QTC Requirement as per API 6A-21st Edition

#1
Hello All,
Could you please provide the QTC size requirements to be followed for the below case :
Items to be manufactured : Blind Flange 20-3/4" 3K PSL 3 and Spacer Spool 20-3/4" 3K x 20-3/4" 3K PSL 3 (Max OD of equipment will be 33-3/4") For this we shall be using Forged Round Bar with 35" OD. So what should be the QTC requirement in case of Batch Furnace and Continuous Production Furnace.

Also as per Addendum 2 any one can elaborate the requirements listed below (Section 6.4.2.3.2)
EXCEPTION At the manufacturer’s option, a 1 25 mm (5 in. ) ER QTC shall be permitted for parts with an
ER greater than 1 25 mm (5 in. ) provided that:
— design documentation provides the stress distribution and demonstrates that the part meets the design
acceptance criteria of Section 5 where the mechanical properties are lower than the requirements
specified in 6.3 for the QTC;
— a qualification forging or a sacrificial part is used to validate the mechanical properties that satisfy the acceptance criteria of the analysis at a depth of 63 mm (2.5 in.) or T/4, whichever is less, at the critical section(s) as identified by the stress distribution in the design documentation;
— a qualification forging or a sacrificial part is used to document that the part meets the Charpy impact requirements of this specification at a depth of 63 mm (2.5 in.) or T/4 of the critical section(s) of the parts, whichever is less; and
— a qualification forging or a sacrificial part having the same heat-treat geometry, material grade, and heat-treat parameters as defined by the manufacturer is used to qualify all the production parts covered by the analysis.
Thanks in advance.

Regards,
Jay
 
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jmech

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#2
If it is heat treated in a continuous furnace, the requirement in 6.4.1 applies: "For material heat-treated in a continuous furnace, the QTC shall consist of a sacrificial production part or a prolongation removed from a production part. The sacrificial production part or prolongation QTC shall qualify only production parts having an identical size and shape." So if you are using heat-treated bar (and not rough-machining and then heat-treating), you have to use a length of the full-size bar as your QTC. If you are rough-machining and then heat-treating, you need to use a rough-machined part of each configuration as a QTC (i.e. test both a rough-machined spool and rough-machined blind flange).

For batch furnace, it is more complicated and the wording has also been revised in Addendum 2. The reason behind the requirement is that 4130 (and similar steels) don't harden to a great depth, so the center of a 35" OD 4130 bar is not accurately represented by a 5"ER QTC and is pretty much guaranteed to be below 75K strength, which could result in a failure if 75K strength is required near the center of the part (and the impact values also tend to be low, which could increase the risk of brittle failure). If any of the following apply, you can use a QTC with a 5" ER (i.e. 4" x 4" x 8" separately forged QTC or 5" trepan):
1. The material is 2 1/4 Cr1Mo or another material other than carbon or low-alloy steel.
2. The required design yield strength is less than 75K. [note that per Table 7, 60K material is allowable for 3000psi-rated bodies, flanged integral end connectors, and blind loose connectors, so this likely applies in your case]
3. The part weight during heat treat is less than 454kg (1000lb).
4. You use the complicated exception.
If none of the above apply, then you are required to use a QTC with at least a 10" ER (i.e. 8" x 8" x 10" separately forged QTC or 10" trepan). Note that you can always use a QTC with a larger ER than these minimums.

The exception is complicated and despite having been involved in drafting it, I'm not sure what it specifically requires when I read it now. The intent of it is that your design documentation needs to show that the part won't be over-stressed even if it has not been effectively through-hardened during heat treating, and that this can justify the use of a 5" ER QTC, but the specific wording of the requirements is unclear.
 
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