introduction -...

This document is not an API Standard; it is under consideration within an API technical committee but has not received all approvals required to become an API Standard. It shall not be reproduced or circulated or quoted, in whole or in part, outside of API committee activities except with the approval of the Chairman of the committee having jurisdiction and staff of the API Standards Dept. Copyright API. All rights reserved.

Addendum API 7K High Pressure Mud and Cement Hose Assemblies WG draft 11a

25 June 2018

Introduction

Please note the text in Italic is not part of the document, only explanation Changes in drilling technology require to update the HP mud and cement hose related sections of API 7K 6th.ed (2015). Several changes proposed in earlier drafts were implemented in 6th edition. On proposal of Katie Burkle, the full text of the HP hose section 9.7 is included. New text and changes are indicated in red. Changes suggested in the present draft will be balloted, (if SC8 decides positively.) This draft includes item 2202 “Hoses used for gas and underbalanced drilling within API Spec 7K”. Draft 8 was discussed at the WG meeting in Calgary, at API Standards Conference June 2017. Neither at the Conference, nor in additional email exchanges was an agreement reached, regarding design family definition. In draft 9 I tried to find a compromise. The requirement of “same number of plies” was removed. Based on audit experience of API additional information on design methodology was included. In the present draft 10 I made corrections in line with the comments of Robert Urbanowski and Guillermo Spangenberg (no other comments were received). Points raised by Robert Urbanowski were discussed at the Denver WG meeting on 11. June 2018, and agreed changes are included in draft 11. The WG proposed the Addendum for letter ballot. Draft 11a contains corrections of mistakes, realized on draft 11 in the meantime. The original scope of the WG was the following:

With increasing drilling depth, and increasing size of the rigs, there is demand for high pressure hoses outside of the scope of API 7K 5th.ed. This subject is item 3201, see SC8 meeting minutes of 26 June 2013.

Draft 10 includes these changes too.


Proposed text of Addendum to API 7K 6th Ed. High Pressure Mud and Cement Hose Assemblies Change in Section 1 Scope c) high-pressure mud and cement hose assemblies Changes in 3 Terms, Definitions, and Acronyms Delete definition 3.1.18 high pressure 3.1.19

high-pressure cement hose assembly

A hose assembly used mainly for the conveyance of cement slurries at high pressure.

3.1.20

high-pressure mud hose assembly

A rotary hose assembly, vibrator hose assembly, or jumper hose assembly. 3.1.24 hose assembly design family Hose assemblies of different internal diameters and rated working pressures, based on the same design methodology and stress criteria, having the same structure of reinforcing plies, same type of nonmetallic materials (rubber or thermoplastic), same liner material, and utilizing the same method of hose coupling attachment, hose to coupling interface design, and gas venting system (if any). Add the following new definitions Hose liner The inner polymeric layer of hose assembly in direct contact with the conveyed fluid. Occasionally a non-sealing metallic carcass may be applied inside of the polymeric liner. Fire Protection System All structural layers circumferentially outside of the reinforcing plies and the coupling

9.7 High-pressure Mud and Cement hose Assemblies

9.7.1 General

This specification applies to high-pressure flexible mud and cement hose assemblies, carrying fluid to the well bore, as listed in Tables 10a and 10b. It includes requirements for flexible hose assemblies used in air, gas, foam gasified liquid, liquid and mist drilling. This specification shall not apply to hoses transporting fluid from the well bore (return lines). Such hoses are covered by the scope of API RP 17B. This specification shall not apply to flexible choke lines and flexible kill lines covered by API 16C. See API RP 7L, Annex A, for information on operating limits, inspection, care, and use of cement hose, drilling mud vibrator and jumper hose, and rotary hose covered by this specification. See API RP 92U for information on underbalanced drilling operations.

9.7.2 Clarifications and Exceptions to Requirements Specified in Section 4 through Section 8


9.7.2.1 Definitions

Consistent with the definitions of the following terms specified in Section 3, the following clarifications are provided

below as they shall apply to the hose assemblies covered by this specification:

a) the primary load shall be the internal pressure;

b) the primary load-carrying components shall be the reinforcing cables, wires, metal armors (of unbonded hose assemblies), and hose couplings, and non-metallic materials utilized in the function of load carrying, e.g. epoxy resin of bonded coupling; (Note: external armors added as protection are not load carrying components)

c) the design load shall be the same as the rated working pressure of the hose assembly specified in Table 10a;

d) the dynamic load shall be comprised of additional loads exerted on the hose assembly that are separate from that

which is created by static pressure, such as pressure pulsations and dynamic bending, flexing or twisting.

Table 10a—Rotary Drilling and Vibrator Hose Assemblies, Cement Hose Assemblies, and Mud Delivery Hose Assemblies, Rated Working Pressure, Test Pressure, Minimum Burst

Pressure

API Grade Rated Working

Pressure Test Pressure

Design Safety Factor

Minimum Burst Pressure

MPa (psi) MPa (psi) MPa (psi)

A 13.8 (2000) 20.70 (3000) 2.50 34.50 (5000)

B 20.7 (3000) 31.05 (4500) 2.50 51.75 (7500)

C 27.6 (4000) 41.40 (6000) 2.50 69.00 (10,000)

D 34.5 (5000) 51.75 (7500) 2.50 86.25 (12,500)

E 51.7 (7500) 77.55 (11,250) 2.50 129.25 (18,750)

F 69.0(10,000) 103.50 (15,000) 2.25 155.25 (22,500)

G 103.5 (15,000) 155.25 (22,500) 2.25 232.88 (33,750)

H 138.0 (20,000) 207.00 (30,000) 2.25 310.50 (45,000)

Note, not part of the document: pressure rating of grade A and B increased, compared to API Spec. 7K 6th Ed. Test

pressure and min burst pressure in MPa is given to two decimals, to reflect the ratio of test pressure and minimum

burst pressure to rated working pressure more exactly. Pressure rating of 15 000 psi hose assemblies in MPa was

changed from 103,4 to 103,5 MPa, to align with API spec 16C ratings. Apart of the change in grade A and B the

difference is less than 0,1%. Successful design validation tests carried out according to API Spec 7K 6th Ed. before

the effective date of the present addendum shall be accepted.

Table 10b—Rotary Drilling and Vibrator Hose Assemblies, Cement Hose Assemblies, and Mud Delivery Hose Assemblies, Dimensions and Minimum Bend Radius (MBR)

Inside Diameter API Grade

Rated Working Pressure

Operational MBR a

Inside Diameter API Grade

Rated Working Pressure

Operational MBRa

mm (in) MPa (psi) m (in) mm(in) MPa (psi) m (in)

50.8 (2.0)

A 13.8 (2000) 0.9 (36)

101.6 (4.0)

B 20.7 (3000) 1.4 (55)

B 20.7 (3000) 0.9 (36) C 27.6 (4000) 1.4 (55)

C 27.6 (4000) 0.9 (36) D 34.5 (5000) 1.4 (55)

D 34.5 (5000) 0.9 (36) E 51.7 (7500) 1.5 (60)

E 51.7 (7500) 1.1 (44) F 69.0 (10,000) 1.8 (72)

F 69.0 (10,000) 1.2 (48) G 103.5 (15,000) 2.0 (79)

G 103.5 (15,000) 1.4 (55) H 138.0 (20,000) 2.2 (87)

H 138.0 (20,000) 1.5 (60)

127.0 (5.0)

B 20.7 (3000) 1,5 (60)

63.5 (2.5)

A 13.8 (2000) 0.9 (36) C 27.6 (4000) 1.5 (60)

B 20.7 (3000) 0.9 (36) D 34.5 (5000) 1.5 (60)

C 27.6 (4000) 0.9 (36) E 51.7 (7500) 1.8 (72)

D 34.5 (5000) 0.9 (36) F 69.0 (10,000) 2.0 (79)

E 51.7 (7500) 1.2 (48)

152.4 (6.0)

B 20.7 (3000) 1.8 (72)

F 69.0 (10,000) 1.2 (48) C 27.6 (4000) 1.8 (72)

G 103.5 (15,000) 1.5 (60) D 34.5 (5000) 1.8 (72)

H 138.0 (20,000) 1.6 (64) E 51.7 (7500) 2.0 (79)

76.2 (3.0)

B 20.7 (3000) 1.2 (48) F 69.0 (10,000) 2.2 (87)

C 27.6 (4000) 1.2 (48)

177.8 (7.0)

B 20.7 (3000) 2.2 (87)

D 34.5 (5000) 1.2 (48) C 27.6 (4000) 2.2 (87)

E 51.7 (7500) 1.2 (48) D 34.5 (5000) 2.2 (87)

F 69.0 (10,000) 1.5 (60) E 51.7 (7500) 2.5 (98)

G 103.5 (15,000) 1.6 (64) F 69.0 (10,000) 2.7 (106)

H 138.0 (20,000) 1.8 (72)

203.2 (8.0)

B 20.7 (3000) 2.5 (98)

88.9 (3.5)

B 20.7 (3000) 1.4 (55) C 27.6 (4000) 2.5 (98)

C 27.6 (4000) 1.4 (55) D 34.5 (5000) 2.5 (98)

D 34.5 (5000) 1.4 (55) E 51.7 (7500) 2.7 (106)

E 51.7 (7500) 1.4 (55) F 69.0 (10,000) 3.0 (118)

F 69.0 (10,000) 1.6 (64) a MBR is taken to the centerline of each hose.

G 103.5 (15,000) 1.8 (72)

H 138.0 (20,000) 2.0 (79)


9.7.2.2 Design Conditions

The following exceptions to the requirements in 4.1 shall apply.

a) The minimum operating temperature of hose assemblies is -20 °C (-4 °F). The manufacturer may specify a lower minimum operating temperature than –20 °C (–4 °F).

b) With regard to the cautionary note in 4.1, operation of the hose assemblies covered by this specification at

temperatures below the minimum specified is not recommended, however in the event that the requirements of

the purchase agreement dictate lower minimum operating temperatures than those specified above, the hose

assembly shall be qualified by conducting a low-temperature bending test at the temperature specified by

manufacturer, in addition to those other tests that are required to establish the temperature range and FSL level

specified in 9.7.3. In addition, when supplementary requirements SR2 and/or SR2A are specified in the

purchase agreement, they shall only apply to the hose coupling.

9.7.2.3 Design Methodology and Strength Analysis

Design methodology shall be approved by qualified third party. Design methodology shall include at least the following:

a) Calculation of stress in the reinforcement at rated working pressure, test pressure and minimum burst pressure, and stress criteria for all cases

b) Coupling wall thickness calculation and stress criteria at minimum burst pressure c) Coupling retention calculation and stress criteria at minimum burst pressure d) Calculation of gas diffusion trough the liner in case of FSL 3 hose assemblies

The requirements specified 4.2.4 and 4.2.5 shall not apply, but design verification calculation shall demonstrate for all hose sizes and pressure ratings, that stress at test pressure in the hose body reinforcement does not exceed 80% of yield stress:

σTP < 0.8xSy

where

σTP is the stress in the reinforcement at test pressure

Sy is the yield stress of reinforcement

The requirements specified 4.2.6 and 4.2.7 shall not apply.

9.7.2.4 Size Class Designation

Size class designation shall be in accordance with the hose assembly diameters and corresponding rated working

pressures specified in Table 10a and 10b.

9.7.2.5 Rating

The rating of hose assemblies covered by this specification shall be in accordance with the rated working pressure

specified in Tables 10a and 10b, and the temperature range and FSL level specified in 9.7.3.

9.7.2.6 Load-rating Basis

The load-rating basis of hose assemblies covered by this specification shall be based on the maximum allowable

stress of the reinforcing cables, wires, or metal armor, the critical areas of the hose coupling, and the interfacing


materials utilized between them if employed in the design.

9.7.2.7 Design Safety Factor (DSF)

The DSF for hose assemblies covered by this specification shall be the ratio of the minimum required burst pressure

specified in 9.7.7.2 and the rated working pressure of the hose assembly specified in Table 10a.

9.7.2.8 Design Validation

Requirements are specified in 9.7.10; Section 5 shall not apply. Note, not part of the document: it was assumed, that correction of design validation (item 7201) will pass. 9.7.2.9 Surface NDE

Surface NDE specified in 8.4.7 shall be limited to the hose coupling. Surface NDE of welds specified in 8.4.9 shall

apply to the weld and HAZ.

9.7.2.10 Proof Load Testing

Proof load testing required by 8.6 shall not apply.

9.7.2.11 Hydrostatic Testing

Hydrostatic testing requirements specified in 8.7.2 shall not apply. Hydrostatic testing shall be in accordance with

9.7.7.

9.7.2.12 Impact Toughness Impact toughness requirements specified in 6.3.1 shall not apply to reinforcing cables, wires or metal armor. 9.7.2.13 Qualification of Reinforcing Materials Reinforcing materials of the hose body shall be qualified according to written procedures of the manufacturer, sections 6.3.2.1 through 6.3.2.3 shall not apply 9.7.2.14 Non-metallic and Composite Materials Sections 6.4.2.5, 6.4.3, 6.4.4.2, 6.4.5, and 6.4.6.1 shall not apply for the epoxy coupling bonding material of high pressure mud and cement hose assemblies. Batch to batch qualification of the epoxy coupling bonding material can be carried out at room temperature, and prequalification of mechanical properties at minimum and maximum operating temperature applies. This is a deviation from section 6.4.4.1.

9.7.3 Temperature Range, Flexible Specification Level (FSL), Fire Protection and Flow Velocity

If known at the time of the purchase agreement, the purchaser shall specify the characteristics of the drilling medium

intended to be conveyed in the high-pressure mud hose assembly.

9.7.3.1 Temperature Ranges

Each hose assembly shall be rated by the manufacturer to operate in one of the three temperature ranges specified as

follows: Temperature Range I: –20 °C to +82 °C (–4 °F to +180 °F); Temperature Range II: –20 °C to +100 °C (–4 °F to +212 °F);


Temperature Range III: –20 °C to +121 °C (–4 °F to +250 °F). Note: The manufacturer may specify a lower minimum operating temperature than –20 °C (–4 °F).

9.7.3.2 Flexible Specification Levels (FSLs)

The FSL designations specified below define four (4) different levels of design validation requirements as specified in 9.7.10 and Table 10c. a) FSL 0: This shall be specified by the purchaser in the purchase agreement for cement hose assemblies only.

This includes all design validation requirements 9.7.10.1 through 9.7.10.8, excluding the pulsating pressure tests in 9.7.10.4 and 9.7.10.5 and the gas decompression test in 9.7.10.6.

b) FSL 1: This shall be specified by the purchaser in the purchase agreement for rotary, vibrator, and jumper hose assemblies for normal service conditions only. This includes all design validation requirements 9.7.10.1 through 9.7.10.8, excluding the high-frequency pulsating pressure test in 9.7.10.5 and the gas decompression test in 9.7.10.6.

c) FSL 2: This shall be specified by the purchaser in the purchase agreement for rotary, vibrator, and jumper hose assemblies that are likely to incur high frequency pressure pulsations with an amplitude exceeding 6.9 MPa (1000 psi) during operation. This includes all design validation requirements 9.7.10.1 through 9.7.10.8, excluding the low-frequency pulsation test specified in 9.7.10.4 and the gas decompression test in 9.7.10.6.

d) FSL 3: This shall be specified by the purchaser in the purchase agreement for rotary, vibrator, and jumper hose assemblies that are likely to be used in air, gas, foam or mist drilling to convey pressurized air, gas, foam or mist. This includes all design validation requirements 9.7.10.1 through 9.7.10.8, excluding the low-frequency pulsation test specified in 9.7.10.4.

9.7.3.3 Fire Protection For high pressure hose assemblies the purchaser may specify fire rating requirement according to supplementary requirement SR6 or SR7. Basic fire protection is described in supplementary requirement SR6. These hose assemblies shall be equipped with a fire protection system ensuring minimum fire rating of 5 minutes at 704 °C (1300 °F) as per design validation testing specified in 9.7.11.2. Advanced fire protection is described in supplementary requirement SR7. These hose assemblies shall be equipped with a fire protection system ensuring minimum fire rating of 30 minutes at 704 °C (1300 °F) as per design validation testing specified in 9.7.11.3.

Table 10c—Flexible Specification Levels and Test Sequence of Rotary Drilling and Vibrator Hose Assemblies, Cement Hose Assemblies, Mud Delivery Hose Assemblies

Hose Assembly Type Cement Rotary, Vibrator &

Jumper Rotary, Vibrator &

Jumper

Hose Service Cement slurry

Standard Drilling Fluids

Air, Gas, Foam or Mist Drilling

Flexible Specification Level FSL 0 FSL 1 FSL 2 FSL 3

9.7.10.2 Deformation Test Under Pressure X X X X

9.7.10.3 Bending Test X X X X

9.7.10.4 Low-frequency Pulsation Test - X - -

9.7.10.5 High-frequency Pulsation Test - - X X


9.7.10.6 Gas Decompression Test - - - X

9.7.10.7 Hydrostatic Pressure Test X X X X

9.7.10.8 Burst Pressure Test X X X X

Note: "X" = requirement, “-“ = not a requirement 9.7.3.4 Flow velocity Maximum allowed flow velocity shall be specified by the manufacturer. 9.7.4 Sizes and Lengths All hose assemblies shall comply with the sizes specified in Table 10b. The length of each hose assembly shall comply

with the dimension specified in the purchase agreement within the tolerances specified in 9.7.5. For rotary hose

applications, the purchaser should refer to the hose length calculation specified in API 7L to determine the optimum

length of a rotary hose for any given application to avoid over-bending, high axial load, or compression during operation.

For vibrator and jumper hose applications, the purchaser shall take into account the change in length of the hose

when it is pressurized as specified in 9.7.5 when specifying the overall length of the hose assemblies in the

purchase agreement. 9.7.5 Dimensions and Tolerances Dimensions of the hose assemblies shall conform to the requirements of Table 10b, and Figure 11. Hose assembly length tolerance and allowed length change at rated working pressure shall conform to Table 10d. The manufacturer shall specify the MBR if it is less than the values listed in Table 10b.

Table 10d-Manufacturing Tolerance of High Pressure Mud and Cement Hose Assembly Length

Manufactured length

tolerance

Nominal length up to and including 6.5 m (21.3 ft) ±65 mm (±2.56 in.)

Nominal length exceeding 6.5 m (21.3 ft) ±1 %.


Ød

< 90°

L

b b

3

2 1a

Key

1 safety clamp

2 end connector

3 inboard end of the coupling

d inside diameter

L nominal length

R bending radius

1a 3

2

NOTE See Table 10b for dimensions.

a Hose manufacturers shall mark the hose with the notation “Attach Safety Clamp Here.” b For hose assemblies longer than 6 m (20 ft) length, this dimension shall be 150 mm (6 in.) to 460 mm (18 in.) from the inboard end of

the coupling. For hose assemblies up to 6 m (20 ft) length, this dimension shall be 150 mm (6 in.) to 250 mm (10 in.) from the inboard

end of the coupling.

Figure 11—Rotary Vibrator and Drilling Hose Dimensions


9.7.6 Hose Couplings and End Connectors

9.7.6.1 Hose Couplings

Hose couplings shall be designed and manufactured so they are fit for purpose with the hose assembly they are attached to. Hose couplings shall be manufactured of impact tested material. Impact testing shall be performed in accordance with the requirements of 6.3.1.1. The minimum average Charpy impact energy of three full-size test pieces tested at the manufacturer specified minimum operating (or lower) temperature shall be 27 J (20 ft-lb), with no individual value less than 20 J (15 ft-lb).

In the event the hose assembly manufacturer elects to substitute or replace the hose couplings with those of different

materials of construction or different physical properties, the hose assembly manufacturer shall take one or more of the

following actions as appropriate:

a) conduct the design validation testing again to qualify the new hose coupling; or

b) arrange for a qualified third party to evaluate the new hose coupling materials and physical properties and

determine that the new hose coupling is fit for purpose with the hose assembly as previously qualified.

Furthermore, if the hose assembly manufacturer elects to alter the nature by which the hose coupling is attached to a

previously qualified hose assembly, the manufacturer shall conduct the design validation testing again to re-qualify the

hose assembly.

9.7.6.2 End Connectors

High-pressure mud and cement hose assemblies shall be furnished with end connectors as specified in the purchase

agreement. Although the design and manufacture of end connectors are not covered by this specification, the hose

assembly manufacturer shall select end connectors that are fit for purpose for the hose assembly they are attached to.

End connectors that are attached to the hose couplings with line pipe threads in accordance with API 5B shall not be

used in hose assemblies with rated working pressures exceeding 34.5 MPa (5000 psi). For hose assemblies with rated

working pressures exceeding 34.5 MPa (5000 psi), the end connector shall either be butt-welded onto the hose coupling,

or it may be machined from the same piece of material that the hose coupling is made of (integral).

9.7.7 Test Pressure and Burst Pressure

9.7.7.1 Test Pressure

9.7.7.1.1 Each high-pressure mud and cement hose assembly shall be hydrostatically tested to 1.5 times the rated

working pressure (see Table 10a). Test pressure shall be held for a minimum of 15 minutes. The test medium shall be

water.

Acceptance criteria shall be: no visible leakage and no bubble, nor blister or indication of delamination on the cover of the hose assembly. Pressure drop shall not exceed 2% of the test pressure during the 15 minutes hold period.

9.7.7.1.2 The pressure test shall be recorded on chart or graph and kept on file by the manufacturer for a minimum

of 10 years.

9.7.7.2 Burst Pressure

High-pressure mud and cement hose assemblies with rated working pressure up to and including 51.7 MPa (7500

psi) shall be designed to have a minimum burst pressure of 2.5 times the rated working pressure (see Table 10a).

Hose assemblies with a rated working pressure of 69 MPa (10,000 psi) and higher shall be designed to have a minimum

burst pressure of 2.25 times the rated working pressure (see Table 10a).


9.7.8 Rated Working Pressure

The maximum rated working pressure of the hose assembly is specified in Table 10a. Maximum surge pressures

encountered in the hose shall be included in the rated working pressure. The rated working pressure is identical to

design pressure.

9.7.9 Marking

9.7.9.1 Hose assemblies shall be marked in accordance with the requirements of Section 10 and the following: a) hose type, e.g. Cement Hose, Rotary Hose etc.; b) month and year of manufacture; c) the rated working pressure; d) the test pressure; e) the working temperature range; f) FSL level; g) “Not Fire Rated” or “Basic Fire Protection 5 min”, or “Advanced Fire Protection 30min” whichever applicable; h) MBR. Additionally, each hose end shall be marked (at the locations specified in Figure 11) with the notation “Attach Safety Clamp Here.” Each hose assembly except unbonded ones and hose assemblies with external armor shall have a longitudinal lay line of a different color than the hose cover. Markings, whether embossed or printed in distinctive colors, shall be vulcanized or similarly affixed into the hose cover, or shall be casted or marked using low-stress, hard-die stamps into the fittings or other metallic parts permanently bonded to the hose assembly. Marking shall be visible, clearly legible and at least 9.5 mm (3/8 in.) high. The requirements specified in 10.2 shall not apply. 9.7.9.2 Additional information may be marked on the hose assemblies at the discretion of the manufacturer or on

request of the purchaser.

9.7.9.3 Rings may be used above one or both of the couplings as a mark to identify the hose assembly grade. If applied,

the rings shall be of a different color than the hose cover. The number of rings for each grade shall be as follows and in

accordance with the grade designations specified in Table 10a:

a) Grade A—1,

b) Grade B—2,

c) Grade C—3,

d) Grade D—4,

e) Grade E—5,

f) Grade F—6,

g) Grade G—7,

h) Grade H—8.

9.7.10 Design Validation Testing of Hose Assembly Design Families

9.7.10.1 General

9.7.10.1.1 Design validation testing shall be performed to prove the integrity of each hose assembly design family

in accordance with the requirements of each FSL level defined in 9.7.3.2. High-temperature pulsating pressure tests specified in 9.7.10.4 and 9.7.10.5 and gas decompression test in 9.7.10.6 are not required for cement hoses. Design validation testing shall be carried out by an independent testing laboratory or witnessed by a third party


agency.

9.7.10.1.2 Successful completion of design validation testing 9.7.10.2 through 9.7.10.8, in accordance with the FSL requirements specified in 9.7.3.2, shall qualify the same size and smaller sizes of the design family for the same or lower rated working pressure for the full temperature range specified in 9.7.3.1 that was used for the tests. For

design validation tests 9.7.10.2 through 9.7.10.8 the hose assembly is regarded as member of the same hose

assembly design family if e.g. external armoring, fire rated cover, heat tracing, or local stiffening is added outside of the main reinforcement. Design verification calculations shall be carried out for other non-tested members of the design family, in line with 9.7.2.3 a), b) and c) for all FSL levels. For FSL 3 hose assemblies 9.7.2.3 d) calculation should verify, that the permeated gas per unit area of the liner does not exceed the amount of permeated gas per unit area of the tested member of the hose design family.

Qualification for higher FSL level also qualifies for lower FSL levels. Hose assemblies with different covers outside of the main reinforcement are also qualified, e.g. with external armoring, fire resistant cover or local stiffening.

9.7.10.1.3 All of the tests, (except the fire test) specified in 9.7.10.2 through 9.7.10.8 shall be performed on the largest internal diameter size hose assembly for a given hose assembly design family.

9.7.10.1.4 Design validation test of the fire protection system as per 9.7.11 shall qualify the same and larger sizes of the hose assembly design family and other hose assembly design families irrespective of their pressure rating, if the following conditions are met with the tested hose assembly: a) the fire protection is applied with the same structure layer by layer, and in the same thickness, b) the mass of reinforcing metal per unit length of hose body is equal or less in the tested hose assembly, then in other hose assemblies covered by the test c) the method of coupling attachment is the same For further details see Annex A.9 SR6 Basic Fire Protection requirement and SR7 for Advanced Fire Protection requirement.

9.7.10.1.5 In connection with high pressure mud and cement hose assemblies, a “burst” is defined as the catastrophic failure of the hose assembly, either by loss of a complete end fitting, or by rupture of the complete assembly. A “leak” is defined as a loss of pressure integrity in the hose assembly, but which allows a significant quantity of flow between the opposing end connectors enough to allow a continued temporary limited use in its intended service.

9.7.10.1.6 The minimum length of the tested hose assembly shall be 3.05 m (10 ft).

9.7.10.1.7 The tests in 9.7.10.2 through 9.7.10.8 shall be performed on the same hose assembly in accordance with the FSL requirements specified in 9.7.3.2 with exceptions listed in 9.7.10.1.8. The sequence of tests shall follow the order of sections 9.7.10.2 through 9.7.10.8.

9.7.10.1.8 In the case where a hose assembly design family is qualified to meet FSL 1, the FSL 2 qualification can be carried out on a different hose assembly of the same design family by performing the tests specified in 9.7.10.5, 9.7.10.7, and 9.7.10.8.

In the case where a design family is qualified to meet FSL 2 the qualification for FSL 3 can be carried out on a different hose assembly of the same design family, by performing the tests specified in 9.7.10.6, 9.7.10.7 and 9.7.10.8.

The fire test in 9.7.11 may be carried out on a different hose assembly without repeating the other tests.

9.7.10.1.9 If the minimum operating temperature specified by the manufacturer is lower than –20 °C (–4 °F), the low-temperature bending test 9.7.10.3.2 shall be carried out at the minimum operating temperature specified by the manufacturer.

9.7.10.2 Deformation Test Under Pressure


The test consists of the following steps at ambient temperature:

a) the length of the hose assembly shall be measured before pressurization; b) test pressure shall meet or exceed that which is specified in Table 10a for at least 15 minutes; c) the pressure shall be lowered to the rated working pressure of the assembly as specified in Table 10a, with

a tolerance of +0 % and –5 %; d) the length of the pressurized hose shall be measured again. Acceptance criteria shall be: the percentage of the length change calculated for the free hose body length between the inside ends of the couplings shall not exceed ±2 % for hose assemblies up to 103.5 MPa (15,000 psi) rated working pressure and ±3 % for 138 MPa (20,000 psi) hose assemblies. 9.7.10.3 Bending Test

9.7.10.3.1 Ambient Temperature Bending Test

Bend the hose assembly to its operational MBR 100 times with the hose at rated working pressure and ambient

temperature. The angle of the hose ends in bent position shall be less than 90 ° as shown in Figure 11.

The acceptance criteria shall be: no leakage, no visible damage, and no collapse or kinking.

9.7.10.3.2 Low-temperature Bending Test

The hose assembly shall be emptied and k ep t at or below the lower of –20 °C (–4 °F), or at the minimum operating

temperature specified by manufacturer for 24 hours. The hose assembly shall then be bent to its operational MBR

100 times at –20 °C (–4 °F) degrees or at the minimum operating temperature specified. The angle of the hose ends in

the bent position shall be less than 90 °, as shown in Figure 11.

If the bend radius for storage is lower than operational MBR, then the test shall be repeated to storage bend radius.

The acceptance criteria shall be: no visible damage and no collapse or kinking.

9.7.10.4 Low-frequency Pulsation Test

Perform 1000 cycles pulsating pressure test. The fluid temperature in the hose assembly shall not be less than the

maximum working temperature of the temperature range specified in 9.7.3.1. The upper pressure limit of the

pulsating pressure test shall not be less than the rated working pressure, and the amplitude of the pressure pulsation

shall be at least 90 % of the rated working pressure. One pressure cycle of raising and lowering the pressure shall not last

longer than 5 minutes.

The acceptance criterion shall be: no visible leakage.

9.7.10.5 High-frequency Pulsation Test

Perform 10,000 cycles pulsating pressure test. The fluid temperature in the hose assembly shall not be less than the

maximum working temperature of the temperature range specified in 9.7.3.1. The upper pressure limit of the

pulsating pressure test shall not be less than the rated working pressure, and the amplitude of the pressure pulsations

shall be at least 90 % of the rated working pressure. One pressure cycle of raising and lowering the pressure shall not last

longer than 10 seconds.

The acceptance criterion shall be: no visible leakage.

9.7.10.6 Gas Decompression Test


The hose assembly shall be pressurized to no less than its rated working pressure, at a minimum. The medium in this test shall be nitrogen or air. The gas temperature in the hose assembly shall be raised to no less than the maximum working temperature of the assembly as specified in 9.7.3.1. Stabilization pressure and temperature shall be maintained for 168 hours, at a minimum. Next, at least 10 cycles of rapid gas decompression cycles shall be conducted from the rated pressure to atmospheric. The decompression rate in the first 90% of each pressure drop shall be 7 MPa/min (~1000 psi/min), at a minimum. For the last 10% of pressure drop a slower rate is acceptable, but no additional flow restriction shall be applied on the outlet. The hose assembly shall be kept for a minimum of 10 hours at or above its rated pressure and at or above its maximum operating temperature between decompressions. The hose assembly shall also be kept for a minimum of 1 hour at atmospheric pressure. Transient temperature changes at decompression and compression stage are acceptable. After completion of the 10 rapid gas decompressions, a gauge test shall be carried out with a spherical pig. The outside diameter of the gauging pig shall be, at a minimum, 95% of the internal diameter of the hose body or 98% of the minimal internal diameter of the end termination, whichever smaller. The gauge test shall be completed by pushing or pulling the spherical pig through the entire internal diameter of the hose assembly. The assembly shall be visually inspected. The assembly shall be inspected internally using boroscope. Acceptance criteria shall be: the gauging pig shall pass without difficulty, and no delamination or blistering shall be observed on the inside or on the outside of the hose. 9.7.10.7 Hydrostatic Pressure Test

Hydrostatic pressure test shall be performed at ambient temperature, at no less than the test pressure specified in Table

10a, and shall be held for a period not less than 4 hours. The test medium shall be water.

Acceptance criteria shall be: no visible leakage. Pressure loss shall not exceed 2 % of the pressure at the start of

the four-hour period. The test medium shall be water.

9.7.10.8 Burst Pressure Test A burst pressure test at ambient temperature shall be performed after completion of the tests listed above. The test

medium shall be water.

Acceptance criteria shall be: the hose assembly shall not burst or leak below the minimum burst pressure specified

in Table 10a for the hose assembly tested.

9.7.11 Design Validation Testing of Fire Protection System

9.7.11.1 General

The purpose of the test is to qualify the fire protection system, in line with 9.7.10.1.4

9.7.11.2 Design Validation of Basic Fire Protection System Flexible hose specified shall be capable of containing the hose rated working pressure while submitted to an external

temperature of 704 °C (1300 °F) for a 5-minute period as detailed in the present chapter.

The fire test shall consist of direct exposure of a flexible hose sample to flame or to radiation within a furnace. The length

of the tested flexible hose shall be at least 3.05 m (10 ft), and at least 1.5 m (5 ft) of the assembly, including one coupling

and end connector should be exposed to temperature, horizontally or vertically.

Test sample shall be pressurized with water before the start of the test to the design working pressure and maintained

above design working pressure during the fire test without any addition of water.

Temperatures are to be measured at the middle and both ends of the exposed area by three pairs of thermocouples

located diametrically opposite to each other at a distance of 25.4 mm (1 inch) from the surface of the tested sample.

The fire exposure duration start at the time of test at which average temperature reading of the six thermocouples rise

above 704 °C (1300 °F) and finish once the 5 min test period is elapsed or alternatively once a leak occur beyond test

period. After switching off the heat source, the hose shall be kept at rated working pressure during the first 30 minutes

of the cool-down period, then the pressure shall be released.


The acceptance criterion shall be: no leakage at design working pressure during the 5-minute exposure to simulated fire

conditions. Leak of the sample is allowed beyond the 5-minute duration during cool-down of sample, however burst of

the sample either passed the 5-minute fire exposure duration or during cool down time will disqualify the tested prototype.

9.7.11.3 Design Validation of Advanced Fire Protection System Flexible hose specified shall be capable of containing the hose rated working pressure while submitted to an external

temperature of 704 °C (1300 °F) for a 30-minute period as detailed in the present chapter.

The procedure is the same as described in 9.7.11.2, but exposure time is 30 minutes.

The fire exposure duration start at the time of test at which average temperature reading of the six thermocouples rise

above 704 °C (1300 °F) and finish once the 30-minute test period is elapsed or alternatively once a leak occur beyond

test period. After switching off the heat source, the hose shall be kept at rated working pressure during the first 30

minutes of the cool-down period, then the pressure shall be released.

The acceptance criterion shall be: no leakage at design working pressure during the 30-minute exposure to simulated

fire conditions. Leak of the sample is allowed beyond the 30-minute duration during cool-down of sample, however burst

of the sample either passed the 30-min fire exposure duration or during cool down time will disqualify the tested

prototype.

Add to Annex A Supplementary Requirements

A.9 SR6 Basic Fire Protection Requirement for High Pressure Mud and Cement Hose Assemblies If required by the purchaser the hose assembly shall be equipped with basic fire protection system, qualified according to section 9.7.11.2 (5 min. in 704 °C fire) SR7 Advanced Fire Protection Requirement for High Pressure Mud and Cement Hose Assemblies If required by the purchaser the hose assembly shall be equipped with advanced fire protection system, qualified according to section 9.7.11.3 (30 min. in 704 °C fire)

Although selection of flexible hose end connectors is not constrained within API 7K, the flexible hoses compliant to SR6 or SR7 should demonstrate fire performance of non API 6A or non API 16A type connectors, by test result or calculation.

Changes in Annex F, Information with Inquiry or Order, F.2

d) High-pressure Mud and Cement Hose assemblies: 1) type (cement hose assembly; rotary hose assembly; jumper hose assembly or vibrator hose assembly; air drilling or gas drilling hose assembly; etc.);

NOTE If application is unusual or different from the listed ones, then give details. For vibrator and jumper hose assemblies, a configuration analysis is recommended in order to avoid over bending or over stressing a hose assembly in its application or layout. 3) length of the hose assembly. The length of vibrator or jumper hoses assemblies should account for the change in length when pressurized. Rotary hose assembly lengths should be calculated according to API 7L. 5) mud type and flow rate (oil based, high aniline, abrasive); composition of gas, mist or foam, if the hose assembly


is intended for air, gas, mist, foam, Underbalanced Drilling or Managed Pressure Drilling (transporting drilling fluid to wellbore only) 8) Flexible Specification Level (described in 9.7.3.2): FSL 0 (cement hose assemblies only), FSL 1 (rotary, vibrator and jumper hose assemblies only), FSL 2 (rotary, vibrator and jumper hose assemblies only), FSL 3 (rotary, vibrator and jumper hose assemblies only, if the hose assembly is intended for Air Drilling with air, gas, foam, or mist, Underbalanced Drilling or Managed Pressure Drilling transporting drilling fluid to wellbore only); 14) define fire rating requirement in three categories:

— No fire rating required — Basic fire rating required according to SR6 (5 min. in 704 °C fire) — Advanced fire rating required according to SR7 (30 min. in 704 °C fire)

Bibliography

Add: API RP 92U Underbalanced Drilling Operations API 92M, Managed Pressure Drilling Operations with Surface Back-pressure API RP 7L Procedure for Inspection, Maintenance, Repair and Remanufacturing of drilling Equipment API Standard 53, Blowout Prevention Equipment Systems for Drilling Wells

introduction -...

Documents