Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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10.30.01.2111
NS-1™ Number: NS 10.30.01.2111
Revision Date: June 2007
Equipment Name: PRODUCTION PACKERS – PERMANENT
Manufacturer: GENERAL
Model/Type: VARIOUS
Material Group: MEDIUM ALLOY STEEL
Service: SOUR

Rev Date Description Change Note

00 05/94 REPLACES NS-1™
– BA 10.30.48.2111 Rev. 01-92
– BA 10.30.60.2111 Rev. 01-92
01 06/04 MINOR CHANGES
02 06/07 MINOR HEADER AND FRONT PAGE ADJUSTMENT

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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SCOPE
This COMBINED NS-1™ specification specifies the minimum quality and inspection requirements to be applied in
the manufacture of Wrought Medium Alloy Steel Production Packers – Permanent.

It applies to:

• SOUR service conditions, employing medium alloy steel (e.g. 9Cr to 13Cr).
• All operating temperatures.
• All sizes and Rated Working Pressures(RWP = Max Differential Pressure from Above, Below and Internal.)

The matrix of this COMBINED NS-1™ provides a quality template that can be applied to any make and type of
Production Packer (Permanent). This COMBINED NS-1™ specification in combination with the manufacturer’s
parts list(s) and drawing(s) completes the product quality specification.

When ordering spare parts or sub-assemblies, the applicable quality requirements shall be those specified for
the components supplemented by the relevant requirements called out for the complete assembly.

Design verification, approval and other design related parameters are specifically excluded from this COMBINED
NS-1™ specification.

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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SUPPLEMENTARY REQUIREMENTS
The following requirements are supplementary to, and shall be applied in conjunction with, the Quality Sub-
specifications specified in the matrix of this COMBINED NS-1™ specification:

1. WELDING
No fabrication welding shall be performed.

No repair welding shall be performed.

2. MATERIAL TESTING
(Ref. Sub-Spec. 10.1 & Sub-Spec. 10.4)

2.1 Chemical Analysis

Chemical analysis shall be carried out on a heat basis-demonstrating conformance to the
manufacturer’s applicable material specification for all elements contained therein.

2.2 Mechanical Testing

Mechanical testing to ASTM A370 shall, as a minimum, establish yield strength, tensile strength,
elongation and reduction in area on a heat basis, representative of any heat treatment that may have
been applied.

Note: Reduction in area is not required on cast steel materials.

3. HARDNESS TESTING
(Ref. Sub-Spec. 70.1)

3.1 Hardness tests shall be carried out on each finished part, and shall meet the requirements of NACE
MR-01-75.

3.2 Hardness testing of parts may be carried out at an earlier stage of machining in the following cases:

i. Where the diameter to wall thickness ratio is such that it can adversely affect the accuracy of the
hardness measurements.

ii. Where hardness testing would destroy the finished part.

4. SURFACE HARDENING – SLIPS

4.1 Surface Hardening Procedure Specifications

Surface hardening shall be performed in accordance with the manufacturer’s documented surface
hardening procedure.

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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The manufacturer’s surface hardening procedure specifications shall describe all the essential
variables and controls pertinent to the special process, including as a minimum:

• The material grade, including chemical analysis and mechanical properties of the slip(s). The
material grade, chemical analysis and mechanical properties of the flat test specimen(s), when
utilised, shall be identical to the slip(s).

• The specified dimensions of the slip(s) being qualified. The flat test specimen, when utilised,
shall be representative of the slip(s) dimensions.

• Surface hardening method (i.e. heat treatment process, temperature, time etc.).

• Process verification; Time, temperature, technique for measuring surface hardness, case depth
and core hardness and acceptance criteria.

Upon request, the manufacturer shall demonstrate that the surface hardening procedure meets the
design requirements of the product.

If the manufacturer desires to use a flat test specimen in place of a sacrificial production slip then the
surface hardening procedure shall be qualified per 4.2 to verify that the flat test specimen provides an
accurate representation of the actual slip(s) properties.

4.2 Flat Test Specimen Qualification Tests

For each type and size of slip utilised, a representative (corresponding) flat test specimen shall be
included with the same surface hardened batch.

Each slip and its corresponding flat test specimen shall be cross sectioned (metallographic method)
and micro hardness tested to determine the surface hardness, case depth and core hardness.

The results of both the slip tests and flat specimen tests shall meet the specified surface hardness,
core hardness and case depth, and shall not differ from each other by more than 2 RC points nor
more than 10% depth of hardness.

Procedure qualification test records shall be made available on request.

4.3 Production Slips

Each production batch of slips shall be verified to meet the requirements of the manufacturer’s
specification.

When a flat test specimen is used, it shall be processed with the production batch of slips and
verified to meet the acceptance criteria of the manufacturer’s specification.

The minimum surface hardness requirement for either the slip or the flat test specimen shall be 52
RC (77 HRA).

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5. COMPLETE ASSEMBLY TESTING

(Ref. Sub-Spec. 100.2)

5.1 The internal parts of each assembled packer shall be hydrostatically tested. During testing a locking
device shall be applied to the packer to prevent activation of the main sealing unit. Hydrostatic
testing shall be carried out to the manufacturer’s procedures and specifications with the following
minimum requirements:

The hydrostatic test shall consist of three parts:

• the primary pressure holding period of 3 minutes minimum duration.

• reduction of the pressure to zero.

• the secondary pressure holding period of 5 minutes minimum duration.

The timing of the holding periods shall not start until the test pressure has stabilized, the equipment
and measuring devices have been isolated from the pressure source and the external surfaces of the
equipment thoroughly dried.

There shall be no leakage or reduction in indicated pressure.

5.2 Test Pressures

5.2.1 The hydrostatic test pressure shall not be less than the packers internal rated working pressure
(i.e. the maximum internal differential pressure).

5.2.2 Should the packer design prohibit utilisation of test fixtures to prevent packer activation,
sub-assembly testing shall be conducted where feasible to the full rated working pressure, or a
lower ’PLUGGED’ TEST pressure rating as defined below. Subsequently the assembled packer
shall be tested to 80% of the minimum packer activation pressure.

For packer designs that have a lower ’PLUGGED’ TEST pressure rating than the working
pressure rating, then the packer should be tested to the packers ’PLUGGED’ TEST pressure
rating. In such cases both the working pressure and the ’PLUGGED’ TEST pressure rating
shall be clearly identified on both the packer and the associated documentation.

INFORMATIVE NOTE:
Definition of ’PLUGGED’ TEST pressure rating: A pressure rating which does not exceed the
internal yield rating or the tensile rating of the connecting members

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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6. FUNCTIONAL TESTING
(Ref. Sub-Spec. 130.1)

6.1 Functional testing shall be carried out to the manufacturer’s specification but shall include the
following as a minimum:

• Each packer assembly shall be internally drifted throughout its entire length using a cylindrical
drift mandrel.

• The drift mandrel shall conform with the size and tolerances (i.e. length and diameter
requirements) specified in ISO 11960, latest revision, unless otherwise specified in the purchase
order.

Note: The above drifting requirements do not apply to hone bore permanent packers. The
dimensions of the honed bore shall be verified in accordance with Quality Sub-Spec. 90.1.

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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MATRIX
Equipment Name: Production Packers, Permanent
Specification: 10.30.01.2111
Manufacturer: General
Model/Type: Various
Material Group: Medium Alloy
Service: Sour

Component Functional Application

Metallic Components

Pressure Containing; Major Load Bearing and Dimensionally Critical Parts

Class: A, B, D Material: Wrought Low/Medium Alloy Steel. See Notes 1 & 2
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.2 Traceability – Heat Traceability
20.3 Traceability – Serialization Traceability
40.1 NDE Surface, General
40.4.1.3 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Technique – MT
Tech. Wet Fluor. Forg.
40.4.2.3 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Required Extent –
One Hundred Percent
40.4.3.6 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Acceptance
Standard – Maximum Permitted Relevant Indications
40.6.1.3 Magnetic Particle and Visual Examination (MT + VE) of Threads – Technique – Wet Fluorescent
Method
40.6.2.3 Magnetic Particle and Visual Examination (MT + VE) of Threads – Required Extent – One
Hundred Percent
40.6.3.2 Magnetic Particle and Visual Examination (MT + VE) of Threads – Acceptance Standard –
Relevant Indications
60.1 Disposition of Defects – Surface Dressing
70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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Pressure Containing; Major Load Bearing and Dimensionally Critical Parts

Class: A, B, D Material: Wrought High Alloy Steel. See Note 2
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.2 Traceability – Heat Traceability
20.3 Traceability – Serialization Traceability
40.1 NDE Surface, General
40.10.1 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Technique
40.10.2.3 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Required Extent –
One Hundred Percent
40.10.3.5 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Acceptance Standard
– Maximum Permitted Relevant Indication
40.12.1 Liquid Penetrant and Visual Examination (PT + VE) of Threads – Technique
40.12.2.3 Liquid Penetrant and Visual Examination (PT + VE) of Threads – Required Extent – One
Hundred Percent
40.12.3.2 d Penetrant and Visual Examination (PT + VE) of Threads – Acceptance Standard – Relevant
Indications
60.1 Disposition of Defects – Surface Dressing
70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

Pressure Containing and Dimensionally Critical Parts

Class: A, D Material :Wrought Low/Medium Alloy Steel – see Notes 1 & 2
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.2 Traceability – Heat Traceability
20.3 Traceability – Serialization Traceability
40.1 NDE Surface, General
40.4.1.3 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Technique – MT
Tech. Wet Fluor. Forg.
40.4.2.3 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Required Extent –
One Hundred Percent
40.4.3.6 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Acceptance
Standard – Maximum Permitted Relevant Indications
40.6.1.3 Magnetic Particle and Visual Examination (MT + VE) of Threads – Technique – Wet Fluorescent
Method
40.6.2.3 Magnetic Particle and Visual Examination (MT + VE) of Threads – Required Extent – One
Hundred Percent
40.6.3.2 Magnetic Particle and Visual Examination (MT + VE) of Threads – Acceptance Standard –
Relevant Indications

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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60.1 Disposition of Defects – Surface Dressing

70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

Pressure Containing and Dimensionally Critical Parts

Class: A, D Material: Wrought High Alloy Steel. See Note 2
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.2 Traceability – Heat Traceability
20.3 Traceability – Serialization Traceability
40.1 NDE Surface, General
40.10.1 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Technique
40.10.2.3 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Required Extent –
One Hundred Percent
40.10.3.5 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Acceptance Standard
– Maximum Permitted Relevant Indication
40.12.1 Liquid Penetrant and Visual Examination (PT + VE) of Threads – Technique
40.12.2.3 Liquid Penetrant and Visual Examination (PT + VE) of Threads – Required Extent – One
Hundred Percent
40.12.3.2 d Penetrant and Visual Examination (PT + VE) of Threads – Acceptance Standard – Relevant
Indications
60.1 Disposition of Defects – Surface Dressing
70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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Major Load Bearing in Tension and Dimensionally Critical

Class: B1, D Material: Wrought Low/Medium Alloy Steel. See Notes 1 & 2
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.2 Traceability – Heat Traceability
20.3 Traceability – Serialization Traceability
40.1 NDE Surface, General
40.4.1.3 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Technique – MT
Tech. Wet Fluor. Forg.
40.4.2.3 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Required Extent –
One Hundred Percent
40.4.3.6 Magnetic Particle Examination (MT) of Forgings, Mech. Tubing and Barstock – Acceptance
Standard – Maximum Permitted Relevant Indications
40.6.1.3 Magnetic Particle and Visual Examination (MT + VE) of Threads – Technique – Wet Fluorescent
Method
40.6.2.3 Magnetic Particle and Visual Examination (MT + VE) of Threads – Required Extent – One
Hundred Percent
40.6.3.2 Magnetic Particle and Visual Examination (MT + VE) of Threads – Acceptance Standard –
Relevant Indications
60.1 Disposition of Defects – Surface Dressing
70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

Major Load Bearing In Tension and Dimensionally Critical Parts

Class: B1, D Material: Wrought High Alloy Steel. See Notes 1 & 2
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.2 Traceability – Heat Traceability
20.3 Traceability – Serialization Traceability
40.1 NDE Surface, General
40.10.1 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Technique
40.10.2.3 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Required Extent –
One Hundred Percent
40.10.3.5 Liquid Penetrant Examination (PT) of Forgings, Mech. Tubing & Barstock – Acceptance Standard
– Maximum Permitted Relevant Indication
40.12.1 Liquid Penetrant and Visual Examination (PT + VE) of Threads – Technique
40.12.2.3 Liquid Penetrant and Visual Examination (PT + VE) of Threads – Required Extent – One
Hundred Percent
40.12.3.2 d Penetrant and Visual Examination (PT + VE) of Threads – Acceptance Standard – Relevant
Indications

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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60.1 Disposition of Defects – Surface Dressing

70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

Major Load Bearing in Compression and Dimensionally Critical

Class: B2, D Material :Wrought Alloy Steel – see Note 3
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.1 Traceability – Limited Traceability
70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

Major Load Bearing in Shear and Dimensionally Critical

Class: B3, D Material :Wrought Alloy Steel – See Note 3
Number Title
10.1 Material Certificates – General
10.4 Type B Material Test Certificate
20.1 Traceability – Limited Traceability
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
120.1 Load Testing – General
160.1 Non-Conformity Procedure – General

Wetted and Dimensionally Critical Parts

Class: C, D Material : Metallic
Number Title
10.1 Material Certificates – General
10.2.1 C.O.C. for raw materials & consumables
20.1 Traceability – Limited Traceability
70.1 Hardness Testing – General
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

Dimensionally Critical Parts

Class: D Material : Metallic
Number Title
90.1 Dimensional Inspection – General
90.2 Dimensional Inspection – Threads
160.1 Non-Conformity Procedure – General

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 Quality and Inspection Requirements for New and Refurbished Drilling and Well Completion Equipment

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Component Functional Application

Non-Metallic Components

Pressure Containing and Dimensionally Critical Parts

Class: A, D Material: Elastomer
Number Title
10.1 Material Certificates – General
10.6 Certification of Non-Metallic Sealing Materials
20.1 Traceability – Limited Traceability
90.1 Dimensional Inspection – General
160.1 Non-Conformity Procedure – General

Wetted and Dimensionally Critical Parts

Class: C, D Material: Elastomer
Number Title
10.1 Material Certificates – General
10.6 Certification of Non-Metallic Sealing Materials
20.1 Traceability – Limited Traceability
90.1 Dimensional Inspection – General
160.1 Non-Conformity Procedure – General

Special Manufacturing Process

Surface Hardened Parts (if applicable)

Class: K Material: See Note 4
Number Title
70.1 Hardness Testing – General
160.1 Non-Conformity Procedure – General

Complete Assembly
Number Title
10.1 Material Certificates – General
10.2.2 Material Certificates – Assembly Certificate
20.3 Traceability – Serialization Traceability
90.1 Dimensional Inspection – General
100.2 Hydrostatic Testing – General
130.1 Functional Testing – General
160.1 Non-Conformity Procedure – General
170.1 Boxing/Packing/Marking – General
170.2 Boxing/Packing/Marking – Critical Service (H2S, CO2, Low Temperature)
180.1.3 Quality Documentation for Non-Welded Products

1. In cases where parts are made from cast steels; Sub-Spec 40.4.1.3, Sub-Spec 40.4.2.3 and Sub-Spec 40.4.3.6
shall be substituted by Sub-Spec 40.2.1.3, Sub-Spec 40.2.2.3 and Sub-Spec 40.2.3.3 respectfully.

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2. When applicable; Threaded parts shall be magnetic particle examined in accordance with Sub-Spec 40.6.1.3,
Sub-Spec 40.6.2.3 and Sub-Spec 40.6.3.2 as indicated.

3. Parts designed to take combined loads (e.g. tension & compression): The most stringent quality require-
ments based on the ""Worst Case"" loading condition shall apply. In such cases class code B1,D shall be
the default.

4. Refer to Supplementary Requirements, Para 4 for surface hardness testing.

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