Ballot: Start Date: API Ballot Summary Sheet 7/25/2011 Spec 20A, 1st Ed. Ballot 1 - Steel, Stainless Steel, and Nickel Base Alloy Castings 3/31/11 Closing Date: 6/3/11 Associate: Ballot ID: 2313 Roland Goodman Coordinator: Roland Goodman VotingCategory Results r Interest Category Company s Affirmative Negative Abstain Did t James Buchanan Rick Faircloth Mike Feeley Mark Fouts Austin Freeman Tim Haeberle Maarten Kuipers Mark Pierce Brent Robertson Joel Russo Eric Wehner Operator-User Operator-User Chevron Cameron Valves and Measurement ConocoPhillips Stainless Foundry & Engineering, Inc. Halliburton Energy Services/Carrollton Fa GE Oil & Gas Inc Mokveld Valves B.V. Forum Oilfield Technologies Inc. Drilling P Quality Electric Steel Castings FMC Technologies Inc. NOV Yes Yes Yes Yes Affirmative Negative Abstain Did t Balloting Totals: 10 0 0 1 Total Responses: Total Ballots: Response Rate ((Affirmative + Negative + Abstain) / Total Ballots): Approval Rate (Affirmative / [Affirmative + Negative] ): Consensus: 10 11 91% 100% YES Must be > 50% Must be > 67% 1
Ballot s and Resolution of 1 Feeley, Mike Negative All s General Proposed Change Resolution My initial review is that the document, to be useful, must cover our problem areas which have been as follows: Duplex corrosion resistance/toughness High Nickel integrity (fissuring) weldability (tramp elements) My initial review is that this document (although requiring text change suggested just addition of ASTM corrosion testing) does not give us the information for discussion as shown in the opportunity to perform Charpy V-notch testing at -40 C/F column for sigma phase determination for group D materials. I think this should be added. In addition, the application of the volumetric examination may not pick up the small fissuring found in high nickel castings and the lack of a weldability testing option does not address any tramp element problems for group E. I would like to see these covered in this document. THIS IS A GENERAL COMMENT FROM MATERIALS ENGINEER IN CONOCOPHILLIPS resolved by revising 4.4.9.3.3 as follows: Impact Testing Duplex materials shall be impact tested to ASTM A923, method B. 2 Buchanan, James Affirmative / all relevant subsections Technical this section needs to be clear that all examinations and testing needs to be performed on the qualification casting and its QTC(s). revise any references to 'qualification test coupon' need to change to 'qualification casting and qualification test coupon'. s 4.3.3, 4.4.6, 4.4.6.b), 4.4.9.3.1.1, 4.4.9.3.2, 5.3.1.l) and 5.4.3.10 revised to include "and its Qualification Test Coupon". 3 Kudla, Flavia Guest / Title General Before Stainless Steel, the title should specify what kind of steel the document covers. Carbon Steel, Alloy Steel, Stainless Steel, Spec 20A title and 1.1 and Nickel Base Alloy Castings for use in the revised. Petroleum and Natural Gas Industry 4 Buchanan, James Affirmative TOC TOC Editorial need to update TOC update TOC 5 Kuipers, Maarten Affirmative / 2 Editorial Iso 2859 is refered to in par 5.6.6 ISO 2859-1 Updated by Word programmatically change required. 5.6.6 refers to ISO 2859-1 6 Haeberle, Tim Negative / 3.2 Technical The acronym "PWHT" is used in 4.4.6, but is not defined. Revise to add, "PWHT post weld heat treatment" 3.2 - Abbreviations revised to add "PWHT" 7 Haeberle, Tim Negative / 3.2 Editorial The acronym "CRA" is used in Table 1, but is not defined. Revise to add, "CRA corrosion resistant alloy" 3.2 - Abbreviations revised to add "CRA" 8 Kuipers, Maarten Affirmative / 4 Editorial typo: all subsections have 4.2.x.x. but have to be 4.3.x.x. 4.3.x.x numbering updated Page 1 of 7
Ballot s and Resolution of 9 Buchanan, James Affirmative / 4.4 Technical Proposed Change Resolution this section needs to be clear that all examinations and testing needs to be performed on the qualification casting and its QTC(s). add: All examinations and testing described in this section and summarized in table 3 shall apply to the qualification casting and its QTC(s). 4.4.1 revised to add "All examinations and testing described in this section and summarized in Table 3 shall apply to the qualification casting and its QTC(s), as applicable. 10 Goodman, Roland Guest Table 6 & 7 4.4 Editorial Table format needs revising. Add table headings for each column. Headings added to Tables 6 and 7. 11 Kuipers, Maarten Affirmative / 4.5 Technical 12 Haeberle, Tim Negative / 3.1.3 Editorial 13 Haeberle, Tim Negative / 3.1.4 Technical 14 Haeberle, Tim Negative / 3.1.6 Technical 15 Kudla, Flavia Guest / 3.1.6 Editorial Foundry techniques is the knowledge of the foundry. Customers of foundries should not be free to take techniques from one foudry to an other, when it is not their own. Revise to read, "General method for producing a casting. This includes the molding practice. Examples of molding practice include, but are not limited to, sand, centrifugal, investment, shell, permanent mold, die or lost foam casting. The definition provided for "equivalent round" is different from the definition already provided in API 6A / ISO 10423. The definition provided for "heat" is different from the definition already provided in API 6A / ISO 10423. The word cast is right below heat and it seems to be out of place. Pattern equipment with detailed rigging, shall be documented and made available for review. Revise to read, "General method for producing a casting. This includes the molding practice. Examples of molding practice include, but are not limited to, sand, centrifugal, investment, shell, permanent mold, die or lost foam casting. Revise to read, " standard for comparing various shaped section to round bars, in determining the response to hardening characteristics when heat-treating low-alloy and martensitic corrosion-resistant steel." 5.2 revised to add: "pattern equipment shall be documented and made available for review." 3.1.3 revised in accordance with proposed 3.1.5 revised in accordance with proposed The definition provided for "heat" is different 3.1.7 revised to read the from the definition already provided in API 6A same as Spec 6A. / ISO 10423. Delete word cast. 3.1.7 - "cast" deleted 16 Haeberle, Tim Negative / 3.1.7 Technical The definition provided for "heat treatment" is different from the definition already provided in API 6A / ISO 10423. Revise to read, "specified, timed sequences of controlled heating and cooling of materials for the purpose of changing physical or mechanical properties." 3.1.8 revised in accordance with proposed 17 Kudla, Flavia Guest / 3.1.9 Technical This definition says Includes the type of melting furnace used such as AIM, AOD and EAF. As AOD process is not a type of melting furnace, the definition should mention refining operations as well. 3.1.9 melt practice Procedure and equipment used to create a heat of metal. Includes the type of melting furnace used, such as AIM and EAF, and the refining process used, such as AOD, when applicable. 3.1.10 revised in accordance with proposed 18 Kudla, Flavia Guest / 3.1.12 Editorial A casting(s) if the plural is applicable, the article A does not work. Casting(s) made and tested 3.1.13 revised to read: "Casting(s) made and tested." "A" deleted. Page 2 of 7
Ballot s and Resolution of 19 Haeberle, Tim Negative / 3.1. Technical 20 Haeberle, Tim Negative Table 1 4.2.1 Technical 21 Haeberle, Tim Negative Table 1 4.2.1 Technical Proposed Change Resolution See Table 1 below. A definition of CRA is required. The suggested change is to the API 6A / ISO 10423 definition. For Material Groups A (carbon steels) and B (low alloy steels), the ASTM standards listed as typical examples listed actually include wider groupings of alloys. ASTM A352 (mentioned for carbon steels) is a standard not only for carbon, but also for low a The listing of duplex stainless steels as a CRA is in conflict with the API 6A / ISO 10423 definition of CRA. Revise to add, "Corrosion resistant alloy nonferrous-based alloy in which any one or the sum of the specified amount of the elements titanium, nickel, cobalt, chromium, and molybdenum exceeds 50 % mass fraction Revise to use more fitting ASTM spec examples that truly give an example of the specific types of steels. Revise Group D to read, "Duplex Stainless Steels". Also add a definition for corrosion resistant alloys and the acronym CRA as suggested above. New 3.1.4 added: "corrosion-resistant alloy". Definition same as proposed Table1, Material Group A "Gr. LCC" added after ASTM A352 Table 1, Material Group D Description changed to "Duplex Stainless Steels" 22 Kudla, Flavia Guest / 4.2.1 Technical Qualification castings shall be produced in accordance with the requirements of Table 3 and the acceptance criteria of Tables 5, 6 and 7. Table 4 shows the acceptance criteria for inclusion level. Qualification castings shall be produced in accordance with the requirements of Table 3 and the acceptance criteria of Tables 4, 5 and 6. 4.2.1 revised to add Table 4 as acceptance criteria. 23 Kudla, Flavia Guest Table 1 4.2.1 Technical ASTM A890 should not be a typical example of duplex/super duplex material as the applicability of A890 is for general applications and the applicability of this Delete ASTM A890 as a typical example. API document is for critical components (pressure containing, pressure controlling components, etc). change required. ASTM A890 is an appropriate reference. 24 Kudla, Flavia Guest / 4.2.1.1 Editorial 25 Kudla, Flavia Guest / 4.2.1.1 Technical 26 Buchanan, James Affirmative / 4.2.3 Technical 27 Haeberle, Tim Negative / 4.2.3 Technical Numerical sequence is not correct as this section is inside 4.3.1. The equivalent round of the qualification test coupon shall be equal to or greater than the equivalent round dimensions of the part it qualifies, except that the equivalent round is not required to exceed 125 mm (5 in). add: repair welding shall be performed in accordance with a qualified welding procedure and casting qualification testing shall include at least the deepest repair (weld metal and HAZ). The section states " cosmetic grinding shall be kept to a minimum. Excessive surface grinding may be cause for rejection ". However, the term "excessive" is not defined and leaves this point of rejection open to interpretation. 28 Haeberle, Tim Negative / 4.3.1 Editorial All the sub-sections are mis-numbered. 4.3.1.1 and all the other paragraphs in the sequence. Propose that equivalent round is not required to exceed 125mm (5in) for CSL-1 and CSL-2 castings. For CSL-3 castings the equivalent round of the test coupon shall be the same as the part it qualifies. numbering revised. 4.3.1.1 revise to read in part: "except that the equivalent round is not required to exceed 125 mm (5 in.) for CSL-1 and CSL-2 castings. For CSL-3 castings the equivalent round of the test coupon shall be the same as the part it qualifies. add: repair welding shall be performed in accordance with a qualified welding 4.2.3 revised to add procedure and casting qualification testing proposed shall include at least the deepest repair (weld metal and HAZ). Need to define provide a rejection criteria for grinding that is not open to interpretation. Task group was unable to define parameters for excessive grinding. Agreed to use "excessive" without acceptance criteria. Revise "4.2.1.1" to read, "4.3.1.1". Revise "4.2.1.2" to read, "4.3.1.2". Revise "4.2.1.3" numbering revised. to read, "4.3.1.3". Revise "4.2.1.4" to read, "4.3.1.4". Page 3 of 7
Ballot s and Resolution of 29 Haeberle, Tim Negative Table 3 4.4.1 Editorial s numbers in the table refer to wrong sections. 30 Haeberle, Tim Negative Table 3 4.4.1 Editorial Proposed Change Resolution The testing requirements are listed in a different order from the order in which they appear in the text sections. For all CSL for columns: mechanical, microstructure, visual, dimensional, hardness, surface NDE, volumetric NDE instead of 4.3.x.x should be 4.4.x.x. For CSL- numbering revised. 4 in Sacrificial Casting the referred section is 4.3.8.1 - should be 4.4.9.2. For CSl-3 and CSL Revise the order of the listings in the table to follow the order in the spec. Task Group agreed that no change is required. 31 Kuipers, Maarten Affirmative Table 3 4.4.1 Editorial typo: all subsections have 4.3.x.x. but have to be 4.4.x.x. 4.4.x.x numbering revised. 32 Kudla, Flavia Guest Table 3 4.4.1 Editorial numbers referred in this table (4.3..) should be 4.4.. Correct clause numbering. numbering revised. 33 Kudla, Flavia Guest Table 3 4.4.1 Technical Microstructure examination for CSL- 3 and CSL-4 should not be restricted to Groups A & B. Remove Group restriction and make it applicable to all groups. Table 3 revised to remove Groups A & B under CSL-3 and CSL-4 for microstructure testing 34 Kudla, Flavia Guest Table 3 4.4.1 Technical CSL-1 should require hardness test of a qualification casting. Call for hardness test for CSL-1. Table 3 revised to call for CSL-1 hardness testing. 35 Kuipers, Maarten Affirmative / 4.4.2 Technical In this paragraph is stated: In the instance where these molding media chaplets are used, the hole remaining in the casting wall will need tob e welded. Add: This weld procedure will not be 4.4.2.1 revised to include considered as a weld repair but as part of the proposed casting production process. 36 Goodman, Roland Guest Table 5 4.4.2 Editorial A table is used to convey a lot of information in a concise format. Table 5 should not be a table and the information should be included in 4.4.2. Delete Table 5 and move the acceptance criteria to 4.4.2. Table 5 deleted and acceptance criteria moved to new 4.4.2.2. Spec 20A revised to replace Table 5 with 4.4.2.2. 37 Kuipers, Maarten Affirmative / 4.4.4 Technical For a good hardness test you need more than one indent. 3 should be better. Add: A minimum of three (3) indentations per casting is required. 4.4.4 revised to include proposed 38 Kuipers, Maarten Affirmative / 4.4.5.3.2 Technical Is with real time imaging meant the digital -ray? 4.4.5.3.2 revised to replace "digital -ray" with "digital radiographic imaging". 39 Buchanan, James Affirmative / 4.4.6 Technical There needs to be mention of acceptance criteria and CVN test temperature. Define acceptance criteria and CVN test 4.4.6.b) revised to add: temperature perhaps based on existing "CVN test temperature and specifications or state that acceptance acceptance criteria shall be in criteria and CVN test temperature shall be accordance with the material according to the materials specification used. specification used". Page 4 of 7
Ballot s and Resolution 40 Kudla, Flavia Guest / 4.4.6 of Editorial- Technical 41 Haeberle, Tim Negative / 4.4.6 a) Technical 42 Buchanan, James Affirmative / 4.4.6.b Technical 43 Kuipers, Maarten Affirmative / 4.4.7 Technical Proposed Change Resolution For the purposes of material qualification testing, stress relief following welding is not considered heat treatment, provided that the PWHT temperature is below that which changes the heat-treated condition of the base material. Material qualification tests may be performed Weld repair should not be allowed on test before the stress-relieving process, provided that the coupons. If a sacrificial casting is being stress-relieving temperature is below that which tested, all testing shall be performed after changes the heat-treatment condition. The two weld repair is completed. statements above are repeating themselves. In addition to temperature, the time of PWHT could affect mechanical properties as well. Weld repair should not be allowed on test coupons. This section does not specify the location within the QTC from which the test specimens must be removed. CVN testing needs to be performed during casting qualification at least for material groups A,B and D but should be performed for all groups. We suggest that for austenitic and duplex stainless steels micrographs with magnifications of both 100x and 400x shall be provided. Utilize the API Spec 6A test specimen locations. revise clause to: CVN test specimens shall be removed from the qualification casting and qualification test coupon and tested in accordance with ASTM A370. The results shall be reported. Add: For Stainless Steel and Duplex steel a micrograph at minimum 400 of the worst and best area shall be made. 4.4.6 revised to add: "Weld repair is not permitted on test coupons. If a sacrificial casting is being tested, all testing shall be performed after any weld repair is completed." 4.4.6.a) revised to add: Tensile test specimens shall be tested in accordance with ASTM A370. Test specimens shall be removed from the QTC such that their longitudinal centerline axis is wholly within the centre core 1/4T envelope for a solid QTC or within 3 mm (1/8 in) of the mid-thickness of the thickest section of a hollow QTC. 4.4.6.b) revised to add: "Charpy (CVN) impact specimens shall be removed from the qualification casting and its qualification test coupon and tested in accordance with ASTM A370." 4.4.7.2 revised to add: For stainless steel and duplex steel, a micrograph at a minimum of 400 of the best and worst area shall be made." 44 Kuipers, Maarten Affirmative Table 4 4.4.7.4 Technical The words "Thin" and "heavy" are not defined??? change required. Terms are defined in ASTM E45. 45 Haeberle, Tim Negative Table 4 4.4.7.4 Editorial The table lists B as "sulfide", but ASTM E45 clearly states that B are alumina type. Revise to read, " B Alumina" 46 Kudla, Flavia Guest Table 4 4.4.7.4 Technical Inclusion B refers to alumina and not sulfide. Write B alumina 47 Haeberle, Tim Negative / 4.4.7.5 Editorial The wording is a bit confusing. Revise to read, " the casting into four (4) approximately equally sized quadrants." Table 4, Inclusion B changed from "sulfide" to "alumina." Table 4, Inclusion B changed from "sulfide" to "alumina." is a duplicate of 50. number is an error. Page 5 of 7
Ballot s and Resolution of 48 Kuipers, Maarten Affirmative / 4.4.8.1 Technical 49 Kuipers, Maarten Affirmative / 4.4.9.2 Technical Proposed Change Resolution The casting supplier shall specify the chemical composition etc. To our opinion the product manufacturer should specify the limits to which the casting supplier has to work. should be more specific as to when a sacrificial casting is required. E.g. for every type, size, pressure class, material. The casting manufacturer shall specify the nominal chemical composition, within the limits of the applicable specification, including composition tolerances, of the material used for the qualification casting.?? change required. Requirement is for qualification. change required. 4.4.9.2 applies to all CSL- 4 castings 50 Haeberle, Tim Negative / 4.4.9.2 Editorial The wording is a bit confusing. 51 Buchanan, James Affirmative / 4.4.9.3.1.5 Technical 52 Haeberle, Tim Negative / 4.4.9.3.1.5 Technical test temperature is for 22Cr duplex stainless steels. A separate test temperature for 25Cr 'super' duplex stainless steels needs to be defined. 22% and 25% Cr duplex are not tested at different temperatures as is customary. Revise to read, " the casting into four (4) approximately equally sized quadrants." revise clause to: For 22Cr duplex stainless steels, the test temperature shall be 25±1 C and for 25Cr duplex stainless steels, the test temperature shall be 50±1 C. For both duplex stainless steels, the exposure time shall be 24 hours. Revise to read, " The ASTM G48 corrosion test is performed at 25 +/-1 C for 22% Cr duplex, and at 50 +/-1 C for 25% Cr super duplex stainless steel castings. The exposure time shall be 24 hours." 4.4.9.2.a) revised as stated in proposed 4.4.9.3.1.5 revised as stated in proposed 4.4.9.3.1.5 revised as stated in proposed 53 Haeberle, Tim Negative / 4.4.9.3.1.6 Editorial The 2 in "g/m2" should be a superscript. Revise "g/m2" have the 2 as a superscript. 4.4.9.3.1.6 revised to read g/m 2 54 Buchanan, James Affirmative / 4.4.9.3.3 and 4.4.9.3.4 Editorial I believe that these two clauses should be sub-clauses to 4.4.9.3.2. 55 Haeberle, Tim Negative / 4.4.9.3.4 Technical Error carried across from ASTM E407. 56 Kudla, Flavia Guest / 4.5.1 Technical Results of the examinations specified in Table 3 shall comply with the acceptance criteria specified in the Tables 5, 6, 7 and the casting supplier s written specification. revise accordingly. Revise to read, ASTM E407 etchant number 98 (K3Fe(CN)6 with KOH or NaOH, with use of subscripts. Results of the examinations specified in Table 3 shall comply with the acceptance criteria specified in the Tables 4, 5, 6, 7 and the casting supplier s written specification. Due to other changes, comment is not relevant. 4.4.9.3.3 was revised to Impact Testing and 4.4.9.3.4 was deleted. is not relevant due to other changes that deleted 4.4.9.3.4. 4.5.1 revised to add Table 4. 57 Haeberle, Tim Negative Table 8 4.7.1.1 Technical There is no explanation as to what the numbers in the table (1-1, 2-1, 2-2, 3-1, etc.) mean. Provide an explanation as to what the numbers mean. Table 7 was revised to change qualification test indicators with text. 58 Kuipers, Maarten Affirmative / 4.7.2 4.7.3 Technical Furnace calibration is one of the most important process influences. Add: For CLS 3 and CSL 4 furnaces shall be calibrated in accordance with documented procedures such as ASTM A991, API 6A 17th edition app. H. 5.6.2 was revised to add: "Heat treatment furnaces shall be calibrated annually in accordance with a recognized international standard such as API 6A, Annex M or AMS 2750." Page 6 of 7
Ballot s and Resolution of 59 Haeberle, Tim Negative Table 9 4.7.4.2 Editorial There may not be a reference to Table 9 in the text. 60 Buchanan, James Affirmative / 5.3.1 Technical 61 Haeberle, Tim Negative / 5.3.2 Technical 62 Buchanan, James Affirmative / 5.3.2.e Technical 63 Buchanan, James Affirmative / 5.4.3 Technical 64 Buchanan, James Affirmative / 5.6.2 Technical 65 Kudla, Flavia Guest / 5.6.2 Technical 66 Buchanan, James Affirmative / 5.6.4.3 and 5.6.5.3 Technical Proposed Change Resolution need to add microstructural examination and corrosion testing as applicable If no reference to Table 9 exists in the text, add one as appropriate. add: microstructural examination and corrosion testing as applicable While the heat treatment processes listed, normalizing, austenitizing and tempering, are appropriate for low alloy Revise to make the section suitable for use steels and martensitic stainless steels, they are not the with all the alloy families covered by this processes used for nickel base alloys, austenitic specification. stainless steels or duplex stain need to add maximum quench media temperature at the start and end of quenching. need to add testing requirements from 4.4.2, 4.4.4, 4.4.7 and 4.4.9 as applicable need to specify acceptable furnace temperature variation tolerances. Suggest referencing API 6A ro 6HT. Furnaces shall be calibrated yearly in accordance with documented procedures. need to address what to do with CSL4 castings that fail NDE since 100% of the lot is NDE'd so performing NDE on '2 additional' castings does not apply add: maximum quench media temperature at the start and end of quenching. add: testing requirements from 4.4.2, 4.4.4, 4.4.7 and 4.4.9 as applicable Reference to Table 8 added to 4.2.1. 5.3.1 revised to add new item: "p) microstructural examination and additional testing, as applicable;" 5.3.2. revised to read: b) temperatures and times for all individual heat treating cycles; items d) and g) deleted. 5.3.2 revised to add: l) maximum quench media temperature at the start and end of quenching. Reference to testing requirements added to 5.4.3 sub-sections. 5.4.3.9 added to address duplex stainless steel castings. see comment. See comment 58 Furnaces shall be calibrated yearly in accordance with Annex P, API 6A, 19 th Edition or Annex H, API 6D, 23 rd Edition, March 2010.. see comment. See comment 58 5.6.4.3 revised by adding applicable CSL to clarify requirement: Failure of a "CSL-2 and CSL-3" casting. Page 7 of 7