16RCD e2 Spec fm Specification for Rotating Control Devices API SPECIFICATION 16RCD SECOND EDITION, SEPTEMBER 2015 API MONOGRAM PROGRAM EFFECTIVE DATE MARCH 10, 2016 Special Notes API publications nec[.]
Purpose
This specification aims to ensure the safety and functional interchangeability of rotating control devices (RCDs) used in air drilling, oil and gas drilling operations, and geothermal drilling.
Technical specifications outline the necessary requirements for design, performance, materials, testing, inspection, welding, marking, handling, storage, and shipping It is important to note that this specification is not applicable to the field use or field-testing of RCDs.
Critical components are those parts having requirements specified in this document.
If product is supplied bearing the API Monogram and manufactured at a facility licensed by API, the requirements of Annex A apply.
Applications
An RCD is a complete system that includes subcomponents enabling rotation and axial movement of the drill string while effectively containing wellbore pressure This specification encompasses various equipment, such as active, passive, and hybrid rotating control devices, as illustrated in Figures 1, 2, and 3, which depict a surface BOP stack-up with each RCD type installed Additionally, it covers RCD bearing assemblies made of both metallic and non-metallic parts, RCD packer units of active and passive types, and RCD housing clamps or locking mechanisms.
Dimensional interchangeability is limited to end and outlet connections per API 6A and API 16A.
Service conditions refer to classifications for pressure, temperature, and wellbore fluids listed in 4.2 for which the equipment is designed.
Product Specification
This specification establishes requirements for products listed in 1.2.1.
Units and Dimensioning
This specification adopts the decimal/inch system as the standard for dimensions, while API size designations are presented as fractions It is important to note that the fractions and their decimal equivalents are considered equal and interchangeable within this specification.
Figure 1—Typical Surface Stack illustrating an Active Rotating Control Device
Figure 2—Typical Surface Stack illustrating a Passive Rotating Control Device
Figure 3—Typical Surface Stack illustrating a Hybrid Rotating Control Device
Flowline valve API 6A Wellhead body
Outer casing Active seal RCD packer
Metric Conversions
Metric conversions are described in Annex G of API 16A, and Annex F of this document.
Annexes
Annexes to this specification are not identified as requirements They are included only as guidelines or information.
The referenced documents are essential for applying this document For dated references, only the specified edition is applicable, while for undated references, the most recent edition, including any amendments, is relevant Manufacturers choosing to adopt alternative nationally or internationally recognized standards instead of a referenced standard must document their equivalency.
API Specification 6A, Specification for Wellhead and Christmas Tree Equipment
API Specification 16A, Specification for Drill Through Equipment, 3 rd Edition, June 2004
API Technical Report 6AF2, Technical Report on Capabilities of API Integral Flanges Under Combination of
ASTM D1418 1 , Standard Practice for Rubber and Rubber Lattices—Nomenclature
NACE MR0175/ISO 15156 2 , Petroleum and natural gas industries—Materials for use in H 2 S-containing environments in oil and gas production
3 Terms, Definitions, Acronyms, and Abbreviations
Terms and Definitions
For the purposes of this document, the following terms and definitions apply.
Defined limits placed on characteristics of materials, products, or services.
An RCD system wherein external pressure is supplied to maintain the seal between the seal element and the drill pipe.
Any portion of equipment between end connections, with or without internal parts, which contains wellbore pressure. NOTE This is sometimes referred to as a shell
1 ASTM International, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428, www.astm.org.
2 NACE International (formerly the National Association of Corrosion Engineers), 1440 South Creek Drive, Houston, Texas 77084-4906, www.nace.org.
Threaded fasteners used to join end or outlet connections.
Threaded fasteners used to assemble API 16RCD pressure-containing parts other than end and outlet connections.
Minimum inside diameter through the bearing assembly.
The minimum inside diameter through the RCD body, including the bottom connection.
Replacement for the seals or packers for protection of the inner bore of RCD, to be installed then pressure control is not required.
Comparison and adjustment to a standard of known accuracy.
(noun) Object at or near finished shape obtained by solidification of a substance in a mold.
(verb) Pouring molten metal into a mold to produce an object of desired shape.
Determination of the chemical composition of material.
Device with internal angled shoulders used to fasten mating hubs.
Device used to fasten and lock mating RCD body components.
Fulfillment of specified requirements in every detail.
End or outlet connection with no center bore, used to completely close off a connection.
Flanges (studded or open face), hub connections or other end connections which are used to join together equipment and are integral to the equipment.
Flanges (studded or open face), hub connections, or other end connections which are used to join together equipment but are not integral to the equipment.
Connections that are not specified in an API dimensional specification, including API flanges and hubs with non-API gasket preparations and manufacturer’s proprietary connections.
Connections in which thread-anchored studs are screwed into tapped holes.
Complete shut-off of wellbore without tubular in wellbore.
System for storing and/or providing permanent copies of test information, such as: strip chart recorders, circular chart recorders, or computer systems.
Date of manufacturer’s final acceptance of finished equipment.
Maximum pressure rating while including rotation of the drill string at a given RPM.
Any single completed unit that can be used for its intended purpose without further processing or assembly.
Examination of parts and equipment for visible defects in material and workmanship.
Examination for internal material defects by radiography, acoustic emission, or ultrasonic testing.
Protruding rim, with holes to accept bolts and having a sealing mechanism, used to join pressure-containing equipment together by bolting one flange to another.
(noun) A shaped metal part formed by the forging method.
(verb) Plastically deforming metal, usually hot, into desired shapes with compressive force, with open or closed dies.
Material originating from a final melt For remelted alloys, a heat shall be defined as the raw material originating from a single remelted ingot.
That 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.
Alternate steps of controlled heating and cooling of materials for the purpose of changing physical or mechanical properties.
That material moved as a batch through one heat treatment cycle.
Protruding rim with an external angled shoulder and a sealing mechanism used to join pressure-containing equipment.
The rotating control device (RCD) integrates a passive packer element with an active packer element that relies on an external hydraulic pressure source for closure force This design ensures that both elements can independently maintain a seal against wellbore pressures, achieving the full static pressure rating of the RCD.
Any internal or integral cavity of an RCD that is used to contain a hydraulic pressure.
3.1.36 hydraulic operating system rated working pressure
Maximum hydraulic pressure at which the equipment is designed to operate.
3.1.37 hydraulic operating system recommended operating pressure
Visual signs of cracks, pits, or other abnormalities found during liquid penetrant (LP) and magnetic particle (MP) examination.
Parts which are joined by the forging, casting, or welding process.
Visible passage of the pressurized fluid from the inside to the outside of the pressure containment area of the equipment being tested.
Sealing component(s) between the rotating control device and the drill string.
Individual piece used in the assembly of a single equipment unit.
RCD system wherein no external pressure is supplied to maintain the seal between the seal element and the drill pipe.
Individuals with characteristics or abilities gained through training, experience, or both, as measured against the manufacturer’s established requirements.
Any heat treatment subsequent to welding, including stress relief.
3.1.46 pressure-containing part(s) or member(s)
Parts exposed to wellbore fluids whose failure to function as intended would result in a release of wellbore fluid to the environment, e.g bodies, bearing assemblies.
3.1.47 pressure-controlling part(s) or member(s)
Parts intended to control or regulate the movement of wellbore fluids, e.g packing elements, seats with a pressure- containing member or part(s).
3.1.48 pressure-retaining part(s) or member(s)
Parts not exposed to wellbore fluids whose failure to function as intended would result in a release of wellbore fluid to the environment, e.g closure bolts and RCD housing clamps.
Maximum internal pressure that the equipment is designed to contain and/or control.
The maximum internal pressure of an RCD is determined by its operational mode, which includes dynamic operation with rotating pipes, stripping with reciprocating pipes, or static conditions with no pipe movement.
Ring grooves lined with metal resistant to metal-loss corrosion.
Drill through equipment is engineered to facilitate the rotation of the drill string while effectively containing pressure This is achieved through the use of seals or packers that create a secure seal against the drill string, including components such as the drill pipe and casing.
Maximum rotating speed specified at a given pressure for a specific pipe size as defined by the manufacturer.
Assignment of a unique code to individual parts and/or pieces of equipment to maintain records.
When the initial pressure decline rate decreases to within the manufacturer’s specified rate.
NOTE This pressure decline can be caused by such things as changes in temperature, setting of elastomer seals, or compression of trapped air in the equipment being tested.
When the initial temperature fluctuations decrease to within the manufacturer’s specified range.
NOTE This temperature fluctuation can be caused by such things as mixing of different temperature fluids, convection, or conduction.
Maximum design verification pressure of a complete RCD with a new element that the equipment is designed to control with no pipe movement.
Controlled heating of material to a predetermined temperature for the purpose of reducing any residual stresses.
Adding or removing pipe from a pressured wellbore while controlling flow from the wellbore.
Maximum pressure when reciprocating or tripping but not rotating the drill string for a specific packer model.
Measurement of the average roughness (RMS) of a surface.
NOTE All of the surface finishes given within this specification are to be considered maximums.
Weld joining two or more parts.
Weld which extends throughout the complete wall section of the parts joined.
Area between two metals to be joined that has been prepared to receive weld filler metal.
Fusion of materials, with or without the addition of filler materials.
Stress levels, measured in pounds per square inch of the loaded area at room temperature, indicate the point at which a material undergoes plastic deformation At this stage, the material will not revert to its original dimensions once the load is removed.
NOTE All yield strengths specified in this standard are considered as being the 0.2 % yield offset strength per ASTM A370.
Acronyms and Abbreviations
For the purposes of this document, the following acronyms and abbreviations apply.
ASTM American Society for Testing and Materials
Size Designation
The size designation of equipment within the scope of this specification shall be in accordance with 4.3.
Service Conditions
The manufacturer must specify the static, dynamic, and stripping pressure ratings, which must be validated according to this specification These pressure ratings apply to new packing elements and must not surpass the pressure rating of the weakest connection exposed to well bore pressure.
Minimum temperature is the lowest ambient temperature to which the equipment may be subjected
Maximum temperature is the highest temperature of the fluid, which may flow through the equipment.
Equipment shall be designed for metallic parts to operate within the temperature ranges shown in Table 1
Equipment shall be designed for wellbore elastomeric materials to operate within the temperature classifications of 8.3.4.3.
Manufacturers shall specify the operating fluid environment (liquid, gas, or multiphase) and compatibility for the seals.
Seals shall be designed to operate within the temperatures of the manufacturer’s written specifications.
Manufacturers shall specify the operating fluid environment (liquid, gas, or multiphase) and compatibility for the seals.
All metallic materials shall meet the requirements of NACE Standard MR0175/ISO 15156 for sour service.
Table 1—Temperature Ratings for Metallic Materials
Equipment-Specific Design Requirements
4.3.1 Flanged End and Outlet Connections
Flanged end and outlet connections shall conform to the dimensional requirements of API 6A.
The rotating control device (RCD) bottom connection pressure rating must be equal to or greater than the static pressure rating of the RCD.
The pressure rating of the side outlet connection must meet or exceed the static pressure rating of the RCD Additionally, 6B and 6BX flange connections can serve as integral connections.
6B and 6BX flanges integral to RCDs shall not contain test connections.
The manufacturer must document the load and capacity for flanged end and outlet connections following the API 6AF2 format, which includes graphs correlating pressure to allowable bending moments for different tensions It is essential for the manufacturer to specify the section of the connection that establishes the stress limitations used in these graphs Additionally, all analytical design methods must comply with section 4.4.
4.3.1.2.1 Pressure Ratings and Size Ranges of Flange Connections
Type 6B and 6BX flange connections shall be designed for use in the combination of API size designation and pressure ratings as according with API 6A.
Dimensions for Type 6B integral flanges shall conform to API 6A Dimensions for all ring grooves shall conform to API 6A.
NOTE Type 6B flange connections are of the ring-joint type and are not designed for face-to-face make-up.
The flange face on the ring-joint side must be either flat or raised and fully machined The nut bearing surface should be parallel to the flange face within one degree Additionally, the flange back face must be fully machined or spot faced at the bolt holes, with the thickness after facing conforming to API 6A dimensions.
Type 6B flange connections can feature corrosion-resistant overlays in their ring grooves Before applying the overlay, it is essential that the preparation of the ring grooves adheres to API 6A standards.
NOTE Other weld preparations may be employed when the strength of the overlay alloy equals or exceeds the strength of the base material.
Dimensions for Type 6BX integral flange connections shall conform to API 6A Dimensions for all ring grooves shall conform to API 6A.
NOTE Type 6BX flange connections are of the ring-joint type and are designed for face-to-face make-up.
The flange face on the ring-joint side must be raised and completely machined, ensuring that the nut bearing surface is parallel to the flange face within one degree Additionally, the back face should be fully machined or spot faced at the bolt holes, with the thickness after facing conforming to the dimensions specified in API 6A.
Type 6BX flange connections can be produced with corrosion-resistant overlays in the ring grooves Before applying the overlay, it is essential to prepare the ring grooves according to the dimensions specified in API 6A.
NOTE Other weld preparations may be employed when the strength of the overlay alloy equals or exceeds the strength of the base material.
4.3.2 Studded End and Outlet Connections
The two types of studded end and outlet connections (6B and 6BX) in this specification shall conform to API 6A. Studded connections 6B and 6BX may be used as integral connections.
The manufacturer must document the load and capacity of studded connections following the format specified for API flanges in API 6AF2, which correlates pressure with allowable bending moments for different tension levels Additionally, the manufacturer is required to specify the section of the connection that includes the stress limitations used to create the corresponding graphs Furthermore, analytical design methods must adhere to the guidelines outlined in section 4.4.
Design for studded end and outlet connections is the same specified in 4.3.1.2 except as follows.
Dimensions for Type 6B studded connections shall conform to API 6A as it relates to the bore size, diameter of the bolt circle, and flange outside diameter (OD).
The studded connection shall be fully machined in accordance with API 6A.
Stud bolt holes must be sized and positioned according to API 6A standards The tapped hole's thread form should meet the specifications outlined in section 4.3.3 Additionally, the minimum depth of the full threads in the hole must equal the stud diameter, while the maximum depth should adhere to the manufacturer's written specifications.
Dimensions for Type 6BX studded connections shall conform to API 6A as it relates to bore size, diameter of the bolt circle, and flange OD.
The studded connection shall be fully machined in accordance with API 6A.
Stud bolt holes must be sized and positioned according to API 6A standards The tapped hole's thread form should meet the specifications outlined in section 4.3.3 Additionally, the minimum depth of the full threads in the hole must equal the stud diameter, while the maximum depth should adhere to the manufacturer's written guidelines.
4.3.3 Studs, Nuts, and Tapped Stud Holes (Bolting)
Bolting for end and outlet connections, both studded and flanged, shall meet the requirements of API 6A.
4.3.4 Hubbed End and Outlet Connections
End and outlet hubs (16B and 16BX), if specified by the manufacturer, shall conform to the requirements of API 16A.
Clamps that shall be used in conjunction with end and outlet hubs (16B and 16BX) if specified by the manufacturer shall conform to the requirements of API 16A
Type 16B hub connections may be manufactured with corrosion-resistant overlays in the ring grooves Prior to overlay, the ring groove shall be prepared as specified in API 6A.
RCDs are identified by several key specifications, including the flange size (top, bottom, and outlet) along with the static pressure rating, the bore through the body, and the minimum restricted inside diameter (ID) with packing elements in place Additionally, the bore through the bearing, if it differs from the minimum restricted ID, and the drift diameter with the bore protector installed are also crucial for identification.
The overall height of RCDs is measured from the bottom face of the bottom connection to the top face of the RCD, and these dimensions must align with the manufacturer's specifications.
Design methods shall conform to 4.4.
End connections on all equipment within the scope of this specification shall conform to the requirements of 4.3.1, 4.3.2, 4.3.4, 4.3.8, and 4.3.9.
Outlet connections shall conform to the requirements of Sections 4.3.1, 4.3.2, and 4.3.4.
Material used for pressure-containing parts or members shall conform to the requirements of Section 5.
Closure bolting and other parts shall conform to the manufacturer’s written specifications.
Gaskets used for equipment manufactured to this specification shall meet all the requirements of API 6A, PSL 1.
Type R, RX, and BX ring-joint gaskets are essential for flanged, studded, and hub connections Types R and RX gaskets can be used interchangeably in Type R ring grooves, while only Type RX gaskets are compatible with SR ring grooves Additionally, Type BX gaskets are specifically designed for use with 6BX ring grooves, and it is important to note that Type RX and BX gaskets are not interchangeable.
Non-API weld neck hubs are not addressed in this edition of API 16RCD.
This section outlines the requirements for alternative end connections (OECs) that can be utilized for joining RCDs, which are not detailed in the API dimensional specifications OECs encompass API flanges and hubs that feature non-API gasket preparations, as well as proprietary connections from manufacturers.
OECs shall be designed in accordance with 4.4.
OECs shall be designed with the same API size designation shown in API 16A, Table 1.
The bore diameter shall conform to the minimum bore dimension shown in API 16A, Table 1.
OEC materials shall meet the requirements of Section 5.
API 16RCD equipment utilizing OECs shall successfully complete the tests required in Section 7.
6B and 6BX blind flanges shall conform to the dimensional requirements of API 6A.
Dimensions of 16B and 16BX blind hubs, if specified by the manufacturer, shall conform to the requirements of API 16A
The design and configuration of blind OECs shall conform to 4.3.8.2, 4.3.8.3, and 4.3.8.4.
4.3.10 Test, Vent, Injection, and Gauge Connections
Sealing and porting of flanges, hubs, and OECs shall conform to the requirements of API 6A.
Design Methods
End and outlet connections shall conform to the requirements of this specification.
Pressure-containing parts or members shall be designed in accordance with API 16A.
Closure bolting shall be designed in accordance with API 16A.
Pressure-retaining parts and pressure-controlling parts shall be designed to satisfy the manufacturer’s written specifications and the service conditions defined in 4.2.
End and outlet connections below the sealing elements shall be integral.
The manufacturer must document the load capacity for the RCD clamp connection following the format specified for API flanges in API 6AF2, which correlates pressure with allowable bending moments for different tensions Additionally, the manufacturer should clarify whether the limitation pertains to the stress level of the clamp or the RCD hub, ensuring that analytical design methods comply with section 4.4.
The manufacturer must document the load and capacity for the OEC following the format specified for API flanges in API 6AF2, which correlates pressure with allowable bending moments for different tensions Additionally, the manufacturer is required to identify the specific part of the connection that includes the stress limitations used to create the graphs Furthermore, analytical design methods must adhere to section 4.4.
Design Verification Testing
Design verification testing is mandatory for the equipment outlined in section 1.2.1 and must be detailed in the manufacturer's written specifications However, it is important to note that design verification testing is not necessary for API clamps, API flanges, API hubs, or API ring gaskets.
Experimental confirmation of the design shall be documented and verified as required in 4.6.
Tests of the operating characteristics for RCDs shall conform to 4.7.
Tests on RCD packing units shall conform to 4.7.
Design temperature verification testing on RCD packing units shall conform to 4.8.2.
Tests of the operating characteristics for OECs shall conform to the manufacturer’s written specifications.
Documentation
Designs including design requirements, methods, assumptions and calculations shall be documented Design documentation media shall be clear, legible, reproducible, and retrievable.
Design documentation shall be reviewed and verified by personnel other than the individual who created the original design.
Design verification procedures and results shall be documented.
Documentation retention for documents in Section 4 shall be for 10 years after the last unit of that model, size, and static pressure rating is manufactured.
Operational Characteristics Tests
All testing shall be in accordance with Table 2.
All operational characteristics tests must utilize water as the wellbore fluid The closing pressure should align with the manufacturer's recommendations and must not surpass the designed hydraulic operating system's working pressure The manufacturer is responsible for documenting the procedure and results, including temperature data, and may refer to the procedures outlined in Annex B.
With the exception of stripping tests, the acceptance criterion for all tests that verify pressure integrity shall be no visible leakage under the test pressure.
If scaling of size and static, dynamic and stripping pressure is utilized, scaling shall conform to Table 2 The manufacturer shall document his technical justification.
Safety procedures shall be in accordance with the manufacturer’s written documentation.
4.7.2.2 Testing Requirements by RCD type
Table 3 outlines the test requirements for each type of RCD Procedures in Annex B may be used
This test will verify the static pressure rating of the RCD, with documentation required to include wellbore pressure records, test mandrel size, and the model/part numbers of the assembly Additionally, it must detail all internal and external seals according to the manufacturer's specifications that will be subjected to wellbore pressure.
Table 2—Required Operational Characteristics Tests and Acceptable Scaling Practices
The test is not applicable to passive-type RCDs Only closure mechanisms with functionally similar designs are eligible for scaling When a single packer element is utilized for various drill pipe (mandrel) sizes, testing must be conducted on both the minimum and maximum outer diameter (OD) mandrels, considering the relevant tool joint geometries All sizes of packer elements must be tested for the corresponding drill pipe size.
The P S rating qualifies all API static pressure ratings that are equal to or below the tested product's rating However, if packers have identical dimensions and materials but different pressure ratings, they only need to be tested at their maximum pressure rating.
P D = Qualifies all API dynamic pressure rating equal to and below that of the product tested.
P ST = Qualifies all API stripping pressure rating equal to and below that of the product tested
S2 = Qualifies all API size designations of the product tested
S3 = Qualifies only the API size designation of the product tested.
This test will assess the dynamic pressure rating of the RCD against the manufacturer's specified wellbore pressure and rotational speed for at least 100 hours The documentation must include records of the wellbore pressure and the mandrel's rotating speed, along with the model and part numbers of the assembly, ensuring all internal and external seals are listed as per the manufacturer's specifications for exposure to wellbore pressure.
This test evaluates the RCD's capability to handle multiple packer element changes while maintaining its operational characteristics It involves accessing the packing unit and conducting a static pressure rating test after every 20th access Documentation will record the number of cycles until failure or a maximum of 100 cycles, whichever occurs first.
This test aims to validate the stripping pressure rating of a specific model RCD packer element by stripping a minimum of 400 tool joints at the manufacturer's specified pressure The documentation will include records of wellbore pressure and temperature, mandrel size, tool joint diameter, test fluid, and the model/part numbers of the packing element.
The stripping test evaluates the effectiveness of the active and/or passive packing unit in maintaining wellbore pressure control while stripping the test mandrel and tool joints through the closed packing unit, ensuring fluid leakage does not exceed 1 gal/min Conducted against the manufacturer's specified maximum wellbore pressure, this test qualifies the packing element for a specific stripping pressure Documentation must include the wellbore pressure utilized during the test.
Bearing Packer Bearing Packer Bearing 1 Passive
Sealing Characteristics Test NA NA NA Yes NA NA Yes 2
Fatigue Test NA NA NA Yes NA NA Yes 2
Stripping Rating Test NA Yes NA Yes NA Yes Yes
Stripping Life Test NA Yes NA Yes NA Yes Yes
Packer Access Test Yes Yes Yes
Dynamic Pressure Rating Test Yes 1 Yes 1 Yes 1
Static Pressure Rating Test Yes 3 Yes 3 Yes 3
1 If the design of an RCD is such that it functionally includes more than one bearing assembly while operating, then each bearing assembly must be tested independently.
2 Both elements must independently maintain a seal against wellbore pressures up to the full static pressure rating of the RCD.
There are no specific static pressure rating test procedures, as this test is a requirement in at least one of the other testing protocols Key factors to consider include the wellbore fluid used, the mandrel size and length along with tool joint geometry, and the recorded reciprocating speed Additionally, it is important to note the number of tool joints stripped or the first 1000 tool joints reached, the volume of wellbore fluid pulled through during the test, and the temperature conditions recorded, including both ambient and surface temperatures of the mandrel.
This test evaluates the performance of an active-type RCD in sustaining a static pressure seal between 50 psi and 120 psi during repeated opening and closing cycles Documentation will include the packing element's inside diameter (ID) measured after every 20 cycles over a duration of 30 minutes, as well as the total number of cycles until failure to maintain the seal, capped at either 364 close/open cycles or 52 pressure cycles, depending on which limit is reached first.
This test aims to establish the necessary closing pressure and the maximum allowable rotational speed required to maintain a seal under wellbore pressures, reaching the full dynamic pressure rating of the active-type RCD Conducted on a drill pipe mandrel in open hole conditions (non-rotating), the test utilizes a mandrel sized for the minimum drill pipe outer diameter compatible with the packer, as specified by the manufacturer The procedure consists of four parts, focusing on the active packer element, starting with a Constant Wellbore Pressure Test.
This test aims to establish the necessary closing pressure to ensure a secure wellbore pressure seal on the test mandrel, with documentation that records the relationship between wellbore pressure and closing pressure Additionally, a constant closing pressure test will be conducted.
The test aims to establish the maximum wellbore pressure achievable at a specified closing pressure with the active-type RCD secured on the test mandrel Results will be documented, detailing the relationship between wellbore pressure and closing pressure during the full closure pressure test.
The test is essential for any RCD designated by the manufacturer as capable of complete shut-off (CSO), as it assesses the closing pressure needed to seal the open hole at half of the rated static pressure Additionally, documentation must include a record comparing wellbore pressure to closing pressure.
Design Temperature Verification Testing for Non-metallic Sealing Materials and Molded Sealing Assemblies
Safety procedures shall be in accordance with the manufacturer’s written documentation.
This procedure aims to assess the performance of non-metallic seals and molded sealing assemblies utilized as pressure-controlling or pressure-containing elements in specified equipment The primary goal is to evaluate the effectiveness of these components when subjected to both low and high temperature conditions.
All tests must be conducted at the extreme temperatures corresponding to the component's temperature class, as outlined in section 8.3.4.3 The manufacturer is responsible for specifying the test fluid and must document both the testing procedure and the results Procedures detailed in Annex C may be utilized for this purpose.
The acceptance criterion for all pressure tests is that there shall be no visible leakage under the test pressure.
If scaling of size and static pressure is utilized, scaling shall conform to Table 2 The manufacturer shall document his technical justifications.
4.8.2 Passive, Active, and Hybrid-types RCDs
Non-metallic seals and molded sealing assemblies in the RCD must undergo testing to ensure they can maintain a seal at the extremes of their temperature classification The required documentation includes elastomer records as specified in the test procedures, temperature records of the RCD wellbore during testing, low-temperature test performance with a minimum of three pressure cycles at rated static pressure and a pressurization hold time of at least 15 minutes, and high-temperature test performance with one pressure cycle at rated static pressure and a minimum pressurization hold time of 60 minutes.
Operating Manual Requirements
The manufacturer must create and provide an operating manual for each model produced, adhering to specified guidelines This manual should include essential information such as operation and installation instructions, physical data, details on packers and seals, maintenance and testing procedures, disassembly and assembly guidelines, parts information, and storage conditions, particularly for rubber and elastomeric materials Additionally, it must specify static, dynamic, and stripping pressure ratings, as well as the rated and recommended working pressures for the hydraulic operating system, and the CSO pressure rating for active-RCD.
This section outlines the material performance, processing, and composition standards necessary for pressure-containing components Additionally, all other parts must be constructed from materials that meet the design specifications outlined in Section 4 when integrated into API 16RCD equipment.
All material requirements shall conform to API 16A.
This section describes the welding requirements for metallic components All welding requirements shall conform to API 16A.
General
This section specifies the requirements relative to quality control to assure that the equipment, materials, and services meet this specification.
Measuring and Testing Equipment
Quality control requirements for measuring and testing equipment shall conform to API 16A Refer to the relevant section in API 16A.
Quality Control Personnel Qualifications
Quality control requirements for personnel qualifications shall conform to API 16A Refer to the relevant section in API 16A.
Quality Control Requirements For Equipment and Parts
Quality control requirements for equipment and parts shall conform to API 16A.
Quality Control Requirements For Specific Equipment And Parts
7.5.1 Pressure-containing and Pressure-controlling Parts
Quality control requirements for pressure containing and pressure controlling parts shall conform to API 16A Refer to the relevant section in API 16A.
7.5.2 Studs and Nuts (Other Than Closure Bolting)
Quality control requirements for studs and nuts shall conform to API 16A Refer to the relevant section in API 16A.
Quality control requirements for closure bolting shall conform to API 16A Refer to the relevant section in API 16A.
Quality control requirements for ring gaskets shall conform to the requirements of API 16A Refer to the relevant section in API 16A.
7.5.5 Non-metallic Sealing Materials and Molded Sealing Assemblies
Quality control requirements for all non-metallic sealing materials and molded sealing assemblies including RCD packer elements shall conform to the requirements of API 16A.
7.5.6 All Other Drill Through RCD Equipment Not Covered in 7.5.1 Through 7.5.5
All quality control requirements shall be documented in the manufacturer’s written specifications.
Quality control for assembled equipment must encompass drift tests, pressure tests, rotating torque tests (when applicable), and hydraulic operating chamber tests Manufacturers have the option to perform these tests with or without a packing element, based on their discretion.
Serialization is required on all assembled equipment and shall be done in accordance with the manufacturer’s written specification.
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).
A drift test is required on RCDs.
Pass a drift mandrel through the bore of the assembly after all pressure testing.
Drift mandrel diameter shall be 0.020 in to 0.030 in less than the manufacturer’s specified size designation of the bore of the bearing assembly and RCD body.
Drift mandrel gauge length shall be at least 2 in longer than any cavity that intersects the bore, but not less than 12 in.
The drift mandrel shall pass through without being forced.
A data acquisition system is required for all hydrostatic and hydraulic control system tests Pressure gauges must meet the specifications outlined in section 7.2.3 Additionally, records must clearly identify the recording device and include the date and signature.
All Residual Current Devices (RCDs) must undergo a hydrostatic body test before leaving the manufacturer's facility The testing fluid used will be either water or a water-additive mixture, with any additives clearly documented in the test records.
7.5.7.6.2 In-plant Hydrostatic Body or Shell Test
RCDs shall be tested with its sealing mechanisms in the open position, if applicable.
The hydrostatic body or shell test pressure shall be determined by the static pressure rating for the equipment Hydrostatic body test pressures shall be 1.5 X static pressure rating.
The hydrostatic body test involves three key steps: first, an initial pressure-holding period lasting at least 3 minutes; second, a reduction of the pressure to zero; and finally, a second pressure-holding period of no less than 15 minutes.
The timing of the test shall not start until the test pressure has been stabilized within the manufacturer’s specified range and the external surfaces have been thoroughly dried.
Following all pressure tests a rotating torque test shall be undertaken on bearing assembly to confirm that the torque is within the manufacturer’s specification, if applicable.
The hydraulic operating chamber test shall be performed on each assembled RCD This test can be conducted in conjunction with a hydrostatic body shell test.
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 acceptance criterion is that there shall be no leakage
If previous tests do not sufficiently evaluate all pressure-containing and load-bearing components of an assembled unit, additional measures must be taken Each assembled RCD must undergo a closed test following the hydrostatic body test, using a hydraulic operating system pressure that does not exceed the manufacturer's specified operating pressure The test fluids must comply with the requirements outlined in section 7.5.7.6.1 The timing for all closed RCD tests should commence only after the test pressure has stabilized, and these tests must be conducted at both low and high pressures, with low-pressure tests always performed before high-pressure tests.
A pressure of 50 psi to 120 psi shall be applied and held below the closed RCD for a time period of not less than 10 minutes after stabilization.
To ensure proper functioning, a pressure equal to or greater than the static pressure rating of the RCD must be applied and maintained below the closed RCD for a minimum duration of 10 minutes after stabilization.
When a manufacturer specifies a Closing Safety Override (CSO), the test must be conducted with the rotating control device (RCD) closed and without the drill pipe, directly on the open hole The high-pressure test should adhere to the guidelines outlined in section 7.5.7.7.3, with the minimum requirement being a pressure that is half of the manufacturer's specified static pressure rating.
Factory Acceptance Test (FAT) Matrix
Table 4 summarizes the factory acceptance tests necessary for each type of RCD.
The acceptance criterion for all pressure tests is that there shall be no visible leakage under the test pressure.
Quality Control Records Requirements
Quality control records mandated by this specification are essential documents that verify compliance of all materials and equipment with the specified requirements.
To demonstrate compliance with NACE requirements, additional records are necessary beyond those outlined in other sections of this document, unless the records specified here also meet the MR0175 criteria.
Records required by this specification shall be legible, identifiable, retrievable, and protected from damage, deterioration, and loss.
Records required by this specification shall be retained by the manufacturer for a minimum of 10 years following the date of manufacture as marked on the equipment associated with the records.
The manufacturer is required to document and maintain records for every batch of raw material utilized in the production of RCD packers and seals, with these records being kept for a minimum of five years.
All records required by this specification shall be signed and dated Computer-stored records shall contain originator’s personal code.
7.7.2 Records to Be Maintained by Manufacturer
The manufacturer shall retain all documents and records as required in Section 4, Section 5, Section 6, and Section 7.
For those parts or components covered in 7.5.1: a) weld procedure qualification record (PQR); b) welder qualification record;
Test Type Passive Active Hybrid
Drift test YES YES YES
Hydrostatic body/shell test YES YES YES
Rotating torque test YES 3 YES 3 YES 3
Hydraulic operating chamber test YES YES YES
Low pressure closed test YES 1 YES 1 YES 1
High pressure closed test YES 1 YES 1 YES 1
Complete shut-off test NO If Applicable 2 If Applicable 2
1 If the previous tests do not adequately address all pressure containing and load bearing members of an assembled unit, then the test shall be conducted.
2 If manufacturer specifies CSO, then the test shall be performed.
3 Only required for RCD with a bearing assembly. c) material test records:
2) tensile tests (Qualification Test Coupons (QTC)),
3) impact tests (QTC, as required),
4) hardness tests (QTC); d) Nondestructive examination (NDE) personnel qualification records; e) NDE records:
4) repair weld NDE records; f) hardness test records; g) welding process records:
4) post-weld heat treatments; h) heat treatment records:
2) actual times at temperature; i) volumetric NDE records; j) hydrostatic pressure test records; k) critical dimensions as defined by the manufacturer.
The manufacturer shall retain individual heat traceability records for closure bolting, as required.
7.7.2.3 Non-metallic Sealing Materials and Molded Sealing Assemblies
The manufacturer shall retain a certification of compliance for non-metallic sealing materials and molded sealing assemblies to manufacturer’s written requirements.
7.7.3 Records to Be Furnished to Original Purchaser upon Product Delivery
A manufacturer’s certificate of compliance stating that equipment conforms to the current edition of API 16RCD shall be furnished to the original purchaser upon product delivery.
General
Only RCDs that are fully manufactured and tested in line with this specification will qualify for API markings, as outlined in the procedures and requirements specified in this section, Table 5, and Annex A.
Subcomponents of a complete RCD shall include traceability markings such that they can demonstrate compliance with this document
Table 5—Marking Requirements and Locations
Marking Rotating Control Device OECs d
(see also Annex A) Nameplate and/or body Manufacturer’s specification
Manufacturer’s name or mark Nameplate and/or body Manufacturer’s specification Manufacturer’s specification
(if applicable) Nameplate and/or body
Serial number Nameplate and/or body Manufacturer’s specification
API size designation Nameplate and/or connection OD a Manufacturer’s specification Body/shell pressure rating Nameplate and/or body Manufacturer’s specification
The temperature rating, manufacturer’s specification, and part number are typically found on the nameplate or body of the product Additionally, the date of manufacture is also indicated on the nameplate or body, ensuring compliance with the manufacturer's specifications.
Hydraulic operating system rated working pressure
Nameplate and/or body (Active/hybrid systems only)
Hydraulic operating system recommended operating pressure
Nameplate and/or body (Active/hybrid systems only)
Hydraulic open and close ports Manufacturer’s specification
(Active/hybrid systems only) Ring groove designation Connection OD a,b,c Manufacturer’s specification c
The alpha-numeric codification system (8.3.4.1) specifies that all API and 16BX hub connections must be clearly marked on the neck of the connection, with a maximum distance of ẵ inches from the required neck length, as outlined in API 16A—Tables 5, 6, 7, and 8 Additionally, all flanges are required to be marked according to API 6A standards If a ring groove is coated with corrosion-resistant material, it should be labeled with “CRA” following the groove number Furthermore, all API 16RCD OECs must be marked in a location that is easily accessible and readable, as determined by the manufacturer.
Types of Identification Stamping
For identification on low-stress areas (such as nameplates, outside diameters of flanges, etc.), the use of sharp “V” stamping is acceptable.
In high-stress areas, acceptable identification methods include dot, vibration, or round “V” stamping Sharp “V” stamping is permitted in these regions only if the component undergoes subsequent stress relieving.
Weld metal overlaid ring grooves shall be marked in accordance with API 6A
8.2.1.4 Body or Shell Pressure Rating Identification
The body pressure rating specified by the manufacturer must be clearly and permanently marked on the RCD body using methods such as welding, milling, casting, grinding, or forging It is essential that this marking is placed in an easily accessible and readable location Note that cold stamping does not fulfill this requirement.
To identify non-metallic components in wellbores, including RCD models, packers, and seals, manufacturers must establish a documented procedure for labeling the necessary codification on the product or its packaging.
8.2.2.2 Non-wellbore Non-metallic Components
Identification of non-wellbore non-metallic components, such as elastomeric seals used in RCD-type RCD actuation systems shall be in accordance with the manufacturer’s written specification.
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 6A.
Closure bolting shall be marked in accordance with the manufacturer’s written specification.
Wellbore non-metallic components must be labeled using an alpha-numeric coding system formatted as AA BBBB CCCC DDDD EE, as outlined in section 8.2.2.1 The significance of each digit in this alpha-numeric sequence is detailed in the following description.
In addition, the manufacturer’s part number shall be marked on the component
Date of manufacture (see 8.3.4.2) CCCC Lot/serial number (per manufacturer’s specs.) DDDD Temperature class (see 8.3.4.3) EE
Table 6—Elastomer Compound Marking Code
Common Name Chemical Name ASTM Code D1418
Kel-F Chloro fluoro elastomer CFM
EPR Ethylene-propylene copolymer EPM
EPT Ethylene-propylene terpolymer EPDM
Isoprene (Natural or synthetic) Polisoprene IR
SBR(GR-S) Styrene-butadiene SBR
NOTE Compounds which are not listed above shall be marked “N/A.”
The date of manufacture shall consist of the month, in numerical form and the last two digits of the year (e.g October
1996 would be coded 1096 for code CCCC).
The temperature class shall be per Table 7:
Storing for Periods of Greater Than 30 Days
All equipment shall be drained after testing and prior to storage.
Prior to storage, parts and equipment shall have exposed metallic surfaces protected with a rust preventative, which does not become fluid at temperatures below 125 °F.
All connection faces and ring gasket grooves shall be protected with durable covers.
The hydraulic operating system shall be flushed with a non-freezing, corrosion-inhibiting fluid in accordance with the manufacturer’s written procedures Ports shall be plugged prior to storing.
Elastomeric seals shall be stored in accordance with the manufacturer’s written procedures.
Table 7—Temperature Class Lower Limit (First Digit) Upper Limit (Second Digit)
NOTE These components may carry a temperature class of 40 °F to 180 °F without performing temperature verification testing provided they are marked as temperature class
“XX” in accordance with this section.
EXAMPLE “EB” has a temperature class of 30 °F to 200 °F.
Loose ring gaskets shall be wrapped or boxed for storage and shipping.
Shipping
All equipment is to be shipped in accordance with the manufacturer’s written procedures.
Use of API Monogram by Licensees
The API Monogram ® is a registered certification mark owned by the American Petroleum Institute (API) and licensed by its Board of Directors The API Monogram Program allows product manufacturers to use the API Monogram on new products that meet specific product specifications and are produced under a quality management system compliant with API Q1 requirements A comprehensive, searchable list of all Monogram licensees is available on the API Composite List website (www.api.org/compositelist).
The API Monogram and license number on products signify a warranty from the licensee to both API and product purchasers, confirming that the products were manufactured under a quality management system compliant with API Q1 standards Licenses for the API Monogram are granted only after a thorough on-site audit verifies that an organization has established and consistently maintained a quality management system that meets API Q1 requirements, ensuring that the products adhere to the relevant API specifications and standards While any manufacturer can assert that their products meet API requirements, only those with a valid API license are authorized to display the API Monogram on their products.
This annex outlines the requirements for organizations seeking to voluntarily obtain an API Monogram license, ensuring that their products meet the relevant API product specifications and standards, as well as the API Monogram Program requirements.
For information on becoming an API Monogram Licensee, please contact API, Certification Programs, 1220 L Street,
N W., Washington, DC 20005 or call 202-682-8145 or by email at certification@api.org.
API Specification Q1, Specification for Quality Management System Requirements for Product Manufacturing for the
Petroleum and Natural Gas Industry
For purposes of this annex, the following terms and definitions apply:
A newly manufactured product by an API licensee adheres to a fully implemented API Q1 compliant quality management system, ensuring it meets all specified requirements of the relevant API product specifications and standards.
Requirements, including performance and licensee-specified requirements, set forth in API Q1 and the applicable API product specification(s) and or standard(s).
NOTE Licensee-specified requirements include those activities necessary to satisfy API specified requirements.
A prescribed set of rules and requirements for a specific product includes definitions of terms, classification of components, and detailed procedures It outlines specified dimensions, manufacturing criteria, material requirements, performance testing, and design activities Additionally, it addresses the measurement of quality and quantity concerning materials, products, processes, services, and practices.
Organization that has successfully completed the application and audit process and has been issued a license by API.
Records and documents required to provide evidence that the applicable product has been designed in accordance with API Q1 and the requirements of the applicable product specification(s) and/or standard(s).
An organization applying the API Monogram to products shall develop, maintain, and operate at all times a quality management system conforming to API Q1
A.5 Control of the Application and Removal of the API Monogram
Licensees must manage the application and removal of the API Monogram by ensuring that only products meeting API specifications display the Monogram Additionally, each licensee is required to create and uphold a marking procedure that outlines the specific marking and monogramming requirements detailed in this annex, as well as any relevant API product specifications or standards.
1) define the authority responsible for application and removal of the API Monogram;
2) define the method(s) used to apply the API Monogram;
3) identify the location on the product where the API Monogram is to be applied;
4) require the application of the licensee's license number and date of manufacture of the product in conjunction with the use of the API Monogram;
The date of manufacture must consist of at least four digits, with two digits for the month and two for the year (e.g., 05-12 for May 2012), unless specified otherwise in the relevant API product specifications or standards.
The application of additional API product specifications and marking requirements is essential Only licensed API licensees are permitted to use the API Monogram and its designated license number on products eligible for the monogram The API Monogram license is specific to a site, meaning it can only be applied at the licensed facility location The monogram may be applied at any suitable time during production; however, it must be removed if the product is found to be non-compliant with the relevant API product specifications, standards, or the API Monogram Program.
For specific manufacturing processes or product types, alternative procedures for API Monogram marking may be permitted Detailed requirements for these alternative marking procedures can be found in the API Policy and the API Monogram Program Alternative Marking of Products License Agreement, accessible on the API Monogram Program website at http://www.api.org/alternative-marking.
Licensees and applicants for licensing are required to keep an up-to-date design package for all products covered by their Monogram license This design package must include objective evidence demonstrating that the product design complies with the latest API product specifications Additionally, these design packages must be accessible during API facility audits.
In specific instances, the exclusion of design activities is allowed under the Monogram Program, as detailed in
Advisory # 6, available on API Monogram Program website at http://www.api.org/advisories.
The API Monogram Program identifies facilities capable of manufacturing equipment that meets API specifications and standards Licensing may be denied or suspended based on a facility's manufacturing capabilities If further review is needed, API can conduct additional audits of subcontractors at the organization's expense to ensure compliance with relevant API product specifications and standards.
A.8 API Monogram Program: Nonconformance Reporting
API requests information on products that do not meet specified requirements and on field failures attributed to specification deficiencies or nonconformities Customers are encouraged to report any issues with API monogrammed products Nonconformances can be reported through the API Nonconformance Reporting System at http://compositelist.api.org/ncr.asp.
Operational Characteristics Test Procedures Used to Define the Operating
This Annex provides recommended guidelines for operational characteristics test procedures of API 16RCD equipment.
Pressure testing on RCDs requires allowance for the pressure to stabilize before timing of the test begins.
Each gauge or pressure transducer used shall be calibrated in accordance with 7.2.
All tests, including rotation, pressure, stripping cycles, and fatigue cycles, must be conducted alongside a data acquisition system The results should be clearly identified, dated, and signed or verified by the tester and any applicable witnesses.
B.5.1 Sealing Characteristics Test (Active RCD)
To conduct sealing characteristic tests on an RCD, first install the RCD on the test stump and connect the opening and closing lines, along with a high-pressure test pump Ensure that both the closing line and wellbore pressure line are equipped with pressure transducers linked to a data acquisition system for permanent record-keeping Next, install the test mandrel in the RCD, using mandrels of maximum and minimum diameter as specified by the manufacturer, and fill the RCD body with water just above the packer element Finally, perform a constant wellbore pressure test.
1) Close RCD with manufacturer’s recommended closing or differential pressure.
3) Lower closing or differential pressure until a leak develops and/or hydraulic control system goes into failsafe mode.
4) Bleed off wellbore pressure and open the RCD
5) Repeat items 1 through 4, increasing wellbore pressure in equal pressure increments until wellbore pressure equals the static pressure rating of the RCD e) Conduct constant closing pressure test as follows.
1) Apply 500 psi closing or differential pressure.
2) Apply increasing wellbore pressure until leak occurs or hydraulic control system goes into failsafe mode or wellbore pressure equals the static pressure rating of the RCD
3) Bleed off wellbore pressure and open RCD
Repeat the steps outlined in items 1 through 3, gradually increasing the closing pressure in consistent increments until it meets the manufacturer's recommended level Additionally, conduct a full closure pressure test if the manufacturer indicates that the active element is capable of CSO.
1) Remove the drill pipe mandrel Fill the RCD body to just above the top of the packer element with water.
2) Close RCD with pressure recommended by manufacturer.
3) Apply wellbore pressure of 50 psi to 120 psi and hold for 3 min If leakage occurs, increase the closing pressure as needed Do not exceed manufacturer’s recommended maximum closing pressure.