for further information), or equivalent national standard, for all elements specified in the manufacturer's written material specification.

6.7 Non-metallic Components

6.7.1 General

The use of non-metallic materials to manufacture primary load carrying components shall be permitted provided that the materials meet the mechanical properties required for the design.

The mechanical property requirements for all non-metallic materials shall be specified with appropriate limits for properties critical to the function of the equipment. The material properties shall be qualified at a minimum temperature of -4°F (-20°C) unless otherwise specified in section 9, and at a specified maximum temperature corresponding to the maximum recommended operating temperature. Material for which the rate of loading affects the mechanical properties, the qualification tests shall be performed at the most severe rate of loading that may be encountered in service.

For materials that do not exhibit yield strength, the value of the ultimate strength multiplied by 0.80 shall be used as the equivalent yield strength.

The manufacturer shall provide specific procedures for the inspection of all non-metallic materials incuding frequency, methods, equipment, and acceptance and rejection criteria to the user/owner in an inspection and maintenance manual upon delivery of the equipment under a purchase agreement. These procedures shall also include recommendations for maximum intervals for replacement due to aging andshelf life of replacement components. The manufacturer shall also provide instructions and information regarding the material’s resistance to chemical attack, along with a list of what types of chemicals will affect the serviceability of the equipment or its ability to be used at its designated rated load. In addition, the manufacturer shall provide the minimum and maximum temperatures that the equipment can be used at its designated rated load, plus any other ambient conditions that could adversely affect the ability of the equipment to be operated at its designated rated load.

6.7.2 Aramid Fiber Cordage with Unbonded Elastomeric Coating Loaded in Simple Tension

The material shall be qualified and controlled for conformance to the manufacturer’s written specification. The material specification shall contain, as a minimum with appropriate limits, the uncoated cordage diameter, the denier of the cordage, the coated cord diameter, the twist density, and the tensile strength. The tensile strength shall be tested in accordance with ASTM D4268 or other international standards.

(Metallic Components Only)How are non-metallics tobe analyzed?

Need better definition of the lot size or "batch"that is qualified by a given specimen, and howthe specimen is taken.

p p p pincuding frequency, methods, equipment, and acceptance and rejection criteria

Place this text in parentheses.

CompositeAramid Fiber Cordage with Unbonded Elastomeric Coating g

6.7.1 General

insert "or 5% of the elastic modulus, whicheveris less",

the value of the ultimate strength multiplied by 0.80 shallybe used as the equivalent yield strength.

Insert "Polymers and polymer composites with aglass transition temperature above the design/operating temperature shall not be used."

operating temperature.

August 2009

Page 5 of 9

8 Quality Control

8.4 Quality Control for Specific Equipment and Components

8.4.7 Surface NDE

8.4.7.4 Acceptance Criteria

8.4.7.5 Non-metallic Components

The manufacturer shall have written specifications defining the maximum defect size, orientation, grouping, etc. for each type of defect expected. The defect types considered are to be at a minimum, voids, cuts, cracks, and/or tears.

The methods for detection and measurement of the expected defects are to be specified and proven effective in detecting defects no larger than 75% of the maximum allowable size or severity. All primary load carrying components are to be examined in both critical and non-critical areas.

ANNEX F(informative)

Load Limiting Design of Manual Tongs

F.1 Purpose

F.1.1 General

The purpose of this annex is to provide standards for certifying a design as load limiting. A load limiting design is one that in the event of an overload, the primary load will be either prevented from increasing or released in a controlled manner without unlatching and with no fragments expelled. Clauses 4.2.4, 4.2.5, 4.6, 5.4, 5.5, and 5.6 regarding the design and design verification testing of manual tongs does not apply to load limiting tongs designed, qualified, and tested in accordance with this annex.

Load limiting designs may be accomplished by the use of materials, components, or mechanisms to release or limit the primary load in an overload condition. The limiting component shall be an integral part of the tool, impossible to be removed, bypassed, or adjusted in the field.

F.1.2 Equipment covered

This specification covers the design, manufacture and testing of load limiting manual tongs.

F.2 Definitions


F.2 Definitions


Move all of these definitions to clause 3.0 Definitions, and insert"In Load Limiting Designs (ref Annex F)" to the end of each def.

insert "delaminations,"

August 2009

Page 6 of 9

F.2.1average limit loadThe numerical average of primary load which causes the limiting component to release the primary load.

F.2.2limiting componentA component, material or mechanism which will release the primary load in the event of an overload

F.2.3load varianceA measure of how widely values are dispersed from the average value

F.2.4secondary loadThe minimum load capacity of all components in the tool except for the limiting component.

F.2.5secondary componentAll components with the exception of the limiting component.

F.3 Design

F.3.1 Average Limit Load

The average limit load shall be determined by testing the limiting component. A minimum sample size of fifty (50) tests of the same size and type of component shall be used. The primary load to the tool required to cause a limit of the load shall be measured or calculated using the mechanical relationship of the measured load to the primary load. The average limit load shall be documented in terms of the output.

Testing shall be performed at the worst case(s) of temperature and rate of loading that may be encountered in service.

Testing of reduced sized specimens is permitted provided that a minimum of two full size tests are conducted to verify the relationship with the specimens.

F.3.2 Load Variance

The load variance of the limit load shall be calculated from the test data used to determine the average limit load. The load variance shall be the greater of the standard deviation (determined from the equation below) or one seventh (1/7) of the average limit load:

2

1

)()1(

1 LLn

Dn

ii�

�

��

�

where

L is the load corresponding to each sample in measuring the average limit load;

n is the number of samples and is the average limit load.

L is the average limit load.

F.2.1average limit loadThe numerical average of primary load which causes the limiting component to release the primary load.

F.2.2limiting componentA component, material or mechanism which will release the primary load in the event of an overload

F.2.3load varianceA measure of how widely values are dispersed from the average value

F.2.4secondary loadThe minimum load capacity of all components in the tool except for the limiting component.

F.2.5secondary componentAll components with the exception of the limiting component.

insert "primary load carrying"

insert "of a load limited design"

and is the average limit load.

August 2009

Page 7 of 9

F.3.3 Rated Load

The rated load shall be a maximum of two load variations below the average limit load. The rated load is given by the equation:

DLR 2��

F.3.4 Secondary Load

The secondary load shall be a minimum of three load variations above the average limit load. The secondary load is given by the equation:

DLS 3��

F.3.5 Design of Secondary Components

All components in the primary load path except the limiting component shall be designed such that the minimum material yield strength is equal to or greater than the stresses created by the secondary load.

F.4 Design Verification Load Test

The test procedure is as follows.

a) An assembled production unit shall be loaded to the maximum rated load. After this load has been released, the unit shall be checked for its intended design functions. The function of all of the equipment’s parts shall not be impaired by this loading.

b) The equipment shall be mounted in a test fixture capable of loading the equipment in a similar manner as found in typical field use. This may include, but is not limited to, the use of springs to simulate the compliance of the expected field loading equipment.

c) Strain gauges shall be applied to the unit at all places where high stresses are anticipated in all secondary components, provided that the configuration of the unit permits such techniques. The use of finite-element analysis, models, brittle lacquer, and so forth, is recommended to confirm the proper location of the strain gauges. Three-element strain gauges are recommended in critical areas to permit determination of the shear stresses and to eliminate the need for exact orientation of the gauges.

d) The design verification test load shall be applied to the unit at a rate expected in field use or, such that the limiting load shall be obtained in a maximum of ten (10) seconds, whichever is the greater rate of loading.

e) The unit shall be loaded at the rate determined in F.4b) until an indication that the load is being limited. The application of the load is then to be stopped manually and held in position for a minimum of 5 minutes. With the application of the load stopped, the measured load on the test unit may decrease in value indicating a release of stored energy. The test unit shall not unlatch and no components, or portions of components, shall become separated from the test unit assembly. This test shall be video recorded.

f) The peak load and the peak stresses computed from the strain gauges shall be recorded. The peak stresses computed shall not be greater than the equivalent stress from the following equation:

two load variations below the average limit load.

replace w/ "the Average Limit Load - two times theLoad Variance."

replace with "2 x Load Variance"

replace with "3 x Load Variance"

D2DD2�

D

August 2009

Page 8 of 9

SFS ty

e

��

where

Sy is the specified minimum yield strength for the component;

Ft is the peak load recorded in testing;

S is the secondary load from clause F.3.4.

The stress values computed from the strain gauge readings shall not exceed the values obtained from design calculations (based on the design verification test load) by more than the uncertainty of the testing apparatus specified in 5.7.

g) Failure of the test unit to meet the above requirements or failure in a secondary component shall be cause for complete reassessment of the design, followed by additional testing of an identical number of production units as originally required, including a unit of the same load rating as the one that failed.

h) Upon completion of the design verification load test, the test unit shall be disassembled and the dimensions of all secondary load-carrying components shall be checked for evidence of permanent deformation. Evidence of permanent deformation shall be compared to expected results in the design analysis. All permanent deformation shall not affect the serviceability of the components.

F.5 Proof Load Testing

The test procedure is as follows:

a) Each production unit or primary load-carrying component shall be load tested in accordance with the requirements of this section.

b) The equipment shall be mounted in a test fixture capable of loading the equipment in the same manner as in actual service and with the same areas of contact on the load bearing surfaces unless design verification testing indicates that the contact area is not the location of maximum stress and that the stresses produced by the alternate loading are not less than the maximum stresses expected from the design analysis and the design verification testing.

c) A test load equal to 1.5 times rated load shall be applied to all secondary components and held for a period of not less than five minutes. Load limiting components are to be tested at a load equal to the rated load and held for a period of not less than five minutes.

d) Following the load test, the design functions of the equipment shall be checked, as applicable. Proper functioning of the equipment shall not be impaired by the load test.

e) Assembled equipment shall be subsequently stripped down to a level that will permit full surface NDE of all primary load-bearing parts (excluding bearings and non-metallic components).

f) All critical areas of the primary load bearing parts shall be subjected to magnetic particle examination in conformance with 8.4.7.1 with the exception of bearings and nonmetallic components. Nonmetallic components shall be visually inspected for cracks, delamination, or other physical damage.

August 2009

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F.6 Quality Control of Limiting Components

Limiting components are to be controlled for a load equal to the average limit load plus or minus two load variations.

NOTE Nonconformance of the limiting component to control within the minimum and maximum loads will necessitate corrective action so that loss of load limiting, and an undesirable failure mode will not occur.

F.7 Product Marking

Manual tongs furnished in conformance with this specification shall be marked with the manufacturer’s name or mark, rated load, and API 7K-LL.

9.7 Manual tongs

9.7.5 Design verification load tests

The design verification load test, as described in Clause 5, shall apply except for load limiting manual tongs.

9.7.6 Proof load testing

Proof load testing, as described in 8.6, shall apply except for load limiting manual tongs. Load limiting manual tongs shall be proof tested in accordance with Annex F.5. Jaw hinge pins of wrought material shall be exempt from this requirement.

9.7.7 Load limiting manual tongs

Load limiting manual tongs shall be designed, and design verification load tested in accordance with Annex F.

add "which shall comply with therequirements of Annex F."

y except for load limiting manual tongs.

api 7k 5th edition item 2201 (reballot) non-metallic...

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