Title AS 4041-1998/Amdt 1-2001 Pressure piping Licensee Licensed to LUU MINH LUAN on 26 Feb 2002 Conditions of use This is a licensed electronic copy of a document where copyright is owned or managed by Standards Australia International Your licence is a single user licence and the document may not be stored, transferred or otherwise distributed on a network You may also make one paper copy of this document if required Web Check-up AS 4041/Amdt 1/2001-04-05 STANDARDS AUSTRALIA Amendment No to AS 4041 — 1998 Pressure piping REVISED TEXT The 1998 edition of AS 4041 is amended as follows; the amendment(s) should be inserted in the appropriate place Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited SUMMARY : This Amendment applies to Preface, Clauses 1.1, and 1.2, Tables 1.3 and 1.4, Clauses 1.7.12, 1.7.39 (new), 1.7.40 (new), 1.7.41 (new), 1.11.1, 1.17, 2.2.1, 2.6.10, 2.6.11 (new), 2.11.6.3, 3.6.2, 3.11.7, 3.12.2 and 3.12.3, Table 3.14.2, Clause 3.15.2.2, Table 3.15.2.2, Clauses 3.19.7.3 to 3.19.7.7, 3.19.8.2, Figure 3.19.8.2, Clauses 3.19.8.4, 3.19.9.2 to 3.19.9.5, Figure 3.19.9.2, Clauses 3.23.2.2, 3.23.2.3, 3.23.4, 3.24.3.5, 3.25.2.1, 3.25.5 (new), 6.5.1, 6.5.2 and 6.6 to 6.10 and Appendices A, D, G, J, L and U Published on April 2001 AMDT No APR 2001 Page Preface Delete last sentence and substitute the following: The traditional value of 1.5P applies for steam and water piping for steam boilers only AMDT No APR 2001 Page Clause 1.1 Add new second paragraph as follows: The Standard makes extensive use of AS/NZS 3992, AS 4037 and AS 4458 AMDT No APR 2001 Page Clause 1.2 AMDT No APR 2001 Page Table 1.3 Item (e), delete ‘AS 3920.1’ and substitute ‘AS 4343’ Delete Table 1.3 including Legend and Notes and substitute the following: ISBN 7337 3577 AMDT No APR 2001 TABLE 1.3 PIPING CLASSIFICATION (See Notes and 2) Limit or requirement Item No 1.1 Description and Clause reference Class piping Class piping 2A Steels designated for pressure purposes Any C, C-Mn austenitic and ferriticaustenitic stainless steel, 3½% Ni, 1Cr-½Mo Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Structural pipe and structural steel (Clause 2.2.4) 1.2 Seamless, hot finished (HFS), or cold finished (CPS) 1.3 Continuous welded (CW) (In America this is called BW) (Clause 2.6.10)(Weld Joint Factor Table 3.12.2) 2.1 C, C-Mn C, C-Mn, austenitic and ferritic-austenitic stainless steel Not permitted Any See Table 2.6.3.4 Non-ferrous metals (Clauses 2.6.3.5 to 2.6.3.8) 1.5 2P MATERIAL - (See Section 2) Ductile iron (Clauses 2.3.2, 2.6.3.4) 1.4 Class piping Any Any Not permitted Any with appropriate tests Not permitted Both permitted Not permitted Permitted to 260°C (see Clause 2.6.10) Permitted Permitted Electric resistance welded (ERW) Cold-drawn electric-resistancewelded (CEW) Permitted with weld joint factor listed in Table 3.12.2 Welds with filler metal added Permitted with weld joint factor listed in Table 3.12.2 DESIGN (See Section 3) Design temperature (excluding material limitations) °C: (a) Maximum (b) Minimum (MDMT see Clause 2.11) Determination (Clauses 3.3, 3.9.4, 3.9.5, 3.9.7, 3.9.8.3, 3.9.9) None 400°C 99°C ≥ MDMT ≥ MDMT 0°C 180°C ≥ MDMT + 20°C; and ≥ − 100°C 2.2 Design pressure (excluding material limitations) Pressure limits across classes depends upon the fluid type (see Table 1.4) Determination of design pressure (see Clauses 3.2, 3.9.1, 3.9.2, 3.9.3, 3.9.5, 3.9.6, 3.9.8.1) 2.3 Design strength at room temperature for C and C-Mn steels (See Note 5) (Clause 3.11) Lower of: 2.4 Re Lower of: or 1.5 Rm Re 2.35 1.5 Lower of: or 0.72 R e20 Rm Re 2.35 1.5 or Rm 2.35 Design factors Class design factor, (M) Weld joint factor, (e) (Clause 3.12) 2.5 Flexibility assessment (Clauses 3.4 to 3.8 and 3.27.2.2) Analysis (Clause 3.11 and 3.27) 2.6 Fatigue assessment (Clauses 3.4 to 3.8) Analysis (Clauses 3.11.7, 3.11.8) (See end of Table for Notes) 0.7 (see Item in this Table) 0.6 (See Clause 3.14.3(a)) 1.0 0.6 Required Required If required If required Required Required If required If required Not required (continued) TABLE 1.3 (continued) Limit or requirement Item No 2.7 Description and Clause reference Class piping Class piping 2A 2P Welded branch connection (Clauses 3.19, 3.20) 2.8 Minimum included angle (Clause 3.19.1) 60° (or 45° when agreed) 45° External non-integral reinforcement (Clause 3.19.8.1, 3.20.3) Not permitted without detailed analysis Permitted Partial penetration or fillet weld (Clause 3.20.3.2) Not permitted without detailed analysis Not permitted without detailed analysis Not permitted Socket weld (Clause 3.24.2.3) Sleeve weld (Clause 3.24.2.4) Bell and spigot (Clause 3.24.2.5) Threaded joints (Clause 3.24.3) Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Permitted Not permitted Permitted Permitted Partial penetration butt welds (Clause 3.24.2.6) Permitted below DN 65 Permitted Not permitted Permitted Not permitted Permitted Permitted T ≤495°C Permitted by agreement T >495°C Permitted Flanged (Clause 3.24.4) Flared, flareless and compression fittings (Clause 3.24.5) Permitted Permitted when used within manufacturer’s recommendations, DN 25 practical upper limit Caulked (Clause 3.24.6) Not permitted Soldered (Clause 3.24.7) Not permitted Permitted Permitted below 75°C Brazed (Clause 3.24.8) 2.9 Permitted below 75°C Not permitted Permitted up to 200°C Bend (Clause 3.15) Mitre (Clause 3.15.4) 2.10 Permitted cut ≤15° Permitted Cut and shut (Clause 3.15.5) Not permitted Permitted Wrinkle (Clause 3.15.3) Not permitted Permitted Ovality (Clause 3.15.2.3) ≤10% ≤12% Non-pressure attachment (Clause 3.23) Partial penetration or fillet weld 3.1 Permitted by agreement Pipe joint (See Note 6) (Clause 3.24) Butt weld (Clause 3.24.2.1) Class piping Not permitted without Permitted by agreement detailed analysis T >250°C T >250°C Permitted WELDING (Includes brazing, see AS 4458, AS/NZS 3992 and Note 3) Personnel requirements Option Option Welder certification (AS 1796) Option Required or Not required Not required or Required Welder qualification (Clause 6.3) Required Required Required Not required Welding supervisor (AS 1796) Not required Required Not required Not required 3.2 Welding procedure qualification (Clause 6.3) Required (except as provided for in Item 3.3) 3.3 Prequalified welding procedure Permitted but be subject to partial re-qualification e.g welder qualification 3.4 Permanent backing ring (Clauses 2.9.1, 3.20.3.4, 3.24.2.1) 3.5 Fit-up (AS 4458) 3.6 Criteria for weld quality 3.7 Dissimilar joints Not permitted Option Permitted Close limits Medium limits Wide limits Very high High Reduced Permitted (continued) TABLE 1.3 (continued) Limit or requirement Description and Clause reference Item No Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Class piping Class piping 2A Class piping 2P EXAMINATION AND TESTING (See Section 6) 4.1 Visual 4.2 Penetrant to 100% to 10% 100% Not required 4.3 Magnetic particle to 100% to 10% Not required 20 to 100% (see AS 4037) to 10% (see AS 4037) Not required 4.4 Radiographic or ultrasonic 4.5 Pressure tests: (Clause 6.6) Hydrostatic pressure test (Clause 6.7) 4.6 Pneumatic pressure test (Clause 6.8.1) 4.7 Initial service leak test (Clause 6.9) Permitted in conjunction with other tests by agreement (Clause 6.8.3) 4.8 Sensitive leak test (AS 4037) Required where Required where specified (Clause 6.8.3) specified (Clause 6.8.3) 4.9 Material test certificate Required Normally required 4.10 Marking (Clause 8.3.2) Required Normally required Not required Normally required Not normally required INSPECTION (Depends on hazard level) (Section 8) CONTROLS Alternatives to Item 4.5 include Items 4.6, 4.7 and 4.8) Normally required (for alternatives see Clause 6.8) Permitted by agreement Permitted in conjunction with other tests (Clause 6.8.2 and 6.8.3) Required Permitted Not required Not required 6.1 Pressure control tolerance +10% +15% 6.2 Design temperature control tolerance (see Note ) + Half the appropriate temperature interval in Table D2 for the material + Double Class and entry, i.e 100% of appropriate temperature interval COPPER PIPING Enquiry No 109/99 For copper piping joined by brazing, refer to Ruling PE/1 update No (February 1999) to AS 4041 — 1998, LEGEND: MDMT = material design minimum temperature (see Clause 1.7) Re = (see Clause 1.7) Rm = (see Clause 1.7) NOTES: This Table outlines the basic difference between the classes, and reference should be made to the text for full details Materials, design, welding, examination and testing and inspection are shown as ‘permitted’ on the basis that such items comply in all other respects with this Standard Welding is taken to include brazing and soldering unless otherwise specified For detailed requirements, see AS 4458 and AS/NZS 3992 Applies generally except as provided by Clauses 3.4, 3.9.5 and 3.10.3 for the creep range Examples of the Class upper temperature control tolerance for API 5L B pipe for the listed maximum temperatures are given below: Maximum temperature, °C 75 405 475 Class tolerance °C +25 +5 +5 See Appendix D design strength and Appendix I determination of design strength See Clause 2.6.2 for possible effect of joint in corrosion performance AMDT No APR 2001 Page 12 Table 1.4 Delete Table 1.4 including Footnote and Notes and substitute the following: TABLE 1.4 APPLICATION OF PIPING CLASSES FOR SERVICE CONDITIONS Service limits for following classes Service conditions (see AS 4343) Class Gas Lethal Liquid Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Design pressure for fluid type (see Note and Clause 3.2) Very harmful Gas Liquid Gas Harmful Liquid Class 2A No service limit Prohibited 10 MPa max No service limit No service limit 10 MPa max Nominal size (see Clause 1.7.21) Max Nominal wall thickness (see Clause 3.14.2) Min Prohibited MPa max No service limit No service limit No service limit No service limit Liquid Design temperature (see Clause 3.3) MPa max Prohibited No service limit Non-harmful Prohibited 10 MPa max Gas Class (see Note 1) Class 2P No service limit No service limit 180°C Maximum No service limit 400°C 99°C Minimum No service limit (see Item 2.1 Table 1.3) No service limit (see Item 2.1 Table 1.3) 0°C −100°C (see Item 2.1 of Table 1.3) All material No service limit No service limit No service limit No service limit except DN 150 max for Type fluid Carbon steel Low alloy steel High alloy steel Non-ferrous metal No service limit See Table 3.14.2 Carbon steel Low alloy steel High alloy steel Non-ferrous metal See Clause 3.14.2(a) See Clause 3.14.2(b) Ductile & cast iron NOTES: See Clause 3.24.2.6 for relaxation for low hazard service As an example, steam above 90°C is fluid No Prohibited No service limit AMDT No APR 2001 Page 14 Clause 1.7.12 AMDT No APR 2001 Page 17 Clause 1.7.39 (new) Delete ‘AS 3920.1’ and substitute ‘AS 4343’ Insert new definition as follows: 1.7.39 AMDT No APR 2001 Assemblies — a collection of individual components joined together Page 17 Clause 1.7.40 (new) Insert new definition as follows: 1.7.40 Gas — a substance which is completely gaseous at 20°C and 101.3 kPa absolute or at 50°C has a vapour pressure greater than 300 kPa Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited For this Standard, gas also includes: AMDT No APR 2001 (a) Compressed gas which is entirely gaseous at 20°C and 101.3 kPa absolute (b) Liquefied gas which is partially liquid at 20°C (c) Refrigerated liquefied gas which is partially liquid because of its low temperature (d) Gas in solution which is a compressed gas dissolved in a solvent (e) Any liquid when it is above its atmospheric pressure boiling point, e.g pressurized high-temperature water which flashes to steam on release of pressure (f) Fluidized solids in compressed air or other gas Page 17 Clause 1.7.41 (new) Insert new definition as follows: 1.7.41 Liquid — any substance below its atmospheric pressure boiling point, e.g water 0.15 and ≤ 0.60 K = 0.60 + 2/3 × (Dob/Doh) (c) For Dob/Doh > 0.60 K = 1.00 3.19.9.5 + A 3, Reinforcement area The area required for reinforcement (AR) shall be A1 + A Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited where A1 A2 A3 = area lying within the reinforcement zone resulting from any excess wall thickness available in the main pipe = dc(th − tmh) = area lying within the reinforcement zone resulting from excess wall thickness available in the branch pipe = 2H(tb − tmb) = area lying within the reinforcement zone resulting from excess thickness available in the extruded outlet lip = 2ro(To − tb − Gb) Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited AMDT No APR 2001 NOTES: Taper bore ID (if required) to match branch pipe 1:3 maximum taper Corrosion and other allowances are shown at bores FIGURE 3.19.9.2 REINFORCED EXTRUDED OUTLETS AMDT No APR 2001 Page 86 Clause 3.23.2.2 Delete Clause and substitute the following: 3.23.2.2 Elevated temperature piping A partial penetration weld to join an attachment for Class piping is not permitted without detailed analysis for design temperatures above 250°C A partial penetration weld to join an attachment may be permitted, with agreement by the parties concerned, for Class 2A piping for design temperatures above 250°C AMDT No APR 2001 Page 86 Clause 3.23.2.3 AMDT No APR 2001 Page 86 Clause 3.23.4 Second line, delete ‘Class 2’ and substitute ‘Class 2P’ Equation 3.23.4(2), delete equation and substitute: q = Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited R We ± L L2 Delete Note and substitute the following: NOTES: Other methods given in WRC 198 and BS 5500 are also acceptable Due consideration should be given to the level of stress already in the pipe due to other loads AMDT No APR 2001 Page 92 Table 3.24.3.5 AMDT No APR 2001 Page 107 Clause 3.25.2.1 Row 2, ‘T ≤ 260’, Column ‘Size range’, delete ‘DN36’ and substitute ‘DN32’ Delete ‘2.25.2.1’ and substitute ‘3.25.2.1’ AMDT No APR 2001 Page 108 Clause 3.25.5 (new) Add new Clause as follows: 3.25.5 Piping located below ground level 3.25.5.1 General Piping which is to be located below ground level shall also comply with this Clause (3.25.5) Such piping includes that installed in basements, cellars, mines, trenches or directly in the ground in order to provide services below ground, or to facilitate traffic on roads, or within buildings, or to protect piping from fire, sun or external interference In all cases, appropriate provision shall be made for — (a) prevention or collection, drainage and removal of significant leaks from piping, particularly lethal and very harmful fluids and gases heavier than air which may seriously deplete oxygen levels in working spaces or form combustible mixtures; and (b) removal of ground water or other material (e.g silt or debris in open or covered trenches) which would seriously affect the performance or safety of the piping Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited 3.25.5.2 Buried piping Piping buried directly in the ground should, if practicable, be avoided particularly where contents are at temperatures above 100°C or below 5°C The design shall consider, and when necessary, make provision for — (a) the soil and surface loads on the piping, particularly for low thickness/diameter ratio or vacuum piping; (b) suitable support against ground settlement or conditions which could damage the piping or its protection coating; (c) protection against external corrosion by suitable material selection, corrosion allowance, coatings, clean fill, drainage or cathodic protection (see Clause 7.4) (d) protection against stray current corrosion; (e) appropriate means for pressure testing, inspection, internal cleaning, isolation, drainage (slope) and detection of leaks which could cause significant losses or hazards to personnel, plant or environment; (f) possible rotation of piping which will encounter selective bottom erosion; and (g) suitable markers and location plans to avoid external damage when modifying or adding services and to facilitate inspection See AS 2885 for further guidance applicable to buried piping AMDT No APR 2001 AMDT No APR 2001 Page 129 Clause 6.5.1 Delete ‘for all liquids are’ and substitute ‘is’ Item (e), delete ‘2000 kPa’ and substitute ‘2 MPa’ Item (e), delete ‘400 kPa’, and substitute ‘0.4 MPa’ Page 129 Clause 6.5.2 Second line after ‘spot non-destructive examination’ add ‘(other than visual examination).’ Delete ‘Classes and 3’ and substitute ‘Classes and 2’ AMDT No APR 2001 Pages 130 to 132 Clauses 6.6 to 6.10 Delete Clauses 6.6 to 6.10 and substitute the following: 6.6 PRESSURE TESTS 6.6.1 General Standard Pressure tests shall be conducted in accordance with AS 4037 and this A pressure test on piping is used to achieve the following: (a) Detect leakage at components and joints (b) Assist in assessing the adequacy of the piping system design, materials and fabrication, e.g that there is sufficient wall thickness, and material strength (c) Partially relieve residual fabrication stresses and sometimes modify shape Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited 6.6.2 Types of pressure tests Piping shall pass one of the following tests as appropriate More tests may be specified by the manufacturer: (a) Hydrostatic test (see Clause 6.7) (b) Pneumatic test (see Clause 6.8.1) (c) Initial service leak test (see Clause 6.9 for method of application and Clauses 6.8.2 and 6.8.3 for circumstances in which they are used) (d) Increased non-destructive examination and leak test (see Clause 6.8.3) (e) Proof hydrostatic test (see Clause 6.8.4) Alternatives to a hydrostatic test should be considered where any of the following apply: (i) The mass of the water would damage the pipe or its supports (ii) The test fluid would damage linings or internal insulation (iii) Residual moisture would contaminate or cause failure of a process or cause corrosion or other unacceptable hazard (iv) Low metal temperature during the test would cause risk of brittle fracture (see AS/NZS 3788 and AS 4037 for information on MDMT) (v) New piping isolated from existing systems by a valve, in cases where water from the hydrostatic test, if leaked past the valve, would seriously contaminate the existing system An alternative to pneumatic testing should be considered when it would introduce an unacceptable hazard from the possible release of stored energy, particularly if low metal temperature during the test would lead to the risk of brittle fracture 6.7 HYDROSTATIC TEST 6.7.1 Application A hydrostatic test shall be made on all piping except when other tests are permitted in lieu by AS 4037 or Clause 6.8 6.7.2 Test pressure The hydrostatic test pressure shall be calculated in accordance with Appendix U The hydrostatic test pressure at any point in the piping system shall comply with the pressures specified Additionally, the minimum test pressure required for any service or material is specified in Paragraph U1 The test pressure at any point includes any static hydrostatic head due to the test fluid NOTE: For guidance on testing pressure vessels and piping together, see Paragraphs U5 and U7 for testing jacketed piping 6.7.3 Hold period The test pressure shall be held for the time specified in Table 6.7.3 The pressure in the piping shall then be dropped to 85–90% of the test pressure for visual examination AMDT No APR 2001 TABLE 6.7.3 HOLD PERIOD FOR HYDROSTATIC TEST Minimum hold period, minutes Nominal size Test pressure, kPa ≤DN 300 >DN 300 6.8 ≤700 >700 10 20 15 25 ALTERNATIVE TO HYDROSTATIC TEST 6.8.1 Alternative to hydrostatic test by use of pneumatic testing As an alternative to hydrostatic testing, and where agreed by the parties concerned, a pneumatic test may be used The test shall be conducted in accordance with AS 4037 The test pressure shall be 90 percent of that specified in Clause 6.7.2 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited 6.8.2 Alterative to hydrostatic test by use of initial service leak test At the owner’s option, piping is exempt from hydrostatic test when each of the following apply: (a) The pipe is certified by the pipe manufacturer to a listed Standard as leak tight by hydrostatic test or non-destructive examination method (b) The piping is made from material groups A1, A2, A3, A4, B, C, E, K, M or nonferrous (c) The design temperature is less than or equal to 180°C and greater than −30°C (d) The design pressure is less than MPa if the hoop stress ≤0.5f or MPa if the hoop stress >0.5f (e) The fluid is either — (i) fluid types and 4; (ii) steam; or (iii) caustic soda or sodium cyanide solutions as used in the mining industry In lieu of a hydrostatic test, each of the following shall be carried out: (i) 100% visual examination of all welds (see Table 8.4 and AS 4037 for form and working omissions) (ii) An initial service leak test in accordance with Clause 6.8A 6.8.3 Alternative to hydrostatic examination and leak test test by use of increased non-destructive 6.8.3.1 General Increased non-destructive examination and leak tests may be used in lieu of a hydrostatic test for butt welds, branch welds, flange welds and minor attachments as given in this Clause 6.8.3 Leak tests should be used on mechanical joints 6.8.3.2 Butt welds, branch welds and flange welds For Classes and piping, butt welds, branch welds, and flange welds, including tie-in and cut-in-welds, may be exempted from hydrostatic testing where these welds comply with each of the following: (a) The pipe is certified by the pipe manufacturer to a listed Standard as leak tight by hydrostatic test or a non-destructive examination method AMDT No APR 2001 (b) Butt welds are located in straight pipe and are not less than one pipe diameter from any branch connection or bend This requirement does not apply to butt weld fittings covered in Clause 2.2.1(f) Branch welds are located in straight pipe and are not less than one pipe diameter from any butt weld or bend (c) They comply with the ovality requirements of this Standard (d) They are subject to 100% visual examination (e) They comply with appropriate non-destructive examination Standards for — (i) 100% radiographic examination, plus either magnetic particle testing or penetrant examination; or (ii) 100% ultrasonic examination, plus either magnetic particle testing or penetrant examination (iii) Fillet welded pressure welds (e.g slip-on flange or socket weld fittings) either 100% magnetic particle testing or 100% penetrant examination in accordance with AS 4037 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited NOTE: When Items (i) and (ii) are not practical, refer to Clause 6.5.3 (f) Examinations (d) and (e) have been carried out after any postweld heat treatment has been carried out (g) They comply with the limits of surface imperfection for piping given in AS 4037 (h) They pass an initial service leak test (Clause 6.8A) or the sensitive leak test (AS 4037) For lethal fluids it shall be the sensitive leak test For Class piping, butt welds, branch welds and flange welds (including tie-in and cutin welds) are exempt from hydrostatic testing where the welds comply with the initial service leak test Any longitudinal welds shall be subject to 20% radiograhic or ultrasonic examination including either magnetic particle testing or penetrant examination 6.8.3.3 Mechanical joints Mechanical joints used within their pressure rating for the service conditions (e.g bolting and screwing) may be exempted from hydrostatic testing provided that the completed piping is subjected to — (a) 100% visual examination; (b) a sensitive leak test (see AS 4037) where the contents are fluid Types or 2; (c) an initial service leak test for piping other than Item (b); and (d) the components being joined have been hydrostatically tested at the time of manufacture or its equivalent 6.8.3.4 Minor attachments The welding or brazing of minor attachments, such as temperature and pressure tappings (DN 40 and below) and minor structural attachments, are exempt from hydrostatic provided — (a) they are subject to 100% visual examination; (b) the joint is subject to 100% magnetic particle or penetrant examination to AS 4037; and (c) failure will not be detrimental to the piping in service 6.8.4 Proof hydrostatic test Where the strength of components cannot readily be calculated, the design pressure may be determined in accordance with the proof hydrostatic test specified in AS 1210 AMDT No APR 2001 6.8A INITIAL SERVICE LEAK TEST The initial service leak test when used shall be made during or prior to the initial operation and after taking all necessary precautions The leak test shall be made with the service fluid at the operating condition of the piping by examining for leaks at each joint and connection not previously pressure tested in accordance with this Standard Where the pressurized fluid is gas or vapour, a preliminary leak test shall be made at one-quarter operating pressure but not more than 200 kPa When the process fluid is Type (very harmful), it is recommended that the preliminary leak test be carried out using an inert medium The pressure shall then be increased gradually in steps until the operating pressure is reached, holding at each step long enough to equalize piping strain and check for leaks Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited 6.9 TESTING PRESSURE-LIMITING DEVICES, RELIEF VALVES, PRESSURE REGULATORS, AND CONTROL EQUIPMENT Pressure-limiting devices, relief valves, pressure regulators, and control equipment shall be examined for the following: (a) Good mechanical condition (b) Adequate capacity, effectiveness, and reliability for operation of the intended service (c) Proper functioning at the correct pressure and temperature (d) Proper installation, and protection from foreign materials or condition that may prevent proper operation (e) Compliance with the relevant product Standard 6.10 REPORT After Class or piping has been completed and tested, the fabricator or manufacturer shall add to the manufacturer’s data report that the piping has been tested in accordance with this Standard AMDT No APR 2001 Page 140 Appendix A Insert new reference ‘4343 Pressure equipment — Hazard levels’ Delete reference AS 4037, substitute ‘AS 4037 Pressure equipment — Examination and testing’ AMDT No APR 2001 Page 154 Appendix D Insert new last paragraph as follows: Design strengths at intermediate temperatures may be obtained by linear interpolation AMDT No APR 2001 Pages 157–160 Table D2 Column 7, delete ‘fe (max.)*’ and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)’ Yield strength 200 MPa, first row: Column 14, insert ‘86’ Column 15, insert ‘79’ Column 16, insert ‘75’ AMDT No APR 2001 Page 161 Appendix D Second paragraph, delete ‘Re 250’ and substitute ‘Re 240’ AMDT No APR 2001 Page 161 Table D4 AMDT No APR 2001 Pages 162–163 Title, delete ‘Re 250’ and substitute ‘Re 240’ Table D5 Column 7, delete ‘fc (max.)* and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fc (max.)’ and substitute ‘f c, fh (max.)’ AMDT No APR 2001 Pages 164–168 Table D6 Column 10, delete ‘fc (max.)* and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fc (max.)’ and substitute ‘f c, fh (max.)’ AMDT No APR 2001 Pages 169–170 Table D7 Column 10, delete ‘fe (max.)* and substitute ‘fc, fh (max.)*’ Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)’ AMDT No APR 2001 Pages 171–173 Table D8 Column 11, delete ‘fe (max.)* and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)’ AMDT No APR 2001 Pages 174–176 Table D9 Column 11, delete ‘fc (max.)* and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fc (max.)’ and substitute ‘f c, fh (max.)’ AMDT No APR 2001 Page 177 Table D10 Column 10, delete ‘fe (max.)* and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)’ AMDT No APR 2001 Page 178 Table D11 Column 8, delete ‘fe (max.)* and substitute ‘fc, fh (max.)*’ Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)*’ AMDT No APR 2001 Page 184 Table G1 Delete the entries first columns under ‘Material’ for type ‘carbon steels’ and type ‘low alloy steels 1Cr-0.2Mo’ and substitute the following: Material Specification Grade CARBON STEELS AS/NZS 1110 AS B 148 AS 2465 4.6 Class 2 All All All AS/NZS 1110 5.8 All LOW ALLOY STEELS 1Cr-0.2Mo Temper Dia or size (mm) (Note 1) Type AS 2465 >24 AS/NZS 1110 8.8 All AS 2465 AS/NZS 1252 — ≤24 All ASTM A 320 L7, L7A, L7B, L7C ≤63 ASTM A 193 B7 ≤63 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited 63 Phmax hydrostatic test pressure is 7.63 MPa f < 3.5 AMDT No APR 2001 Example 2: Paragraph U2 Service = other than steam or water Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Pipe specification = API 5L X42 Class = or 2A Temperature = 50°C Design life = indefinite Size = 273.1 × 4.8 Max OD = 273.1 mm Min thickness = 4.8 mm Re = 289 MPa (from Table D2 or material specification) Rm = 413 MPa (from Table D2 or material specification) f   Rm   = 176 MPa depends on  2.35   P = 6.2 MPa Phmax = fh × 2t D = 9.15 MPa Phcalc = 0.83 Re f × P = 1.36 P NOTE: 0.83 × Re f < 3.5 = 8.45 MPa Since Phcalc < Phmax hydrostatic test pressure is 8.45 MPa For steam or water service: Phcalc = 1.5 P = 9.30 MPa Since Phcalc > Phmax hydrostatic test pressure is 9.15 MPa Example 3: Paragraph U2 Service = other than steam or water Pipe specification = ASTM A 106B Class =1 Temperature = 450°C Design life = 150 000 hours Size = 168.3 × 21.95 (XXS) Max OD = 169.9 mm Min thickness = 19.21 mm Re = 240 MPa (from Table D4 or material specification) Rm = 413 MPa (from Table D4 or material specification) f = 56 MPa P = 14.25 MPa AMDT No APR 2001 Phmax 2t D = fh × = 48.84 MPa = 0.83 Phcalc Re f × P = 3.56 P NOTE: 0.83 × Re f > 3.5 = 3.5 P = 49.88 MPa Since Phcalc > Phmax hydrostatic test pressure is 48.84 MPa For steam or water service: Phcalc = 1.5 P = 21.38 MPa Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Since Phcalc < Phmax hydrostatic test pressure is 21.38 MPa Example 4: Paragraph U3 Service = other than steam or water Pipe specification = API 5L X42 Class = 2P Temperature = 99°C Design life = indefinite Size = 273.1 × 4.8 (Class 2P) Max OD = 273.1 mm Min thickness = 4.8 mm Re = 289 MPa (from Table D2 or material specification) Rm = 413 MPa (from Table D2 or material specification) f = 208 MPa (0.72 × Re) P = 7.3 MPa Phmax = fh × 2t D = 9.10 MPa Phcalc = 1.25 P = 9.13 MPa NOTE: 1.25 × 0.72 = 0.9 Since Phcalc > Phmax hydrostatic test pressure is 9.14 MPa ... Clauses 1. 1, and 1. 2, Tables 1. 3 and 1. 4, Clauses 1. 7 .12 , 1. 7.39 (new), 1. 7.40 (new), 1. 7. 41 (new), 1. 11. 1, 1. 17, 2.2 .1, 2.6 .10 , 2.6 .11 (new), 2 .11 .6.3, 3.6.2, 3 .11 .7, 3 .12 .2 and 3 .12 .3, Table 3 .14 .2,... AS/ NZS 11 10 AS B 14 8 AS 2465 4.6 Class 2 All All All AS/ NZS 11 10 5.8 All LOW ALLOY STEELS 1Cr-0.2Mo Temper Dia or size (mm) (Note 1) Type AS 2465 >24 AS/ NZS 11 10 8.8 All AS 2465 AS/ NZS 12 52 —... APR 20 01 Page 64 Table 3 .15 .2.2 AMDT No APR 20 01 Page 71 Clause 3 .19 .7.3 AMDT No APR 20 01 Page 72 Clause 3 .19 .7.4 AMDT No APR 20 01 Page 72 Clause 3 .19 .7.5 AMDT No APR 20 01 Page 72 Clause 3 .19 .7.6