Comment Ballot Version February 2019ballots.api.org/ecs/sc19/ballots/docs/19ICD_e1-20190301.pdf2019/03/01 · API 13B-1, Recommended Practice for Field Testing Water-based Drilling

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

© American Petroleum Institute

Comment Ballot Version February 2019

Inflow Control Devices

API SPECIFICATION 19ICD FIRST EDITION, XXXX 2019


i

Special Notes

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ii

Foreword

The verbal forms used to express the provisions in this specification are as follows:

— the term “shall” denotes a minimum requirement in order to conform to the specification;

— the term “should” denotes a recommendation or that which is advised but not required in order to conform to the specification;

— the term “may” is used to express permission or a provision that is optional;

— the term “can” is used to express possibility or capability.

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Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, [email protected].

mailto:[email protected]


iii

Table of Contents

Table of Contents will be generated with Final Page Proofs.


© American Petroleum Institute 1

1 Scope

This specification provides requirements and guidelines for inflow control devices (ICDs) for both production and injection, as defined herein, for use in the petroleum and natural gas industry. This specification provides requirements for the functional specification and technical specifications, including design, design verification and validation, materials, documentation and data control, and quality requirements. Products covered by any other API specification, such as sand screens and sliding sleeves are not included. Also not included are externally controlled downhole devices including interval control valves (ICVs). This specification does not cover the connections to the well conduit, the effects of corrosion, or ICDs designated for use in thermal recovery applications. Installation, application, and operation of these products are outside the scope of this specification.

This specification includes the following annexes:

- Annex A: Use of API Monogram by Licensees;

- Annex B: ICD Joint Components and Screen Attributes;

- Annex C: Test Article, Test Fixture and Instrumentation Requirements;

- Annex D: Cavitation Testing;

- Annex E: Validation Test Requirements – ICD Flow Performance Test;

- Annex F: Validation Test Requirements – Device Erosion Test;

- Annex G: Validation Test Requirements – Mud Flow Initiation Test and Sediment Plugging Test;

- Annex H: Validation Test Requirements - Flow Integrity Test;

- Annex I: Validation Test Requirements - Static Pressure Test



2 Normative References

The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any addenda) applies.

ANSI/ASQC Z1.4, Sampling Procedures and Tables for Inspection by Attributes

ANSI/NCSL Z540-3, Requirements for the Calibration of Measuring and Test Equipment

API 19SS, Sand Screens

API 5CT, Specification for Casing and Tubing

API 13B-1, Recommended Practice for Field Testing Water-based Drilling Fluids

API 19C, Measurement of and Specification for Proppants Used in Hydraulic Fracturing and Gravel-packing Operations

ASME, Boiler and Pressure Vessel Code (BPVC) Section II-Materials, Part D- Properties (Customary)

ASME, Boiler and Pressure Vessel Code (BPVC) Section IX-Welding, Brazing, and Fusing Qualifications

ASME, Boiler and Pressure Vessel Code (BPVC) Section VIII-Rules for Construction of Pressure Vessels Division 1

ASNT SNT-TC-1A, Personnel Qualification and Certification in Nondestructive Testing

ASQ H1331, Zero Acceptance Number Sampling Plans

ASTM E165, Standard Practice for Liquid Penetrant Testing for General Industry

ISO 2859-1, Sampling procedures for inspection by attributes – Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection

ISO 9712, Non-destructive testing - Qualification and certification of NDT personnel

ISO/IEC 17025, General requirements for the competence of testing and calibration laboratories



3 Terms and Definitions

3.1 Terms and Definitions

For the purposes of this document, the following terms and definitions apply.

3.1.1 annulus The space between two concentric objects, such as the clearance between the test fixture ID and the test article OD. 3.1.2 autonomous inflow control device AICD ICD that preferentially restricts the flow of unwanted over wanted fluids based upon the fluid properties and downhole flowing conditions.

3.1.3 cavitation Condition where cavities or voids form in liquids that result from rapid drops in local pressure, such as can occur across an ICD and thereby affect flow performance. 3.1.4 density The ratio of mass divided by volume. 3.1.5 design family ICDs where the configuration, materials, and functionality are the same, and the design stress levels in relation to material mechanical properties are based on the same criteria, but nominal sizes vary, such as base pipe diameter, 3.1.6 differential pressure pressure drop The difference between the outlet and inlet pressure of the test article, which is used along with volumetric flow rate (and fluid properties) to characterize flow performance.

3.1.7 erodent The solid particulates, such as SiO2, that make up the slurry used during the erosion test.

3.1.8 erosion The process of abrading or wearing away a solid surface by solid particles due to contact or impact. 3.1.9 erosion test A test to characterize the change in flow performance of a test article caused by material loss due to erosion. 3.1.10 flow initiation pressure



The pressure required to cause a substance to flow. 3.1.11 flow integrity rating The maximum flowing pressure, in injection mode, which an ICD can operate and still perform within its flow performance 3.1.12 flow integrity test A test to determine the maximum flowing pressure, in injection mode, which an ICD can operate and still perform within its flow performance 3.1.13 flow meter An instrument used to measure the volumetric or mass flow rate of a fluid. 3.1.14 flow performance The pressure drop vs volumetric flow rate response when flowing fluid through the test article. 3.1.15 flow performance test A test to characterize flow performance of a device, which can be carried out for several ICD element settings or sizes in production or injection direction. 3.1.16 inflow control device ICD A downhole device designed to control the volumetric flow rate of fluids from or to the reservoir based upon an induced pressure drop, without intervention from surface. 3.1.17 ICD element The specific component of the ICD joint that controls flow by generating a pressure drop response to fluid flow. 3.1.18 ICD joint A complete joint, including connections, that contains one or more ICD elements and any accessories, such as a sand control screen. 3.1.19 ICD settings The number of unique settings available per ICD joint. 3.1.20 inlet pressure The pressure directly upstream of the ICD element as defined by the flow direction. 3.1.21 interval control valve ICV Remotely controlled downhole valve which is permanently installed in a wellbore and is adjustable without physical intervention to regulate fluid flow from and to the reservoir.



NOTE: the term regulate may include choking of the flow or on-off functions 3.1.22 manufacturer Principal agent in the design, fabrication and furnishing of equipment, who chooses to comply with this specification 3.1.23 mass flow rate The amount of mass flowing per unit of time. 3.1.24 mud High density fluid that contains solids and exhibits a Bingham Plastic behavior. 3.1.25 Newtonian fluid A fluid the viscosity of which is independent of shear rate (shear stress divided by shear rate is a constant). 3.1.26 non-Newtonian fluid A fluid that exhibits a yield point and/or its viscosity is shear rate dependent. Examples are Bingham, pseudoplastic, and viscoelastic fluids. 3.1.27 outlet pressure The pressure directly downstream of the ICD element as defined by the flow direction. Also known as back pressure.

3.1.28 outlet temperature Temperature of fluid downstream of the test fixture as defined by the flow direction. 3.1.29 particle concentration In a given volume of slurry, the mass of the particles divided by the total mass of the slurry (i.e., mass fraction or ppmw). 3.1.30 particle size distribution A distribution of particle diameters representative of a bulk supply of particles and is typically measured via sieve or a laser particle scanning technique which outputs cumulative and incremental fractions by weight versus particle diameter. 3.1.31 plugging test A process of evaluating a drilling mud's potential to plug or influence the performance of the test article. 3.1.32 pressure sensor A sensor used to measure the (gauge) pressure of the fluid within a specific section of the test fixture.



3.1.33 qualified person An individual or individuals with characteristics or abilities gained through training or experience or both as measured against established requirements, such as standards or tests that enable the individual to perform a required function. 3.1.34 rheology The quantitative/mathematical relationship between shear stress and shear rate for a fluid.

3.1.35 static pressure rating The pressure differential rating of the ICD when flow through the ICD element is in the injection direction and intentionally blocked off at the ICD element. 3.1.36 static pressure test A test to determine the pressure differential rating of the ICD when flow through the ICD element is in the injection direction and intentionally blocked off at the ICD element. 3.1.37 substantive design change Change to the design, identified by the supplier/manufacturer, that may affect the performance of the product in the intended service condition. 3.1.38 test article A representative assembly used for ICD testing purposes. 3.1.39 test fixture An assembly which houses a test article. (See Annex C.) 3.1.40 thermal recovery applications Application that intentionally introduces heat to recover hydrocarbons from a reservoir 3.1.41 Type 1 component Type 1 weld Component or weld that isolates pressure and/or may be loaded in tension as the result of axial loads 3.1.42 Type 2 component Type 2 weld Component or weld that does not meet the criteria of a Type 1 weld. 3.1.43 un-wanted fluid The fluid type that the ICD preferentially restricts the flow through the device.

3.1.44 viscosity The measure of a fluid’s resistance to shear deformation, usually given in units of centipoise (cP).



3.1.45 volumetric flow rate The volume of fluid flowing per unit of time.

3.1.46 wanted fluid The fluid type that the ICD preferentially allows to flow through the device.



3.2 Abbreviated Terms

AICD – autonomous inflow control device AQL – acceptance quality limit ASQ – American Society for Quality BPVC – Boiler and pressure vessel code CFD – computational fluid dynamics COC – certificate of conformance dP – differential pressure FEA – finite element analysis ID – inside diameter (in) LB – box handling length (reference figure B.2) LH – ICD housing length (reference figure B.2) LS – length of screen or debris barrier (reference figure B.2) LP – pin handling length (reference figure B.2) MTR - material test report NDE – non-destructive evaluation OD – outside diameter (in) ppm – parts per million (by weight or by volume) ppmw – parts per million by weight SiO2 – Silicon dioxide



4 Functional Specification 4.1 General The user/purchaser should provide a functional specification to order products which conform to this specification. The specification shall include the following requirements and operating conditions as the user deems appropriate, and/or may identify the supplier’s specific product. These requirements and operating conditions may be conveyed by means of a dimensional drawing, data sheet, or other suitable documentation and other technical documentation as applicable to the Validation Grade. 4.2 ICD Type Description ICDs are installed in the completion string along the wellbore to control the inflow or outflow of fluids from or to the reservoir. An ICD may contain moving parts or no moving parts and, once installed, is not connected to surface for adjustability, such as with a permanent electric or hydraulic line.

The user/purchaser should specify: - ICD Service Level: Production, Injection, or Both - ICD Type Classification per Table 1 - ICD Validation Grade per Table 2 - ICD Quality Grade per Table 3

The user/purchaser should provide well parameters, operational parameters, and other relevant parameters, as applicable, according to 4.3, 4.4, 4.5, and 4.6. For all sand screens defined with an ICD, API 19SS should be referenced and applied as required for validation level and quality grade of the sand screen component. ICDs are classified into three Types shown in Table 1

Table 1 ICD Type Classification

Type 1 An ICD with no moving parts, Such as; a nozzle, orifice, tube or helical channel.

Type 2N An AICD with no moving parts.

Type 2M An AICD with moving parts.



4.3 Well Parameters The user/purchaser should specify, as applicable, the following well parameters:

- True Vertical Depth (TVD) and Measured Depth (MD) - Directional survey of the well with maximum dogleg severity - Fluid type(s) to be controlled - Viscosity of well fluids (oil, gas, water) at reservoir conditions - Density of well fluids (oil, gas, water) at reservoir conditions - Static reservoir pressure - Static reservoir temperature - Future reservoir abandonment pressure - Well head pressure - Artificial lift type - Minimum required tensile and torque ratings for ICD product - Maximum OD for ICD product - Minimum required internal ID drift for the installed ICD product - Any other relevant well parameter(s)

4.4 Operational Parameters The user/purchaser should specify, as applicable, the following operational parameters:

- ICD Adjustability: Wellsite adjustable or non-adjustable - Installation method: tubing or liner deployment - Setting depth, TVD and MD - Number of completion interval compartments - Estimated length of each completion interval compartment - Target fluid rate(s) by compartment with maximum production and/or injection dP across ICDs

during well operation - Stimulation requirements, including maximum injection rates and dP across ICDs during

stimulation - Minimum required burst and collapse pressure ratings for ICD product - Downhole ICD shut-off capabilities: unique settings, temporary shut-off, or permanent shut-off

4.5 Environmental Compatibility 4.5.1 General Where the user/purchaser has material selection and/or corrosion property data of the operating environment based on historical data and/or research, the user/purchaser may state which material(s) should be used. Otherwise, material compatibility may be specified according to 4.5.2.



4.5.2 Well Conditions The following should be provided by the user/purchaser to ensure compatibility, as applicable:

- Volumetric Flow rate range - Pressure range - Temperature range - Well life estimate and solids loading estimate - Production/Injection fluid type(s) - CO2 concentration estimate (%) - H2S concentration estimate (ppm) - Chloride concentration estimate (ppm) - Composition and properties of any additional fluid treatments such as kill pills, solvents, or acids - Exposure contact time duration for stimulation treatments

4.6 Compatibility with Related Well Equipment The following information should be provided by the user/purchaser, as applicable:

- Sand control screen or debris barrier type (See API 19SS for sand screen types) - Base pipe size for ICD installation, including pipe OD, weight, and metallurgy - Drift ID of the casing and open hole ID - Minimum restrictions through which the ICD Joint must pass (a completion diagram is preferred) - IDs and ODs of tubing and casing sizes - Lengths applicable to the ICD joint - ICD Diagnostic Plans: pressure/temperature sensors or tracers - Size, type, material, configuration, and connections between product and other well equipment - Size, type, and configuration of other products or tools that pass through or over the product - Size, type, and configuration of other products used in conjunction with this product.

4.7 Design Validation Grades The user/purchaser may select the design validation grade V3, V2, or V1 as per Table 2 for each product to be provided. If the user/purchaser does not specify the validation grade, V3 applies.

4.8 Quality Grades The user/purchaser may select the quality grade QL3, QL2, or QL1 as per Table 3 for each product that is to be provided. If the user/purchaser does not specify the quality grade, QL3 applies.



5 Technical Specification 5.1 General The supplier/manufacturer shall prepare a technical specification, which conforms to the requirements defined in the functional specification. If the technical specification does not fully meet the functional requirements, the supplier/manufacturer shall identify the differences to the user/purchaser. The supplier/manufacturer shall also provide to the user/purchaser the product data sheet as noted in Section 6.2.3. ICDs produced according to this specification shall be designed and developed under an industry recognized quality management system (QMS) that conforms to quality management Specification API Q1. The following technical documentation contains performance and test documentation for the ICD device as applicable to the Validation Grade;

- Operating flow performance curve dP versus Q and basis for curve, including fluid types with viscosities and densities.

- Erosion test min/max volumetric flow rate and dP - Erosion Test duration and sand concentration - Flow Initiation Pressure(s) - Static Pressure Rating(s) - Flow Integrity Test; max pressure, rate and duration - Sediment Plugging Test; pre/post flow performance curves

5.2 Technical Characteristics The following criteria shall be met: The ICD shall perform in accordance with the functional specification and provide predictable flow performance, resistance to erosion and plugging, and shall maintain integrity across the pressure range as applicable to the validation grade. 5.3 Design Requirements 5.3.1 Materials Materials (both metallic and non-metallic) shall be stated by the supplier/manufacturer and shall be suitable for the operational parameters and the environment specified in the functional specification. The supplier/manufacturer shall have documented specifications for all materials used in the manufacture of ICDs. The performance characteristics of the materials shall be suitable for the parameters specified in the well parameters for production or injection or both.



The user/purchaser may specify materials for the specific corrosion environment in the functional specification. If the supplier/manufacturer proposes to use another material, the supplier/manufacturer shall provide documented evidence to the user/purchaser for acceptance that this material has performance characteristics suitable for all requirements specified for the well, including any production/injection parameters. Materials used in the construction of the ICD components shall be provided to the user/purchaser. Base pipe material shall conform to the requirements of API 5CT unless otherwise specified in the functional specifications. 5.3.2 Material Substitution Material substitution is a temporary change to a bill of material for a validated component which does not change the rating of the product. Material substitutions from those used in the validation tested product are allowed without validation. The manufacturer's selection criteria for these substitutions shall be documented and the substituted material shall conform to the design, functional, and technical requirements of this specification. Material substitutions require approval by a qualified person from the supplier/manufacturer and the supporting documentation incorporated into the manufacturing records for those units affected. In cases where the user/purchaser specifies material(s) of construction, deviations from such materials shall require user/purchaser notification. 5.3.3 Metals Specifications The supplier’s/manufacturer’s specifications shall define the following, as applicable:

a) Chemical composition limits b) Heat treatment conditions c) Mechanical property limits, as applicable:

I. Tensile strength II. Yield strength III. Elongation IV. Hardness

5.3.4 Non-metals Specifications The supplier’s/manufacturer’s documented specifications for non-metallic compounds shall define those characteristics critical to the performance of the material, such as:

- Compound type - Tensile strength (at yield for thermoplastics) - Tensile strength (at break for elastomers) - Elongation at break - Tensile modulus (at 50% or 100% as applicable) - Compression set - Durometer (elastomer/thermoplastics hardness) - Hardness (ceramic/carbides) - Density (ceramic/carbides)

Specifications shall include test methods used for determining material characteristics.



5.4 Design Verification Design verification shall be performed to ensure that the ICD design meets the supplier’s/manufacturer's technical specifications. Design verification examines the design by evaluating activities such as design reviews, design calculations, validation tests, comparison with similar designs and historical records of defined operating conditions. The supplier/manufacturer shall apply a design margin (i.e., the difference between what the maximum capacity a part can operate at compared to what it actually does operate at) to each component and/or assembly using a documented methodology and practice. The documented design margins shall be utilized in the creation of component or assembly capabilities and/or ratings. Within each design family, the supplier/manufacturer may utilize FEA, CFD, mechanical strength calculations or other proven methods to determine performance ratings for sizes and similar configurations not tested within the limitations of scaling as outlined in Section 5.5.4. The material's minimum specified yield strength and minimum specified material conditions shall be used in the calculations, and the calculations shall include consideration of temperature effects. De-rating of metal mechanical properties due to temperature shall be verified by a qualified person and in accordance with; a) industry recognized published data, or b) data established by the supplier/manufacturer, or c) data provided by the material supplier. NOTE; ASME BPVC, Section II, Part D contains temperature de-rated tensile strengths for many materials. 5.5 Design Validation Requirements 5.5.1 General Products shall be supplied to at least satisfy the design validation grade specified in the functional specification. The supplier/manufacturer shall document the test procedure and results, and shall maintain on file material certifications and drawings that show all the applicable dimensions, materials and tolerances of parts contained in the tested product. Pre- and post-test dimensional inspections of critical operational areas, as determined by the supplier/manufacturer, shall be conducted, documented and maintained by the supplier/manufacturer. Validation tests shall be conducted according to the requirements specified in the respective annexes of this specification.

5.5.2 Validation Test Requirements The supplier/manufacturer shall document all parameters and results of the evaluations that demonstrate conformance to the validation grade. Three design validation grades (V3 to V1) for each flow direction provide the user/purchaser the choice of requirements to meet a specific preference or application.



Design validation grade V3 is the minimum grade and represents equipment whereby the validation method has been defined by the supplier/manufacturer. The complexity and severity of the validation testing increases as the grade number decreases.

5.5.2.1 Validation test requirements for rated functionality The supplier/manufacturer shall meet the validation test requirements specified in the respective annexes to the selected validation grade. Validation depends on the direction of flow. The validation grades are as follows:

Supplier/manufacturer shall specify whether the product was validated for Production or Injection or both.

Table 2 Design validation grade for both production and injection

Validation Test

Annex

Design Validation Grade

V3 V2 V1

Flow Performance E Supplier/manufacturer defined

Yes Yes

Erosion F Optional or Supplier/manufacturer

defined

Optional or Supplier/manufacturer

defined

Yes

Plugging G Optional or Supplier/manufacturer

defined

Optional or Supplier/manufacturer

defined

Yes

Flow integrity H Optional or Supplier/manufacturer

defined

Yes Yes

Static Pressure I Optional or Supplier/manufacturer

defined

Yes Yes

NOTE: Optional means that the test is not required.

5.5.2.2 Validation Test Annexes The supplier/manufacturer shall establish values for the flow performance, erosion, plugging, flow integrity and static pressure rating of the ICD, and excluding end connections. The performance values shall be based on results of the validation tests in accordance with the following annexes:

- Annex E. Validation Test Requirements - ICD Flow Performance Test - Annex F. Validation Test Requirements - Erosion Test - Annex G. Validation Test Requirements - Plugging Test - Annex H. Validation Test Requirements - Flow Integrity Test - Annex I. Validation Test Requirements – Static Pressure Test



5.5.2.3 Special Feature Validation A special feature is a component or subassembly that provides a functional capability that is not validated during the validation testing conducted in accordance with Table 2. The supplier/manufacturer shall identify, in design documentation, all special features included in the product design. Special features shall be validated by the supplier/manufacturer to their rated limits to documented procedures including acceptance criteria and with the design validation records approved by a qualified person other than the individual who created the original design. This validation may include test results, operational histories and evaluations. The supplier/manufacturer's design validation records shall include the design requirements, test procedures, test results or evaluations of special features. The supplier/manufacturer shall identify those special features that shall be included in the functional testing. 5.5.3 Design Changes All design changes shall be documented and reviewed against the design verification and design validation to determine if the change is a substantive change. A substantive change is a change to the design, identified by the supplier/manufacturer that affects the performance of the product in the intended services condition. A design that undergoes a substantive change becomes a new design requiring design verification in accordance with Section 5.4 and design validation in accordance with Section 5.5. Design changes identified as non-substantive are valid with proper documentation and justification. It is the vendor’s responsibility to provide evidence on how the device was validated/proved if the change was identified as non-substantive. The supplier/manufacturer shall, as a minimum consider the following for each design change:

- Interchangeability of the replaced or changed components/subassembly relative to the base design

- Material changes - Functional changes - Dimensional changes - Design intent

5.5.4 Design Validation by Scaling Scaling is the process by which the performance ratings of untested ICD designs may be determined based on the results of validation-tested ICD designs within a design family. The supplier/manufacturer may apply flow, erosion, plugging and pressure ratings for different ICD settings and base pipe sizes within a design family. Limitations on Scaling are included within Annexes E, F, G, H and I. Scaling requires approval by a qualified person from the supplier/manufacturer and the supporting documentation incorporated into the design package documentation.





6 Supplier/Manufacturing Requirements 6.1 General This clause contains the detailed requirements to verify that each product manufactured meets the requirements of the functional and technical specifications. These include requirements for documentation and data control, product identification, quality control and functional testing. ICDs produced according to this specification shall be manufactured, assembled, inspected and tested under a Quality Management System in conformance with API Q1. 6.2 Documentation and Data Control 6.2.1 General The supplier/manufacturer shall establish and maintain documented procedures to control all documents and data that relate to the requirements of this specification. These documents and data shall be maintained to demonstrate conformance to specified requirements. All documents and data shall be legible and shall be stored and retained in such a way that they are readily retrievable in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss. Documents and data may be in any form of type of media, such as hard copy or electronic media. All documents and data shall be available and auditable by the user/purchaser. All documentation and data associated with design verification (see 5.4), design validation (see 5.5), design change justification (see 5.5.3), and the design file shall be maintained for 10 years after date of last manufacture. Quality documentation includes all documents and data necessary to demonstrate conformance to all of Section 6.4. Quality documentation shall be retained by the supplier/manufacturer for a minimum of 5 years from date of manufacture or repair. These shall be available and auditable by the user/purchaser. Documentation of designs shall include:

- Design requirements, including those pressures, operational loads, material, environmental and other pertinent requirements on which the design is based

- Design criteria, including assumptions - Functional and technical specifications - Design drawings and manufacturing specifications - Material specifications and certifications, including yield strength as applicable - Design verification - Design validation evaluation/testing procedures/acceptance criteria and their approved results - Pre and post inspection results for the components/assemblies that were utilized for the validation

testing, including actual dimensions of the critical dimensions - All reporting required by the annexes for the specific validation grade - Instructions providing methods for the safe assembly and disassembly of the product and stating

the operations that are permitted to preclude failure and/or non-compliance with the functional and technical requirements

- Operating manual



Design documentation showing conformance to the design requirements, including annexes, shall be retained for a minimum of ten years from the last date of manufacture of that particular design.

6.2.2 Operating Manual An operating manual shall be available for all products supplied in accordance with this specification. Operating manuals shall contain at least the following information:

- Manual reference number and revision - Operational procedures and related tools - Pre-installation inspection procedures - Representative drawing showing major dimensions (ODs, IDs, and lengths) - Requirements for handling, shipment, and storage

6.2.3 Product Specification Data Sheet Product data sheets for each product shall be supplied for quality grade QL1 or as requested by the user/purchaser and shall contain the following information, as applicable:

- Name and address of supplier/manufacturer - Supplier/manufacturer assembly or part number - Supplier/manufacturer product name - Product type (Type 1, Type 2N or Type 2M) - Service Level: Producer, Injector, or both - Validation Level: (V1, V2 or V3) - Quality Grade: QL1, QL2 or QL3 - Materials description - Max OD - Overall length - Base pipe size - Temperature range - Static pressure rating - Flow integrity rating - Erosion volumetric flow rate and differential pressure ratings, test duration and test sand

concentration Additional ICD Joint information, as applicable:

- Product type - Materials description - External drift diameter - Internal drift diameter - Max OD (without centralizers) - Max OD (with centralizers) - Filter Assembly OD - ICD Housing OD - Joint overall length - Screen jacket length - Base pipe nominal size (screen size), material, grade, mass - Base pipe end connections



- Screen type (mesh or wire wrap) - Pore size (mesh) or slot size (wire wrap) - API 19SS Validation and Quality Grade - Centralizer details; quantity, location, type/configuration

6.3 Product Identification Each product furnished to this specification shall be permanently identified according to the supplier/manufacturer’s specifications. The manufacturer’s specifications shall define the type, method of application and location of the identifications. The following information shall be included as a minimum:

- Manufacturer identification - Manufacturer part number - Job Lot Trace Number - Product type (Type 1, Type 2N or Type 2M) - Service Level: Producer, Injector, or both - Validation Level: (V1, V2 or V3) - Quality grade (QL1, QL2, or QL3) - For quality grade QL1, a unique serial number providing traceability

6.4 Quality Requirements 6.4.1 General This specification provides for three grades of quality control requirements, which allows the user/purchaser to select the grade that is required for a specific application. Quality grade QL3 is the minimum level of quality offered by the specification and is consistent with quality grades that are minimum industry practice. Quality grade QL2 provides additional inspection and verification steps, and quality grade QL1 is the highest grade provided by this specification. If user/purchase does not define quality grade, QL3 shall be the minimum. Quality control requirements are summarized in Table 3 and detailed in Section 6.4.2 through Section 6.4.8.

Item

Quality Grade

QL3 QL2 QL1

Certification

Material certification - Metals COC or MTR COC or MTR MTR

Material Certification- Non-metalics None COC COC



Basepipe thread certification – Premium Threads COC COC COC

Component Traceability

Housing Job lot Job lot Serialized

Base pipe Job lot Job lot Serialized

ICD Element Job lot Job lot Job Lot

All other ICD Components Job lot Job lot Job lot

ICD components/elements inspection

All other components Supplier/manufacturer’s documented specifications Sampling Plan Sampling Plan

Hardness

Type 1 components None Sampling Plan 100 %

Type 2 components None None None

Assembly Verification

Type 1 welds Visual Surface NDE per sampling plan and visual

Surface NDE 100 %

Type 2 welds Visual Visual Visual

ICD Joint Dimensions Supplier/manufacturer’s documented specifications Sampling Plan 100 %

ID drift, OD drift, Supplier/manufacturer’s documented specifications Sampling Plan 100 %

Threads (visual inspection) Supplier/manufacturer’s documented specifications Sampling Plan 100 %

Assembly traceability Job lot Job lot Serialized

QC documentation Retained by supplier/manufacturer

Retained by supplier/manufacturer

Retained by supplier/manufacturer

Product Data Sheet Upon request form user/purchaser

Upon request form user/purchaser Required

Table 3 Summary of Type 1, 2N, and 2M ICD’s quality requirement

Note: See Section 6.4.2.5 for sampling plan requirements



6.4.2 Certification 6.4.2.1 Material certification Material used in the manufacture of components shall meet the following requirements:

- QL2 and QL3: COC stating that the material meets the supplier/manufacturer's documented specifications or MTR showing conformance to the supplier/manufacturer's documented specifications

- QL1: MTR so that the supplier/manufacturer can verify that the material meets the supplier/manufacturer's documented specifications

MTRs provided by the material sub supplier or the supplier/manufacturer are acceptable documentation of mechanical properties. MTRs shall be legible and reproducible and shall be an original or direct copy of a document unaltered as issued by its source. 6.4.2.2 Thread certification Basepipe threads shall be provided with a COC stating that each thread conforms to the thread manufacturer's specifications.

6.4.2.3 Component traceability Component traceability shall meet the following requirements.

- QL1 and QL2 and QL3: All components shall be job-lot traceable

6.4.2.4 Component Inspection Component inspection shall meet the following requirements

- For QL3, components shall be inspected in accordance with the supplier/manufacturer's documented specifications and acceptance criteria

- For QL2:

a) Visually inspect basepipe per a sampling plan in accordance with 6.4.2.5 (minimum 1 for lot sizes of fewer than 10) in each basepipe job lot in accordance with the supplier/manufacturer's documented specifications and acceptance criteria to verify the perforation pattern and that all perforations are clear of burrs.

b) Dimensionally inspect all other components per a sampling plan that meets the requirements of an international standard or national standard, such as ISO 2859-1, ANSI/ASQC Z1.4, or ASQ H1331.

- For QL1:

a) Visually inspect 100% of the basepipe in accordance with the supplier/manufacturer's

documented specifications and acceptance criteria to verify the holes location and number of holes and that all perforations are clear of burrs.

b) Dimensionally inspect all other components per a sampling plan defined in 6.4.2.5.



6.4.2.5 Sampling plans Sampling Plans shall meet one of the following requirements:

- For ISO 2859-1 use a 2.5 AQL, Inspection Level II, Normal Table utilizing c=0 for all lot sizes - For ANSI/ASQC Z1.4 use a 2.5 AQL, Inspection Level II, Normal Table utilizing c=0 for all lot

sizes - For ASQ H1331 using an index level of 2.5 - Equivalent sampling specifications may be utilized provided the Average Outgoing Quality Limit

(AOQL) is the same or better and the Acceptance Number (c) = 0 6.4.3 Welding and Brazing 6.4.3.1 General Welding shall conform to the supplier/manufacturer's documented specifications. Welding and brazing shall meet the following requirements:

- Welding and brazing procedures, qualifications, and personnel qualification shall be in accordance with ASME BPVC, Section IX

- Material and practices not listed in the ASME BPVC, Section IX shall be applied using weld procedures qualified in accordance with the methods of ASME BPVC, Section IX

6.4.3.2 Inspection Nondestructive examination (NDE) of components and welds shall meet the following requirements.

- Type 1 welds for QL3 shall be visually inspected per supplier/manufacturer’s documented specifications.

- Type 1 welds for QL1 and QL2 shall be visually inspected per the requirements of an international

or national standard such as ASME BPVC, Section V, Article 9.

- Type 1 components and welds for QL2 shall be NDE inspected using liquid penetrant or magnetic particle methods per a sampling plan that meets the requirements of an international or national standard such as ISO 2859-1 or ANSI/ASQ Z1.4.

- Type 1 components and welds for QL1 shall be 100 % inspected using liquid penetrant or

magnetic particle methods and visual inspection.

- Type 1 Braze joints for QL1 shall be visually inspected under 10X magnification as follows: - Where possible, both sides of each brazed joint shall be examined. - There shall be evidence that the brazing filler metal has penetrated the joint. In a butt joint

there shall be no concavity. - The presence of a crack in the braze shall be cause for rejection. - Pinholes or open defects in the braze shall be cause for rejection. - Defects in the braze may be repaired or rebrazed.

- Type 2 welds for all quality levels shall be visually inspected per supplier/manufacturer’s

documented specifications.



- Type 2 components for QL1 shall be visually inspected per the supplier/manufacturer’s documented specifications.

- When surface NDE is required, visual inspection and either magnetic particle inspection or liquid

penetrant inspection shall be performed in the final material condition. Surface NDE shall be performed on all external surfaces and to the maximum extent on internal surfaces.

- Magnetic particle inspection shall meet the requirements of an international or national standard

such as ISO 10893-5 or ASTM E709.

- Liquid penetrant inspection shall meet the requirements of an international or national standard such as ISO 10893-4 or ASTM E165.

- NDE acceptance criteria shall be according to the supplier/manufacturer’s documented

specifications.

- NDE for nonmetallic components shall be visual inspection.

- Visual inspection of O-rings shall be in accordance with ISO 3601-3 or equivalent.

- Visual inspection of components other than O-rings shall be in accordance with the supplier/manufacturer’s documented specifications.

- All NDE procedures shall be approved by a Level III examiner qualified in accordance with ASNT

SNT-TC-1A, ISO 9712, or equivalent national or international standard.

6.4.4 Assembly Verification Assembly verification shall meet the following requirements after all manufacturing processes are complete: ICD Joint Dimensions include; Screen or debris barrier length (LS), Pin handling length (LP), Box handling length (LB), ICD housing length (LH), Joint overall length (OAL), and Outside diameter OD. See Annex B.

- QL3: a) Assembly verification shall be in accordance with the supplier/manufacturer's documented specifications and acceptance criteria.

- QL2:

a) All ICD Joints shall meet the requirements shall meet the requirements for components in Table 3.

b) Verify the ICD LS, LP, LB, LH, and OD in accordance with a sampling plan in meeting the requirements of 6.4.2.5.

c) Basepipe or mandrel shall be ID drift inspected

- QL1:

a) All ICD Joints shall meet the requirements for QL1 components in this specification.



b) Verify the ICD LS, LP, LB, LH, and OD on 100% of the ICD assemblies. c) Basepipe or mandrel shall be ID drift inspected

6.4.5 Assembly Traceability Assembly traceability shall meet the following requirements:

- QL2 and QL3: ICD or ICD Joint assemblies shall be job lot traceable

- QL1: ICD or ICD Joint assemblies shall be individually serialized

6.4.6 Quality Control Documentation Documentation showing conformance to the manufacturing requirements of this specification shall be retained for a minimum of five years from the date of manufacture. Quality control documentation includes all documents and data necessary to demonstrate conformance to Section 6.4.2 through 6.4.8.

6.4.7 Calibration Systems Equipment used to inspect, test or examine material or other equipment shall be identified, controlled, calibrated and adjusted at specified intervals in accordance with documented manufacturer instructions and consistent with nationally or internationally recognized standards, such as ISO/IEC 17025 or ANSI/NCSL Z540-3, to maintain the accuracy required by this specification. Technologies for inspections with verifiable accuracies equal to or better than those listed in this specification may be applied with appropriate documentation and when approved by a qualified person(s). Calibration intervals for measuring and test equipment shall be established based on repeatability, amount of usage, environment and past history for that type of instrument. For standard, adjustable, hand measurement tools the initial calibration interval shall be three months until a recorded calibration history for that instrument can be established. Intervals may then be lengthened or shortened. The calibration interval cannot be increased by more than twice the previous interval and shall not exceed more than one year. Non-standard or non-adjustable measurement devices such as surface plates, threaded plug/ring gauges, coordinate measuring machine (CMMs), optical comparators, etc. shall be calibrated initially and the calibration interval set based on equipment type, usage, and operating environment. Calibration intervals shall not exceed five years for this type of equipment.

Calibration standards used to calibrate measuring equipment shall be checked and approved at least once every three years by qualified individuals using qualified equipment with traceability to the applicable national or international standards agency. Instruments and calibration standards that have not been used during the calibration interval and that have been maintained in accordance with proper practice may have their calibration cycle extended for an amount equal to the designated cycle.



Inspection, measurement, and testing equipment shall only be used within the calibrated range. Pressure measuring devices shall be calibrated with a master pressure measuring device or a dead weight tester. Calibration intervals for pressure measuring devices shall be a maximum of three months until documented calibration history can be established. Calibration intervals shall then be established based on repeatability, degree of usage, environment, and documented history.

6.4.8 Personnel Qualification 6.4.8.1 General Personnel performing inspections for acceptance shall be qualified in accordance with supplier/manufacturer's documented specifications. For the purpose of this specification, certification to ISO 9712/ASNT SNT-TC-1A for visual inspection is not required. 6.4.8.2 Non-destructive Examination Personnel Personnel performing NDE shall be qualified in accordance with the manufacturer's documented training program that is based on the requirements specified in ISO 9712/ASNT SNT-TC-1A. 6.4.8.3 Visual Examination Personnel Personnel performing visual inspection for acceptance shall take and pass an annual vision examination in accordance with the manufacturer's documented procedures that meet the applicable requirements of ISO 9712/ASNT SNT-TC-1A. 6.4.8.4 Welding Inspectors Personnel performing visual inspections of welding or Brazing operations and completed welds / braze joints shall be qualified and certified as:

a) AWS-certified welding inspector, or b) AWS-senior certified welding inspector, or c) AWS-certified associate welding inspector, or d) Welding (or Brazing) inspector certified by the manufacturer's documented training program.



Annex A (informative)

API Monogram Program Use of API Monogram by Licensees

To be populated prior to publication.



Annex B (informative)

ICD Joint Components and Screen Attributes

B.1 General

This annex includes descriptions of ICD joint components, descriptions and dimensions.

Figures B.1 and B.2 are illustrations of examples of ICD configurations showing components and dimensions.

Figure B.1 Examples of ICD Joint showing ICD components



a) ICD Element: Flow-regulating component(s).

b) Base Pipe: The pipe, including connections, on which is mounted all ICD components, and which is designated per API 5CT Specification for Casing and Tubing.

c) Filter Assembly: The sand control screen or debris barrier that is often integrated with the ICD to provide wellbore sand retention and/or protect the ICD from larger solids. (See API 19SS)

d) ICD Housing: External structure that houses the ICD component(s).

e) End Ring: A ring that is located at the end of the filter assembly and seals off the gap between the filtration unit and base pipe so as to not let unwanted solids pass.

f) Bypass Ring (if applicable): A ring that allows fluid to flow between the ICD and filter assembly. This may or may not be part of the housing, depending on the filtration unit type.

Note: Figure B.1 is an example for reference only; individual designs can vary.

Figure B.2 ICD Joint Dimensions



Annex C

(normative) Test Article, Test Fixture and Instrumentation Requirements

C.1 General This annex summarizes related equipment and instrumentation requirements to ensure accurate and representative measurements in the ICD test procedures described in this specification. C.2 Test Article and Test Fixture C.2.1 Test Article The test article shall meet the following requirements: a) Consist of a base pipe section including the ICD element, the ICD housing, the attachments to the base pipe with attachment method, and bypass ring (if applicable) used to attach the ICD to the ICD joint. b) Exclude the screen or debris filter section unless the end user specifies one for the erosion test. c) Manufactured in accordance with the design to be validated. d) Manufactured per Quality Level QL1. C.2.2 Test Fixture A representative test article inside a test fixture is illustrated in Figure C.1. The design of the test fixture shall consider minimizing the pressure drop in the annulus between the fixture and test article. For the Erosion Test, the design of the test fixture shall also consider minimizing settling of the sand. The production direction is from the right to the left (Figure C.1), the test fluid enters the ICD housing from the annulus between base pipe OD and the test fixture ID and exits from the base pipe. For injection direction, the test fluid passes through the test article and test fixture in reversed direction. Pressure shall be recorded in low velocity regions/stagnate zones inside the test fixture, avoiding the obstruction of any flow path. The entire test assembly shall be filled with test fluid, avoiding any air pockets. Table C.1 summarizes orientation requirements for the test article and the test fixture depending on the testing program and the ICD type as defined in Section 4, Table 1.



Production Orientation

Injection Orientation

Key

A- Inlet B- ICD Test Article C- Test Fixture D- Outlet

Figure C.1 Representative test article



Annex ICD Type Type 1 Type 2N Type 2M

Cavitation (Annex D)

Not Specified Not Specified Horizontal Positions P1 and P3

Flow Performance (Annex E)

Not Specified Not Specified Horizontal Positions P1, P2, and P3

Erosion (Annex F)

Vertical Vertical Vertical

Plugging (Annex G)

Horizontal Positions P2 or P3

Horizontal Positions P2 or P3

Horizontal Positions P1 and P3

Flow Integrity (Annex H)

Not Specified Not Specified Not Specified

Static Pressure (Annex I)

Not Specified Not Specified Not Specified

Table C.1 Summary of ICD Element position and test fixture orientation for annex tests

Figure C.2 Test Fixture orientation (cross-section)

.



C.3 Instrumentation Requirements The test facility instrumentation for all tests in this document shall meet the requirements listed below:

- The instrumentation for mass or volumetric flow rate shall be appropriate for the fluid type and range of mass or volumetric flow rates expected. Different types of flow meters may be needed for different fluids, and different sized meters may be needed for different ranges of flow rate

- Flow meter to measure mass or volumetric flow rate of the test fluid to an accuracy of +/- 2% of mass or volumetric flow rate reading or better during the test. Measured mass or volumetric flow rates should be within operating range of the flow meter as specified by the manufacturer

- Pressure shall be measured with pressure transducers of an established accuracy of 2% of the ΔP reading or better during the test

- Temperature shall be measured with an accuracy of +/- 4 degrees Fahrenheit reading or better during the test

- Data acquisition sampling rate should be a minimum frequency of 1 Hz

- Measurement devices shall be calibrated as described in Section 6.4.7



Annex D (normative)

Cavitation Testing

D.1 General This annex specifies the test method requirements for determining the outlet pressure (back pressure) to minimize the effects of cavitation across the ICD. ICD cavitation will affect the flow testing results listed in this specification. Cavitation testing is required for all devices. For Type 2M and Type 2N devices, the flow test results may not stabilize as required in the test procedure and the supplier/manufacturer will specify the outlet pressure to be used for further validation testing. D.2 Cavitation Test A cavitation test consists of flowing the test fluid through the ICD in production and/or injection direction at varying outlet pressures to determine the outlet pressure that minimizes the effects of cavitation. This outlet pressure shall be used, at minimum, during the flow performance and erosion tests.

D.2.1 Cavitation Test Requirements During data collection periods, either the volumetric flow rate or differential pressure will be specified to be the parameter to be controlled. The control parameter shall be stable per the following:

i) If the control parameter is the volumetric flow rate, the volumetric flow rate shall remain within 2% of the specified volumetric flow rate or +/- 0.1 gpm (gallons per minute), whichever is greater.

ii) If the control parameter is the differential pressure, the differential pressure must remain within 4% of the specified differential pressure.

During any period of data collection at a specific differential pressure and volumetric flow rate, upstream temperature fluctuations shall not exceed a temperature range that will result in a viscosity fluctuation of +/- 5%, for viscosities below 5 centipoises, and +/- 7% for viscosities above 5 centipoises.

NOTE: Fluctuations in flow conditions may be the result of the test facility rather than the ICD. A bypass line may determine the source of the fluctuation.

D.2.2 Test Fluid Property Characterization During ICD flow testing data collection periods, viscosity and density of the test fluids at test pressure and temperature at the fixture inlet conditions shall be determined. Direct measurement or an indirect correlation shall be used to report the actual viscosity and density entering the ICD during a flow test. This correlation may be interpolated but not extrapolated.



D.2.3 Cavitation Test Procedure D.2.3.1 General For each ICD product, the available ICD settings (e.g. nozzle size or flow path) shall be tested and characterized separately in the direction of rated service; production, injection, or both. For each test fluid, a minimum of 2 different pressure differentials, or volumetric flow rates, distributed across the operating range from minimum to maximum pressure differential shall be tested. Test procedure for each test fluid: a) Install test sample with the appropriate ICD setting into test fixture and ensure proper sealing. b) Depending on the desired flow direction (production versus injection), connect test fixture to the flow loop. c) Bleed all air within the test fixture. d) For oil-based fluids, capture a sample from the flow loop after the flow loop has been filled with the test fluid and system volume recirculated at least three times. Results of sample analysis shall be used to characterize the test fluid. e) Begin circulating the test fluid, adjusting the rate to achieve the desired pressure differential, or volumetric flow rate, across the test article. f) Identify an outlet pressure required to minimize cavitation. D.2.3.2 Fixed Differential Pressure Method Test procedure: a) Increase the outlet pressure by a minimum of 30 psi until a 2% or less change in volumetric flow rate is achieved with the increased outlet pressure. b) Maintain stable flow for at least five minutes, record temperature and pressures. c) Repeat for a minimum of three different outlet pressure points that results in less than 2% change. d) Record the ratio of outlet pressure versus pressure differential across the test article that is required to minimize cavitation. D.2.3.3 Fixed Volumetric Flow Rate Method Test procedure: a) Increase the outlet pressure by a minimum of 30 psi until a 4% or less change in differential pressure is achieved with the increased outlet pressure.



b) Maintain stable flow for at least five minutes, record temperature and pressures. c) Repeat for a minimum of three different outlet pressure points that results in less than 4% change. d) Record the ratio of outlet pressure versus pressure differential across the test article that is required to minimize cavitation.

For Type 2M or 2N devices that do not stabilize, the supplier manufacturer shall document the outlet pressure specified for testing. D.3 Cavitation Test Report The following information shall, as a minimum, be reported: a) fluid density and viscosity at each inlet test temperature b) inlet and outlet pressure b) inlet temperature c) volumetric flow rate d) outlet pressure required to minimize the effects of cavitation e) The ratio of outlet pressure versus pressure differential across the test article that is required to achieve a pressure differential and volumetric flow rate combination independent of outlet pressure



Annex E (normative)

Validation Test Requirements – ICD Flow Performance Test

E.1 General This annex provides test requirements and test protocols to characterize the flow performance of ICDs for single-phase flow including water, oil, and gas as test fluids. For production ICDs, flow performance needs to be evaluated in a production direction from annulus between the test fixture ID and test sample OD into the base pipe. For injection, the flow direction needs to be reversed (from base pipe ID to the annulus between the test fixture ID and test sample OD). For each ICD product, the available ICD settings (e.g. nozzle size or flow path) shall be tested and characterized separately. For example, a minimum of one test of each nozzle size (e.g., 1.6 mm, 2.5 mm, etc.) must be tested. This annex is not applicable for multi-phase flow performance testing. E.2 ICD Flow Performance Test E.2.1 ICD Flow Performance Test Requirements The system pressure shall be as follows: a) For liquids, the required outlet pressure to avoid cavitation shall be determined according to Annex D. b) For gases, the system upstream pressure shall be:

I. at an upstream pressure (and temperature) to replicate the gas properties (density and/or dynamic viscosity) anticipated under service conditions; or II. at the maximum operating pressure rating of the ICD as specified by the manufacturer

c) For gases, the minimum downstream test pressure shall be:

I. at a value equal to one-half of the upstream pressure to replicate critical flow (gas velocity at sonic velocity somewhere in the device); or II. at a value equal to the upstream pressure minus the maximum operating differential pressure rating of the ICD as specified by the manufacturer; or III. at a value that will result in the maximum operating flow rating of the ICD (at the test upstream pressure and temperature conditions), as specified by the manufacturer

The test conditions shall follow the guidelines specified below:



Testing shall be performed at an upstream temperature that is needed to obtain the fluid properties of interest (dynamic viscosity, density, etc.) unless the ICD device has a specific temperature dependent effect which requires the test to be performed at an upstream temperature similar to those expected in service, or at a temperature range suitable to demonstrate the temperature dependent effect. Testing shall be performed at stable flow conditions as per Annex D.2 For ICD’s whose performance may be dependent on their orientation, particularly those that contain moving parts or that may be gravity dependent, multiple tests may be required to establish the sensitivity to orientation (Annex C) E.2.2 ICD Flow Performance Test Procedure Test fluids shall be chosen to replicate the desired range of viscosity and density at the test temperature and pressure conditions for the test article as specified by the ICD manufacturer. A fluid properties analysis shall be performed, or published fluid property data shall be available for all test fluids to establish the viscosity and density dependency on temperature and pressure. Test procedures for each test fluid specified under Test Fluids shall fulfil the following requirements: For Type 1 ICDs, flow performance shall be performed with a representative single-phase fluid.

For Type 2M and Type 2N ICDs, flow performance shall be performed with a representative single-phase fluid. Single-phase tests shall be performed with at least two fluids representing both wanted and unwanted fluids. Each single-phase flow performance test shall be performed at the same differential pressures across the ICD.

The following test procedures are valid for production and injection direction: a) Install test article into test fixture and ensure proper sealing and orientation (Annex C). b) Draw a fluid sample from the flow loop after the flow loop has been filled with the fluid of interest and recirculated at least three times. This sample shall then be analyzed for viscosity and density. c) Record stabilized differential pressure, temperature and volumetric flow rate at five steps across the ICDs range of investigation, ensuring sufficient outlet pressure to avoid cavitation (Annex D). d) Record data as required in Section E.6. All relevant data will be recorded for a minimum of three minutes of stable flow (Section D.2). Data shall be recorded at a minimum frequency of one hertz for each measured parameter. e) When changing test fluids ensure that test facility flow lines and fixtures are clean and flushed of previous fluids per documented procedures. f) Repeat for each test fluid. E.3 ICD Flow Performance Test Report



The following information shall, as a minimum, be reported:

a) Time history plots of inlet, outlet, differential pressure, volumetric flow rate, mass flow rate, density and temperature.

b) Report the mean stabilized values of differential pressure, volumetric flow rate, mass flow rate, viscosity, density and temperature.

c) Orientation, position (horizontal or vertical), flow direction

d) Test Procedure

e) Fluid type and applicable viscosity test results

f) For Type 2M and Type 2N ICDs, the Volumetric Flow Rate (Q) for each test fluid shall be reported along with a Choking Efficiency (CEQ) based on volumetric flow rates for each set of wanted and unwanted fluids at the same tested differential pressure, at the service temperature and pressure conditions; Where CEQ = (Qwanted fluid – Qunwanted fluid) / Qwanted fluid CEQ simplifies to the following Reference Choking Efficiency for Type 1 ICDs Reference Choking Efficiency, CEReference = 1- (ρwanted / ρunwanted)0.5 Choking Efficiency Gain, CEGain = (CEReference - CEQ) / (CEReference) for cases where ρunwanted is < ρwanted and CEGain = (CEQ – CEReference) / (CEReference) for cases where ρunwanted is > ρwanted

If erosion testing is performed as per Annex F, pre and post erosion flow performance tests shall be performed per Annex E with the following reported in the flow performance test report:

- Pre and post erosion test Volumetric Flow Rates (Q) and differential pressures - Pre and post erosion test Choking Efficiency (CEQ) - Pre and post erosion test Choking Efficiency Gain

E.4 Limitations of Scaling for Annex E Flow Performance Test Flow performance: ICD settings (e.g. nozzle size or flow path) and functionality are the same. The flow performance rating of a tested ICD article may be applied as the rating for an untested ICD article of the same design that has the same choke diameter or flow path, as well as the same entrance and exit loss coefficients, as long as the untested ICD article does not alter the performance based on proven CFD or calculation methods. For Type 1 ICDs, flow performance estimates are allowed between tested choke diameters based on proven CFD or calculation method(s).



Annex F (normative)

Validation Test Requirements – Device Erosion Test

F.1 General This annex provides test requirements for evaluating erosion resistance of the device by establishing the change in flow performance of the ICD in either production or injection direction. NOTE: The following equation may be used to compare well life and field sand concentration for a given set of test results.

ttest = twell × SCfield

SCtest ×

365.25 × 24 × 103

42 × 8.34

where: - ttest is the test duration (hours) - twell is the anticipated well life (years) - SCfield is the anticipated sand production of the well (pound per thousand barrels) - SCtest is the sand concentration in the test (ppmw, parts per million by weight)

F.2 Device Erosion Test F.2.1 General For production ICDs, Erosion performance shall be evaluated in a production direction from annulus between the test fixture ID and test sample OD into the base pipe. For injection ICDs, the flow direction shall be reversed (from base pipe ID to the annulus between the test fixture ID and test sample OD). F.2.2 Device Erosion Test Requirements Establish erosion resistance by passing sand slurry through the test article at either a constant pressure differential or volumetric flow rate. The flow performance will be documented before and after the erosion test and is indicative of the device’s resistance to erosion. Revealing erosion resistance of the surrounding components are intended to be included, as these components may become the limiting factor related to overall life of the test article. Validation test shall meet the following requirements: a) The test sample/fixture shall meet the requirements of Annex C. b) The test sample/fixture shall be oriented as per Figure F.1. c) The slurry temperature at the inlet shall be held at 70°F +/-20°F.



d) The slurry concentrations shall be a maximum of 20,000 ppmw + /- 12.5% throughout the test

e) Minimum test duration is 24 hours for a 20,000 ppmw slurry concentration. A longer test duration is required if less than 20,000 ppmw slurry concentration is used, and shall be calculated using the following equation where SCtest is expressed in units of ppmw and ttest in units of hours;

ttest =480,000

SCtest

f) Pressure sensor equipment shall not obstruct any flow path which may affect the flow performance characteristic of the device.

g) For Type 1 ICDs, post-erosion flow performance testing shall be performed per Annex E, using the same test fluid(s) and differential pressure used prior to erosion testing.

h) For Type 2M and Type 2N ICDs, post-erosion flow performance testing shall be performed per Annex E using the same wanted/unwanted test fluids and differential pressure used prior to erosion testing.

i) Particle concentration shall be monitored throughout the erosion test. j) SiO2 particles shall not be recirculated



Figure F.1 Producer and Injector Erosion Test Arrangement

F.2.3 Device Erosion Test Fluid



Test fluid shall be water mixed with abrasive particles (erodent) per the below requirements: a) Test erodent material shall be quartz sand (SiO2). b) Particles shape shall be irregular and angular exhibiting sharp edges, 0.3 maximum roundness. Reference API 19C Section 7.4 for specific instructions to compare individual sand particles to the below chart.

Figure E2 API 19C Roundness Chart



Figure E3 Example of an irregular and angular particle

c) Particle size distribution for producers shall be within the below range:

I. D10 of < 10 μm II. D50 of 40 - 50 μm III. D90 of < 135 μm IV. Particle size shall not exceed 150 μm

d) Particle size distribution for injectors shall be within the below range:

I. D10 of < 10 μm II. D50 of 20 - 30 μm III. D90 of < 80 μm

F.2.4 Device Erosion Test Procedure Silicon dioxide sand/water slurry is flowed through a test article at either a fixed mass or volumetric flow rate or pressure drop. For production, the slurry shall enter the ICD from an annular space and exit from the ICD’s base pipe. For injection, the slurry shall enter the ICD from the base pipe and exit through the annular space. A single pass setup is required. Appropriate outlet pressure shall be maintained in the base pipe to eliminate cavitation across the ICD as per Annex D.



Validation test procedure shall meet the following requirements: a) Inspect device (such as functionally critical features, dimensions, weight, and photographs as defined by the supplier manufacturer) b) Document the method to calculate total mass of sand pumped through the test article c) Perform the pre-erosion flow performance test d) Perform the erosion test at the desired differential pressure or, mass or volumetric flow rate for the defined test duration.

i) Measure and record the sand concentration exiting the sample directly after start up and every 30 minutes thereafter until the initial settling has stabilized within the allowable particle concentration variation of +/- 12.5%

ii) Measure and record the sand concentration at a minimum of once per hour after the initial stabilization

e) Perform post-erosion flow performance test f) Inspect device after testing (such as functionally critical features, dimensions, weight, and photographs as defined by the supplier manufacturer) F.3 Device Erosion Test Report The following information shall as minimum be reported: a) Time history plots of inlet, outlet, differential pressure, inlet fluid temperature, test flow direction, and volumetric flow rate across the ICD b) Report the initial and final differential pressure, volumetric flow rate and total flow time values during the erosion test c) Total mass of sand pumped through the test article d) Particle concentration method and procedure, and concentration results at minimum intervals e) Particle size distribution per the supplier’s specification f) Evidence of particle shape assessment g) Flow performance before and after test h) Inspection results and photographs of the device pre and post erosion test i) Technical assessment that the product passed the test F.4 Limitations of Scaling for Annex F Erosion Performance Test



The erosion rating of a validated ICD article may be applied as the rating for an untested ICD of the same design family that has velocities through the article equal to or less than the ICD qualified at a given differential pressure or volumetric flow rate rating. The component materials must exhibit equivalent or higher hardness, and the axial length components must be the same or longer.



Annex G (normative)

Validation Test Requirements – Mud Flow Initiation Test and Sediment Plugging Test

G.1 General This annex describes the test requirements for establishing plugging potential and associated clean-up parameters of an ICD when filled with drilling mud having Non-Newtonian fluid properties. The intent is to measure the pressure required to initiate flow after a specified settling time while determining if the settled mud alters the flow performance of the ICD. The test mud shall be made according to a defined formulation and shall be within given rheological properties. G.2 Mud Flow Initiation Test and Sediment Plugging Test G.2.1 General

The Mud Flow Initiation Test and Sediment Plugging Test shall be conducted in a production direction from annulus between the test fixture ID and test sample OD into the base pipe.

G.2.2 Mud Flow Initiation Test and Sediment Plugging Test requirements In the mud flow initiation test, the test fluid is pumped in the production direction through the ICD and exits from the base pipe. The flow is stopped and held at a no-flow condition for a defined amount of time. Fluid flow is restarted. Inlet & outlet pressures, fluid temperature, and volumetric flow rate are recorded throughout the test. Repeat this sequence for each additional test fluid and/or for varying no-flow time durations. The flow performance characteristic of the ICD will be assessed after exposure to the mud. In the sediment plugging test, the fluid is pumped in the production direction, flow is stopped and held. Conduct a flow performance test. In the sediment plugging test, water is pumped in the production direction through the ICD and exits from the base pipe to establish the flow performance characteristics of the ICD. Water is replaced by the sediment test fluid and flowed for a defined amount of time. The flow is stopped and held at a no-flow condition for a defined amount of time. The test fluid is replaced by water for flow performance testing in order to re-assess flow performance characteristic of the ICD. Inlet and outlet pressures, fluid temperature, and volumetric flow rate are recorded throughout the test. Validation test shall meet the following requirements: a) Tests shall be performed at ambient temperature, but kept within +/- 10° F b) Pressure shall be monitored as in the flow performance test



c) Volumetric flow rate measured with appropriate metering device (see Annex C, Section C.4) d) Mud properties are to be measured using API 13B-1 G.2.3 Test Fluid Requirements The test fluid is a water based, Non-Newtonian, drilling mud with the following properties: a) Density of 11-12 pounds per gallon

- Measured via mud scale b) Rheology (viscosity and gel strength)

- Measured with concentric cylinder viscometry, eg.Fann 35A viscometer

c) Fluid Rheology properties per Table G.1

Viscous fluid Settling fluid 600 rpm (1022 s-1) No target No target 300 rpm (511 s-1) No target No target 6 rpm (10.22 s-1) target 6 rpm > 15 target 6 rpm < 8

PV (=600 rpm – 300 rpm), [cP] No target No target YP (=2 x 300 rpm – 600 rpm), [lb/100 ft2] target YP> 40 target YP < 24

Table G.1 Targets for Fluid Rheology Measurements

Additive Viscous fluid Settling fluid Freshwater [bbl]; [m3]

1.0; 1.0

Soda Asha [lb/bbl]; [kg/m3] 0.25;0.71

Dilute viscous fluid with 30 – 40 vol% water Xanthan gum, API grade [lb/bbl]; [kg/m3] 1 - 1.25; 2.85 – 3.57

Starch, API grade [lb/bbl]; [kg/m3] 8 - 10; 22.8 – 28.5

Barite, API Spec 13Ab [lb/bbl]; [kg/m3] 197; 562

Silica Sand, D10<95 μm, 100<D50<115, D90>120 [lb/bbl]; [kg/m3]

45; 128

Table G.2 Composition of Test Fluids at Ambient Temperature (70°F)

a for use in hard, calcium-rich water with hardness greater than 400mg/l, or if water hardness is unknown b there will be a 13% volume increase with the addition of barite G.2.4 Mud Flow Initiation Test Fluid Preparation Procedure

The test fluid preparation for the mud flow initiation test shall meet the following requirements:



- Review Safety Data Sheets for all additives and use all applicable personal protective equipment (PPE)

- Add Soda Ash to potable water - Add Xanthan Gum

Note: Dispersible Xanthan gum for ease of mixing is recommended. Non-dispersible forms may require additional steps to avoid polymeric lumps:

- Agitate for 60 minutes - Slowly add starch - Agitate for 30 minutes - Add barite - Agitate for 30 minutes - Measure mud properties

G.2.5 Mud Flow Initiation Test Procedure Mud flow initiation test procedure shall meet the following requirements: a) Measure viscosity and yield point b) Weigh mud with a mud scale c) Verify solids content and size based on supplier’s specifications d) Inlet and outlet mud temperatures are to be measured and recorded throughout all tests.

- Verify weight and viscosity - Completely fill the test fixture with mud - Record a volumetric flow rate and pressure drop reference point - Stop flowing - Hold for 4 hours - Increase sample inlet pressure at a maximum rate of 30 psi per minute until mud begins to flow,

or until the maximum allowable pressure. The point where mud begins to flow is the Flow Initiation Pressure

- Hold at this condition for 5 minutes, or until stabilization - Take a sample of the mud exiting the ICD and record properties - Repeat the volumetric flow rate OR pressure drop from the reference point - Stop flowing - Remove the test sample - Clean test fixture thoroughly to remove the mud

G.2.6 Mud Sediment Plugging Test Procedure Mud sediment plugging test procedure shall meet the following requirements:

- Install a new test article into the test fixture



- Perform a flow performance test per Annex E, with water, at a minimum of 5 different pressure drop and volumetric flow rate combinations distributed across the operating range excluding the outlet pressure requirement

- Dilute the mud used in the Mud Flow Initiation Test per Table G.2 - Add silica sand - Agitate for 30 minutes - Verify weight and viscosity - Completely fill the test fixture with mud - Flow mud through test fixture at the minimum volumetric flow rate from the flow performance test

until the test fixture/sample volume has turned over a minimum of three times - Take a sample of the mud exiting the ICD and record properties

Stop flowing

- Hold for 4 hours - Block in test fixture and clean mud out of test facility - Perform a flow performance test with water, with 5 target volumetric flow rates from previous flow

performance tests (second bullet point above) - Start at lowest target volumetric flow rate - Hold rate constant until dP has met stability criteria (Annex D.2) - Repeat for each of the next 4 rates

G.3 Mud Flow Initiation Test and Sediment Plugging Test Report G.3.1 Mud Flow Initiation Test The following information shall be reported for the mud flow initiation test: a) Time history plots of inlet, outlet, differential pressure, and volumetric flow rate across the ICD and inlet/outlet test fluid temperature, direction of test b) Flow Initiation Pressure c) Mud ingredients, concentrations and silica size distribution. d) Measured mud properties G.3.2 Mud Sediment Plugging Test The following information shall be reported for the mud sediment plugging test: a) Time history plots of inlet, outlet, differential pressure, and volumetric flow rate across the ICD and inlet/outlet test fluid temperature, direction of test b) Flow performance data before and after each mud test c) Mud ingredients, concentrations and silica size distribution d) Measured mud properties G.4 Limitations of Scaling for Annex G Plugging Performance Test



Plugging performance: The plugging rating of a tested ICD may be applied as the rating for an untested ICD that has the same or less restrictive flow path geometry



Annex H (Normative)

Validation Test Requirements - Flow Integrity Test

H.1 General This annex describes the test requirements for validating the flow integrity ratings of an ICD. The flow integrity test will validate the maximum rated flowing pressure for injection and production mode. The test shall be conducted in the injection and production direction. Validation test shall meet requirements outlined below in Sections H.2 – H.4. H.2 Flow Integrity Test H.2.1 General

The Flow Integrity Test shall be conducted in the production direction from annulus between the test fixture ID and test sample OD into the base pipe and then the flow direction shall be reversed (from base pipe ID to the annulus between the test fixture ID and test sample OD).

H.2.2 Flow Integrity Test Requirements Test article and test fixture may be installed in horizontal or vertical orientation as per Table C1. Testing shall be performed at ambient temperature. Test fluid shall be water. The temperature of the water shall be recorded at the outlet of the test fixture during the test. H.2.3 Flow Integrity Test Procedure Flow integrity test procedure shall meet the following requirements: a) Inspect device (measure critical dimensions as defined by supplier/manufacturer pre-test) b) Perform flow performance test per Annex E using water. Pump test fluid in production and/or injection direction for eight hours at maximum rated pressure differential across the ICD while measuring the volumetric flow rate. Staging the ramp up of differential pressure to the estimate or desired maximum differential pressure shall be performed in a similar manner to Annex E. c) A predetermined outlet pressure shall be applied to avoid cavitation effects that would result in a divergence in flow performance, see Annex D for details e) Repeat flow performance test per Annex E using water.



f) Compare pre-test and post-test flow performance curves. d) Inspect device post-test (measure critical dimensions as defined by supplier/manufacturer post-test) H.3 Flow Integrity Test Report The following information shall be reported for flow integrity testing: a) Rates and ΔP during flow integrity test, including maximum differential pressure and rate across test article, direction of test b) Pre and post flow performance (Annex E). c) Report fluid temperatures measured during the test d) Critical ICD dimensions prior to and upon completion of testing e) Observations from inspection of device internally and externally (dimensional change, bulging or any form of structural damage shall be reported after device has been disassembled) H.4 Limitations of Scaling for Flow Integrity Test Flow Integrity ratings of the tested ICD may be applied to smaller ICD sizes with the same or higher material strength.



Annex I (normative)

Validation Test Requirements - Static Pressure Test

I.1 General This annex describes the test requirements for validating static pressure rating of field adjustable ICDs. The static pressure test requires the ICD element(s) are isolated from flow per the design. The test shall be conducted in the injection and production direction. Validation test shall meet requirements outlined below in Sections I.2. – I.4. I.2 Static Test I.2.1 General

The Static Pressure Test shall be conducted in the production direction from annulus between the test fixture ID and test sample OD into the base pipe and then the flow direction shall be reversed (from base pipe ID to the annulus between the test fixture ID and test sample OD).

I.2.2 Static Test Requirements The static test shall meet the following requirements: a) Testing shall be performed at maximum rated temperature b) The flow path through the ICD element shall be plugged c) Both production and injection tests are required.

I.2.3 Static Test Procedure Static test procedure shall meet the following requirements: a) Inspect device (measure critical dimensions as defined by supplier/manufacturer pre-test) b) Stabilize temperature and increase pressure to the rated pressure. Ensure that unpressurized side is vented to the atmosphere c) Hold the maximum achieved pressure for a duration of 15 minutes. Document total pressure drop over 15-minute hold period.



d) Acceptance Criteria –in accordance with the supplier/manufacturer's documented acceptance criteria e) Inspect device (measure critical dimensions as defined by supplier/manufacturer post-test) I.3 Static Pressure Test Report The following information shall be reported for the static pressure test: a) Direction of pressure test, production or injection b) Report the test pressure, inlet pressure versus time during static test, and total pressure drop during 15-minute hold period. Documentation to include test pressure chart. c) Report fluid temperatures measured during the test d) Critical dimensions prior to and upon completion of testing. e) Observations from inspection of device internally and externally (dimensional change, bulging or any form of structural damage shall be reported after device has been disassembled). I.4 Limitations of Scaling for Static Pressure Test The static pressure ratings of a tested ICD may be applied as the ratings for a smaller ICD size, with the same or higher material yield strength.



Bibliography

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