Title AS 4041-1998 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 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited AS 4041—1998 (Incorporating Amendment No 1) Australian Standard™ Pressure piping Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited This Australian Standard was prepared by Committee ME/1, Pressure Equipment It was approved on behalf of the Council of Standards Australia on 13 March 1998 and published on July 1998 The following interests are represented on Committee ME/1: A.C.T WorkCover Australasian Corrosion Association Australasian Institute of Engineering Inspection Australian Aluminium Council Australian Building Codes Board Australian Chamber of Commerce and Industry Australian Institute of Energy Australian Institute of Petroleum Australian Liquefied Petroleum Gas Association Boiler and Pressure Vessel Manufacturers Association of Australia Bureau of Steel Manufacturers of Australia Department for Administrative and Information Services, S.A Department of Labour, New Zealand Department of Training and Industrial Relations, Qld Electricity Corporation of New Zealand Electricity Supply Association of Australia Institute of Metals and Materials, Australasia Institution of Engineers, Australia Institution of Professional Engineers, New Zealand Metal Trades Industry Association of Australia National Association of Testing Authorities, Australia New Zealand Engineering Federation New Zealand Heavy Engineering Research Association New Zealand Institute of Welding New Zealand Petrochemical Users Group New Zealand Timber Industry Federation Victorian WorkCover Authority Welding Technology Institute of Australia WorkCover N.S.W Work Health Authority, N.T Workplace Standards Authority, Tas WorkSafe Western Australia Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems To maintain their currency, all Standards are periodically reviewed, and new editions are published Between editions, amendments may be issued Standards may also be withdrawn It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased Detailed information about Standards can be found by visiting the Standards Australia web site at www.standards.com.au and looking up the relevant Standard in the on-line catalogue Alternatively, the printed Catalogue provides information current at January each year, and the monthly magazine, The Australian Standard, has a full listing of revisions and amendments published each month We also welcome suggestions for the improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities Contact us via email at mail@standards.com.au, or write to the Chief Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW 2001 This Standard was issued in draft form for comment as DR 97114 AS 4041—1998 (Incorporating Amendment No 1) Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Australian Standard™ Pressure piping Originated in part as part of AS CB15 — 1959 Previous edition AS 4041 — 1992 Second edition 1998 Reissued incorporating Amendment No (April 2001) COPYRIGHT © Standards Australia International All rights are reserved No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher Published by Standards Australia International Ltd GPO Box 5420, Sydney, NSW 2001, Australia ISBN 7337 1934 AS 4041 — 1998 PREFACE This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee ME/1, Pressure Equipment, to supersede AS 4041 — 1992, Pressure piping This Standard incorporates Amendment No (April 2001) The changes arising from the Amendment are indicated in the text by a marginal bar and amendment number against the clause, note, table, figure, or part thereof affected Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited This Standard is the result of a consensus among representatives on the Joint Committee to produce it as an Australian Standard Consensus means general agreement by all interested parties Consensus includes an attempt to remove all objection and implies much more than the concept of a simple majority, but not necessarily unanimity It is consistent with this meaning that a member may be included in the Committee list and yet not be in full agreement with all clauses of this Standard This Standard makes use of current American and British Standards such as ANSI/ASME B31.3, Process piping, and BS 806, Specification for the design and construction of ferrous piping installations for and in connection with land boilers, as well as Australian Standards This has been done where practicable to align with international practices to provide flexibility in design and to enable current proven computer programs for either of the above Standards to be used to satisfy the design requirements of this Standard (see Clause 1.6) Comparison of this Standard with ANSI/ASME B31.1, Power piping and ANSI/ASME B31.3 shows that for the same pressure and application, piping to this Standard may be thinner than piping to the two American Standards at low to medium temperatures These two American Standards have been consulted as a major source of material, but preference has been given to BS 806 for ferrous materials Certain subject matter either unique to BS 806 or too complex to modify has been copied direct and the source acknowledged The extension of scope in this edition to embrace room-temperature-safe fluids brings into contrast three different traditions of steel pipe engineering which exist side by side in Australia All are successful in their particular scope of application The first tradition is that of power and process piping using steam and other hazardous fluids This tradition is noted for higher safety factors, thick pipe, and the greater use of pre- and post-weld heat treatment and sophisticated quality assurance Another tradition is the non-code tradition for room temperature safe fluids This is more influenced by the third tradition than by the first It uses thick or thin pipe and rarely applies postweld heat treatment and only uses limited quality assurance The third pipe tradition is that of petroleum and natural gas pipelines This tradition uses lower safety factors, thin pipe, rarely applies preheat and rarely uses postweld heat treatment but has adequate quality assurance A1 The extension of scope that joined tradition and (and possibly tradition in special cases) presented the Committee with a difficulty in preventing unnecessary increases in costs for the present non-code piping systems in Australian while maintaining safety The more conservative requirements of tradition 1, represented by BS 806 and ANSI/ASME B31.3 are not appropriate for applying these features to room-temperature safe fluids in modern low carbon equivalent pipe steels Hence a four-tier pipe classification system is introduced to ensure adequate safety, performance and economy of piping systems for the wider range of industrial applications from critical pipe used in power stations to low hazard piping found in small industrial plant In summary this edition will generally permit thinner steel pipe to be used for a given pressure than previously Also there is a change to some of its pressure testing equations for steel pipe  The traditional value of 1.5P applies for steam and water piping for steam boilers only AS 4041 — 1998 This Standard is arranged similarly to AS 1210, Pressure Vessels, including Supplement 1, Unfired Pressure Vessels — Advance design and construction (Supplement to AS 1210 — 1997), and its class system parallels that of these Standards Without inferring equality of the safety factor, the alignment of classes is approximately as follows: AS 4041 Class 2A 2P AS 1210 Class 1H 2H — Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Australian, American, and British material and component Standards which are used to a considerable extent in Australia have been listed This Standard now provides for a wider range of materials than previously covered A basis for specifying non-metallic pressure piping is given by reference to ANSI/ASME B31.3 but with provision for substitution of equivalent Australian Standards The Standard follows in principle other Standards forming part of AS/NZS 1200, Pressure equipment, in providing guidance for owners, designers, manufacturers, inspection bodies and users in the form of minimum engineering requirements for the safe design, fabrication, installation, testing, and commissioning of pressure piping based on world-wide advances and experience It also provides basic requirements and references for welding qualification, non-destructive testing, operation, maintenance and in-service inspection The principle objective of this Standard is clear uniform national requirements which will result in reasonably certain protection of the general public, persons installing and operating the piping, and of adjacent property and environment, which give economic piping, and which show where a margin for deterioration may be necessary to give adequate and safe service life Additional requirements may be necessary to prevent damage from unusual conditions, third parties and abnormal forces The Standard provides an authoritative source of important principles, data, and practical guidelines to be used by responsible and competent persons It is not practicable nor indeed desirable for the Standard to specify every aspect of piping design and fabrication It is neither an instruction manual nor a complete design or construction specification The Standard does not replace the need for appropriate experience, competent engineering judgement, and the application of fundamental engineering principles Users of this Standard are reminded that it has no intrinsic legal authority, but may acquire legal standing in one or more of the following circumstances: (a) Adoption by a government or other authority having jurisdiction (b) Adoption by a purchaser as the required standard of construction when placing a contract (c) Adoption where a manufacturer states that piping is in accordance with this Standard Acknowledgment is gratefully made to the American Society of Mechanical Engineers and the British Standards Institution for the considerable assistance provided by the above referenced national Standards Statements expressed in mandatory terms in notes to tables and figures are deemed to be requirements of this Standard The term ‘normative’ has been used in this Standard to define the application of the appendix to which it applies A ‘normative’ appendix is an integral part of a Standard AS 4041 — 1998 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited CONTENTS SECTION SCOPE AND GENERAL 1.1 SCOPE 1.2 RESPONSIBILITIES 1.3 CLASSIFICATION OF PIPING 1.4 CLASSIFICATION OF FLUIDS 1.5 SELECTION OF PIPING CLASS 1.6 ALTERNATIVE STANDARDS 1.7 DEFINITIONS 1.8 NOTATION 1.9 NON-SI UNITS 1.10 REFERENCED DOCUMENTS 1.11 REPORTS AND CERTIFICATES 1.12 NOT ALLOCATED 1.13 NOT ALLOCATED 1.14 NON-METALLIC PIPING 1.15 INTERPRETATION OF STANDARDS 1.16 NEW DESIGNS, MATERIALS AND FABRICATION 1.17 DIMENSIONAL AND MASS TOLERANCES 1.18 ALTERNATIVE DESIGN OF ACCESSORIES Page METHODS 8 12 14 14 17 18 18 18 18 18 18 18 18 19 19 SECTION MATERIALS AND COMPONENTS 2.1 GENERAL 2.2 QUALIFICATION OF MATERIALS AND COMPONENTS 2.3 LIMITATIONS ON MATERIALS AND COMPONENTS 2.4 PROPERTIES OF MATERIALS 2.5 IDENTIFICATION OF MATERIALS AND COMPONENTS 2.6 LIMITATIONS ON APPLICATION 2.7 MATERIALS AND COMPONENTS FOR CORROSIVE SERVICE 2.8 DISSIMILAR MATERIALS 2.9 BACKING RINGS AND FUSIBLE INSERTS 2.10 BRAZING MATERIALS 2.11 MATERIALS FOR LOW TEMPERATURE SERVICE 20 20 24 24 25 25 28 29 29 29 29 50 50 50 51 51 52 52 SECTION DESIGN 3.1 GENERAL 3.2 DESIGN PRESSURE 3.3 DESIGN TEMPERATURE 3.4 DESIGN LIFE 3.5 STATIC AND DYNAMIC LOADS AND FORCES 3.6 RISK ANALYSIS 3.7 THERMAL EFFECTS 3.8 EFFECTS OF MOVEMENT AT SUPPORTS, ANCHORS AND TERMINALS 3.9 DESIGN PRESSURE AND TEMPERATURE FOR PIPING ASSOCIATED WITH STEAM BOILERS 3.10 DESIGN CRITERIA 3.11 DESIGN STRENGTH 3.12 DESIGN FACTORS 3.13 ALLOWANCES 3.14 WALL THICKNESS OF STRAIGHT PIPE 52 52 56 57 60 61 62 AS 4041 — 1998 Page Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 PIPE BENDS REDUCERS BIFURCATIONS, SPECIAL FITTINGS AND CONNECTIONS EXPANSION FITTINGS AND FLEXIBLE HOSE ASSEMBLIES BRANCH CONNECTIONS AND OPENINGS WELDED BRANCH CONNECTIONS DESIGN OF CLOSURES FOR PIPE ENDS AND BRANCHES DESIGN OF OTHER PRESSURE-RETAINING COMPONENTS ATTACHMENTS PIPING JOINTS DESIGN REQUIREMENTS PERTAINING TO SPECIFIC PIPING NOT ALLOCATED FLEXIBILITY, STRESS ANALYSIS AND SUPPORT DESIGN PIPE SUPPORTS INFORMATION TO BE SUPPLIED INFORMATION TO BE SUPPLIED BY THE OWNER SECTION FABRICATION AND INSTALLATION 4.1 SCOPE 4.2 FABRICATION 4.3 INSTALLATION 4.4 THERMAL INSULATION 4.5 IDENTIFICATION 64 69 70 70 71 86 86 86 87 89 107 110 110 122 126 126 127 127 127 128 128 SECTION WELDING AND ALLIED JOINING PROCESSES 129 SECTION EXAMINATION AND TESTING 6.1 SCOPE 6.2 RESPONSIBILITY 6.3 QUALIFICATION OF WELDING PROCEDURES AND WELDERS 6.4 NON-DESTRUCTIVE EXAMINATION 6.5 ALTERNATIVES TO NON-DESTRUCTIVE TESTING 6.6 PRESSURE TESTS 6.7 HYDROSTATIC TEST 6.8 ALTERNATIVE TO HYDROSTATIC TEST 6.8A INITIAL SERVICE LEAK TEST 6.9 TESTING PRESSURE-LIMITING DEVICES, RELIEF VALVES, PRESSURE REGULATORS, AND CONTROL EQUIPMENT 6.10 REPORT SECTION PROTECTIVE SYSTEMS AND DEVICES 7.1 GENERAL 7.2 PRESSURE AND TEMPERATURE CONTROL SYSTEMS 7.3 PRESSURE RELIEF SYSTEMS 7.4 CORROSION PROTECTION 7.5 FIRE PROTECTION 7.6 EARTHING 7.7 PROTECTION FROM IMPACT 7.8 LIGHTNING PROTECTION 7.9 HUMAN CONTACT PROTECTION 7.10 NOISE CONTROL 7.11 ISOLATION PROTECTION (FOR INTERCONNECTED PIPING) 7.12 NOT ALLOCATED 130 130 130 130 131 132 132 133 134 135 135 136 136 136 137 137 137 137 138 138 138 138 138 AS 4041 — 1998 Page 7.13 PROTECTION AGAINST INTERFERENCE 138 SECTION QUALITY ASSURANCE AND INSPECTION 8.1 GENERAL 8.2 REVIEW OF DESIGN 8.3 MATERIAL AND COMPONENT INSPECTION 8.4 GENERAL INSPECTION OF FABRICATION 139 140 140 140 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited SECTION COMMISSIONING AND OPERATION 9.1 COMMISSIONING 141 9.2 OPERATION 141 APPENDICES A LIST OF REFERENCED DOCUMENTS B NOMINAL SIZES AND OUTSIDE DIAMETERS OF PIPE C NOT ALLOCATED D MATERIAL PROPERTIES, DESIGN PARAMETERS AND TENSILE STRENGTHS E LINEAR EXPANSION F YOUNG MODULUS G DESIGN TENSILE STRENGTH FOR FLANGE BOLTING H LODMAT ISOTHERMS I DETERMINATION OF DESIGN STRENGTH J DESIGN PRESSURE FOR SAFETY VALVE DISCHARGE PIPING K TYPICAL FORGED BRANCH FITTINGS L REINFORCEMENT OF A BRANCH AND AN OPENING M TYPICAL BRANCH WELDS N WELD DETAILS O FILLET-WELDED SOCKETS P SLEEVE JOINT Q NOTES ON PIPING STRESS ANALYSIS R METHOD OF ASSESSING FLEXIBILITY S EXAMPLE OF STRESS CALCULATION IN A SECTIONALIZED PIPING SYSTEM T STANDARD PIPING DESIGN U HYDROSTATIC TEST PRESSURE 142 153 156 157 182 184 186 190 191 195 199 200 210 218 226 227 228 231 253 263 267 INDEX 272 AS 4041 — 1998 STANDARDS AUSTRALIA Australian Standard Pressure piping S E C T I O N Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited A1 S C O P E A N D G E N E R A L 1.1 SCOPE This Standard sets out minimum requirements for the materials, design, fabrication, testing, inspection, reports and pre-commissioning of piping subject to internal pressure or external pressure or both Specific requirements are given for piping constructed of carbon, carbon-manganese, low alloy and high alloy steels, ductile and cast iron, copper, aluminium, nickel, titanium and alloys of these materials General requirements and reference to Standards for non-metallic piping are included  The Standard makes extensive use of AS/NZS 3992, AS 4037 and AS 4458 Piping complying with BS 806, ANSI/ASME B31.1, ANSI/ASME B31.3 and ANSI/ASME B31.5 are deemed to meet the requirements of this Standard (see Clause 1.6) This Standard applies specifically to pressure piping, i.e piping which may present a significant risk of injury to people, property or the environment owing to hazards arising from— (a) the effects of pressure, either as a result of internal pressure causing an explosion or projectile, or as a result of external pressure causing buckling and collapse; (b) release of contents which are lethal, toxic, harmful to human tissue (e.g hot, cold, corrosive) flammable, combustible or are otherwise hazardous; or (c) release of contents which directly or indirectly result in injury or damage e.g piping for pollutants, fire-fighting purposes or cooling purposes This Standard is intended to apply to the following piping except when varied by the relevant Standard: (i) Piping for land steam boilers, prime-movers, refrigerant and other industrial plant except where the piping forms an integral part of a boiler or pressure vessel and the requirements of AS 1210 or AS 1228 apply (ii) Hydraulic piping, water piping (including feed water piping), process piping, hot water piping exceeding 99°C and water piping forming part of a fire protection system (see AS 3689 and AS 4118) See also Items (A) to (G) of this Clause (iii) Piping within boundaries of chemical manufacturing or processing installations, petroleum refineries, petrochemical plant, gas process plant, refinery tank farms, terminals and bulk handling plants (iv) Oil fuel piping within the scope of AS 1375, AS 1692 and AS 1940 (v) Liquefied petroleum gas piping within the scope of AS 1596 (vi) Anhydrous ammonia within the scope of AS 2022 (vii) Low-temperature and refrigeration piping within the scope of AS 1677 (viii) Piping for road tank vehicles within the scope of AS 2809 (ix) Compressed air piping, the design pressure of which exceeds 70 kPa (internal) or 32 kPa (external) (x) Piping for low pressure gas systems complying with AG 601 (xi) Other piping covered by Standards Australia Standards which require compliance with this Standard www.standards.com.au © Standards Australia 265 TABLE T1 AS 4041—1998 (continued) FLANGE BOLTING Size Thickness Material DN ≤600 Spec TA Spec TB Bolts and nuts Table ‘D’ Bolts and nuts Table ‘E’ AS/NZS 1111 Gr 4.6 and AS/NZS 1112 Gr 150# Studs and nuts ASTM A193 B7/ ASTM A194 2H Nuts DN ≤600 Bolts and nuts AS/NZS 1111 Gr 4.6 and AS/NZS 1112 Gr BRANCHES/TEE FITTINGS Size Thickness Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Form/material Spec TA Spec TB DN ≤150 Heavy Heavy Screwed/AS 3672, AS 3673, Scrd BSP T/P DN ≤50 3000# 3000# Threadolet/ANSI B16.11/ ASTM A105 DN ≤50 3000# 3000# Sockolet/ANSI B16.11/ ASTM A105 DN ≤600 Std wt Std wt Weldolet/ANSI B16.11/ ASTM A105 DN ≤150 Sch40 Sch40 ANSI B16.9/ ASTM A234 WPB 200 ≤DN ≤400 Sch10 Sch20 ANSI B16.9/ ASTM A234 WPB 450 ≤ DN ≤600 Sch10 Std wt ANSI B16.9/ ASTM A234 WPB www.standards.com.au © Standards Australia Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited AS 4041—1998 266 TABLE T2 FILLET SIZES AND REINFORCING PAD SIZES FOR WELDED BRANCHES TO FIGURE M6 millimetres Main sizes Branch sizes ≤20 25 32 40 50 65 80 100 150 200 250 300 350 400 450 500 600 Fillet sizes and reinforcing pad sizes ≤20 25 32 40 50 65 80 100 150 200 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6−TA 6+6×14−TB 7 7 7 7 7 7 7 7−TA 7+6×18−TB 7 7 7 7 7 7 7−TA 7+6×21−TB 7 7 7 7 7 7 7−TA 7+6×27−TB 10 10 10 10 10 10 10 10 10 10 10 10−TA 10+6×31−TB 10 10 10 10 10 10 10 10 10 10 10−TA 10+6×38−TB 12 12 12 12 12 12 12 12 12 12−TA 11+6×50−TB 12 12 12 12 12 12 12 12 12−TA 13+6×76−TB 12 12 12 12 12 12 12 12−TA 12+6×103−TB 12 12 12 12 12 12 12−TA 12+6×130−TB 12−TA 12+6× 155−TB 12 12 12 12−TA 12+6×155−TB 12−TA 12+6×155−TB 12 12 12 12−TA 12+6×171−TB 12−TA 12+6×171−TB 12 12 12−TA 12+6×197−TB 12−TA 12+6×197−TB 12 12−TA 12+6×220−TB 12−TA 12+6×220−TB 12−TA 12+6×243−TB 12+6×248−TA 12+6×243−TB 250 300 350 400 450 500 600 12+6×300−TA 12+6×294−TB NOTE: Fillet sizes are the same for Spec TA and TB unless otherwise noted in the table © Standards Australia www.standards.com.au 267 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited A1                                                                  APPENDIX AS 4041 — 1998 U HYDROSTATIC TEST PRESSURE (Normative) U1 GENERAL U1.1 Scope This Appendix sets out requirements for the determination of hydrostatic test pressure for various materials and service conditions It also contains examples of the calculation of hydrostatic test pressure for various piping types See Paragraph U8 U1.2 Requirements for hydrostatic test pressure The hydrostatic test pressure for any service and system shall be the minimum of Items (a), (b) and (c), but shall not exceed Item (c) as follows: (a) Phcalc (see Paragraphs U2, U3, U4 and U6) (b) The maximum test pressure for any component or in-line equipment except pressure vessels For pressure vessels see Paragraph U5 (c) Phmax as calculated from Equation U1.2(1) 2t D Phmax = f h × U1.2(1) where Phmax = maximum pipe hydrostatic test pressure, in megapascals fh = 90% specified minimum yield strength at test temperature, in megapascals = 0.9 Re U1.2(2) D = measured (or maximum per purchase specification) outside diameter of pipe, in millimetres t = measured (or minimum per purchase specification) wall thickness, in millimetres Re = specified minimum yield strength at test temperature, in megapascals U2 FERRITIC, AUSTENITIC AND FERRITIC-AUSTENITIC STEEL PIPING, CLASSES 1, 2A AND U2.1 Steam and water piping associated with steam boilers The calculated hydrostatic test pressure shall be determined from the following equation: U2.1(1) Phcalc = 1.5 × P where Phcalc = calculated hydrostatic test pressure, in megapascals P = design pressure, in megapascals U2.2 For all other piping services The calculated hydrostatic test pressure shall be determined from the following equation: Phcalc = 0.83 × www.standards.com.au Re f × P U2.2(1) © Standards Australia AS 4041 — 1998 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited A1 268  where  Phcalc    P  Re    f   and                   = design pressure, in megapascals = specified minimum yield strength at test temperature, in megapascals = design strength at design temperature, in megapascals Maximum value of 0.83 × Re f U2.2(2) 3.5 NOTE: Equation U2.1(1) is based on BS 806 Some values of R e and f are listed in Appendix D U3 FERRITIC STEEL PIPING CLASS 2P for piping to Class 2P is Phcalc = 1.25 × P The calculated hydrostatic test pressure U3(1) where Phcalc = calculated hydrostatic test pressure, in megapascals P = design pressure, in megapascals U4 NON-FERROUS METALS The calculated hydrostatic test pressure shall be determined from the following equation: Phcalc                                     = calculated hydrostatic test pressure, in megapascals except that ft 1.5P ft f f U4(1) shall not exceed 6.5, where ft = design strength at test temperature, in megapascals f = design strength at design temperature, in megapascals U5 PIPING AND PRESSURE VESSELS TESTED TOGETHER For piping attached to a pressure vessel where the test pressure is not more than the test pressure for the vessel, the piping may be tested with the vessel at the test pressure of the piping Where the test pressure of the piping is greater than the vessel test pressure and it is not practicable to isolate the piping from the vessel, the piping and the vessel may be tested together at the test pressure of the vessel provided that — (a) the owner agrees; and (b) the test pressure of the vessel is not less than 77% of the piping calculated test pressure adjusted for temperature (see Paragraphs U2, U3 and U4) U6 PIPING SUBJECT TO EXTERNAL PRESSURE Piping subject to external pressure in service shall be tested to an internal hydrostatic test pressure of the maximum of Items (a) and (b) but shall not be less than Item (b) as follows: (a) Phcalc = 1.5 Pdiff U6(1) where Pdiff = differential design pressure, in megapascals (b) 100 kPa © Standards Australia www.standards.com.au 269 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited A1                                   AS 4041 — 1998 U7 JACKETED PIPING The test pressure for internal piping of jacketed piping shall be determined according to the internal or external design pressure, whichever is critical using Paragraph U1 The test shall, if necessary, be performed before completion of the jacket so that any joints of the internal piping can be visually inspected The test pressure for the jacket shall be determined in accordance with Paragraph U1 and according to the design pressure of the jacket, unless otherwise limited in the engineering design U8 EXAMPLES Example 1: Paragraph U2 Service = other than steam or water Pipe specification = API 5L B Class = or 2A Temperature = 50°C Design life = indefinite Size = 273 × 4.8 Max OD = 273 mm Min thickness = 4.8 mm Re = 241 MPa (from Table D4 or material specification) Rm = 413 MPa (from Table D4 or material specification) f P   Re   = 160 MPa depends on  1.5   = 5.62 MPa     Phmax = fh ×   Phcalc     2t D = 7.63 MPa = 0.83    Re f × P = 1.25 P NOTE: 0.83 × Re f Phmax hydrostatic test pressure is 7.63 MPa     Example 2: Paragraph U2   Service = other than steam or water   Pipe specification = API 5L X42 www.standards.com.au © Standards Australia AS 4041 — 1998 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited A1 270                 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 ×   Phcalc 2t D = 9.15 MPa = 0.83 Re f × P R = 1.36 P  NOTE: 0.83 × e < 3.5 f   = 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 A106B   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  2t Phmax  = fh × D © Standards Australia www.standards.com.au 271 A1   Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited   AS 4041 — 1998 = 48.84 MPa Phcalc = 0.83 Re f × P R  NOTE: 0.83 × e >3.5 = 3.56 P f   = 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  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  2t Phmax  = fh × D   = 9.10 MPa  Phcalc  = 1.25 P   = 9.13 MPa   NOTE: 1.25 × 0.72 = 0.9   Since Phcalc > P hmax hydrostatic test pressure is 9.14 MPa www.standards.com.au © Standards Australia AS 4041 — 1998 272 INDEX Clause Accessory 1.7.1, 1.18 Clause Brazed piping joints 3.24.8 3.24.8 Agreement 1.7.2 Brazing materials Alarm 9.1.3 Butt welds 3.24.2.1 Allowances corrosion erosion grooving machining manufacturing tolerance mechanical strength threading 3.13.3 3.13.3 3.13.4 3.13.4 3.13.2 3.13.5 3.13.4 Cast, pipe 3.14.5 Casting quality factor 3.12.4 Caulked piping joints 3.24.6 Certificates 1.11 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Class design factor Alternative Standards 1.6 Alternative tests to hydrostatic and pneumatic tests 6.8 Attachments intensity of radial loading thickness welding 3.23.4 3.23.3 3.23.2 Classification of fluids of piping Cleaning 3.11.4 4.3.3 1.7.3, 3.27.2.3, 4.3.5, Appendix Q Commissioning Bell and spigot socket Appendix O Component Bifurcations 3.17 Components corrosive service inspection Blowdown systems 3.9.6, 3.9.7 vessel 3.9.6.3 Boiler feed water piping 3.9.5 Bolting, design tensile strength Appendix G 1.4 1.3 Closures for pipe ends and branches 3.21 Cold spring Bearing stresses 3.12.3 9.1 1.7.4 2.7 8.3 identification (see Identification of materials and components) limitations (see Limitations on materials and components) qualification of (see Qualification of materials and components) Branch fittings, forged Appendix K Branch connections and openings application extruded outlets location material for reinforcement reinforcement required reinforcement not required shape size types welded welds © Standards Australia 3.19.1 3.19.9 3.19.5 3.19.6 3.19.6, Appendix L 3.19.8 3.19.7 3.19.3 3.19.4 3.19.2 3.20 Appendix M Compression piping joints 3.24.5 Compressive stress 3.11.2 Continuous pipe bends 3.15.2 Control equipment 6.9, 9.1.4 Control piping 3.25.3 Corrosion allowance 3.13.3 definition 1.7.5 protection 7.4 www.standards.com.au 273 AS 4041 — 1998 Clause Clause Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Corrosive service component for materials for 2.7 2.7 Crease pipe bends 3.15.3 Creep-fatigue interaction 3.11.8 Cut-and-shut, pipe bends 3.15.5 Definitions accessory agreed agreement cold spring component corrosion design designer design strength extruded outlet fabrication fitting fluid hydrostatic test inspection inspection body installation may mitre bend mitre joint nominal pressure nominal size owner parties concerned pipe pipe support pressure piping pressure, design proprietory components service conditions shall should socket welded joint strength temperature, design temperature, material design minimum temperature, minimum operating temperature, maximum operating testing thickness, actual thickness, design pressure thickness, nominal thickness, required verification weld joint factor 1.7.1 1.7.2 1.7.2 1.7.3 1.7.4 1.7.5 1.7.6 1.7.7 1.7.8 1.7.9 1.7.10 1.7.11 1.7.12 1.7.13 1.7.14 1.7.15 1.7.16 1.7.17 1.7.18 1.7.19 1.7.20 1.7.21 1.7.22 1.7.23 1.7.24 1.7.25 1.7.26 1.7.27 1.7.28 1.7.29 1.7.30 1.7.31 1.7.32 1.7.33 1.7.34.1 1.7.34.2 1.7.34.4 1.7.34.3 1.7.35 1.7.36.1 1.7.36.2 1.7.36.4 1.7.36.3 1.7.37 1.7.38 approval 8.2.2 criteria normal operating conditions 3.10.2 pressure 3.10.1 temperature 3.10.1 variations in normal operating conditions 3.10.3 definition 1.7.6 factors casting quality 3.12.4 class 3.12.3 weld joint 3.12.2 life 3.4 other methods 3.1.3 other pressure-retaining components 3.22 parameters Appendix D pressure, design 3.2 blowdown systems 3.9.6, 3.9.7 boiler feed water piping 3.9.5 condition for safety valve discharge piping 3.9.8 drain systems 3.9.6, 3.9.7 main steam piping 3.9.1, 3.9.9 reduced pressure systems 3.9.3 reheat piping 3.9.2 specific piping 3.25 steam piping 3.9.4 strength bearing stress 3.11.4 compressive stress 3.11.2 creep-fatigue interaction 3.11.8 definition 1.7.8, 1.7.33 determination Appendix I longitudinal stress, occasional loads 3.11.6 longitudinal stress, sustained 3.11.5, 3.11.6 pressure retaining components 3.11.1 shear stress 3.11.3 stress range 3.11.7 temperature externally insulated piping 3.3.3 heated piping 3.3.5 internally insulated piping 3.3.4 uninsulated piping 3.3.2 Designer Drain systems 3.9.6, 3.9.7 vessels for boilers 3.25.2 for high pressure steam piping 3.25.2 Drainage systems of steam piping www.standards.com.au 3.25.1 Dynamic loads and forces 3.5 Earthing 7.6 Erosion allowance Design against failure 3.1.2 alternative 1.18 1.7.7 3.13.3 Examination and testing for qualification 6.3 © Standards Australia AS 4041 — 1998 274 Clause Clause non-destructive responsibility 6.4 6.2 Expansion fittings 3.18, 3.27.2.1 linear Appendix D External pressure Extruded outlet 3.14.4 1.7.9 3.19.9 Fabrication definition 1.7.10 inspection 8.4 Information to be supplied 3.29 In-process examination 6.5.3 Initial service leak test 6.8.2 Inspection 1.7.14 Inspection body 1.7.15 Inspection Section Inspectors Installation 8.1.3 1.7.16, 4.3 Fillet-welded sockets Appendix O Instrument piping Fire protection 3.25.3 7.5 Interference, protection from 7.13 Fitting 1.7.11 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Internal pressure 3.14.3 Flange bolting, design tensile strength Appendix G Isolation protection 7.11 Flanged joints 3.24.4 Flared piping joints 3.24.5 Joint, sleeve Flareless piping joints 3.24.5 Joints (see Piping joints) Flexibility analysis 3.27, Q1 method of assessing Appendix R Appendix P Lightning protection 7.8 Limitation on materials and components 2.3 Flexible hose assemblies 3.18 Identification, materials and components 2.5 Impact, protection from 7.7 Limits on application ambient and high temperature service aluminium and aluminium alloys carbon and low and medium alloy steels copper and copper alloys ductile iron high alloy steels iron castings nickel and nickel alloys steels titanium and titanium alloys AS 1074 pipe bolting for flanges deterioration fittings for forming and bending flange gaskets valves bodies bypasses drain spindles trim 2.11.6 Linear expansion Fluid definition 1.7.12 Forces 3.5 Forged branch fittings Appendix K Grooving allowance 3.13.4 Gusseted pipe bends 3.15.5 Human contact protection Hydrostatic test 7.9 1.7.13, 6.7 Hydrostatic test calculation examples Appendix U Impact tests © Standards Australia 2.6.3.6 2.6.3.2 2.6.3.5 2.6.3.4 2.6.3.3 2.6.3.4 2.6.3.7 2.6.3.2 2.6.3.8 2.6.10 2.6.7 2.6.2 2.6.4 2.6.9 2.6.6 2.6.8 2.6.5.2 2.6.5.6 2.6.5.3 2.6.5.5 2.6.5.4 Appendix E www.standards.com.au 275 AS 4041 — 1998 Clause Clause Load-supporting structure 3.28.5 Movement at supports, anchors and terminals 3.8 Loadmat isotherms Appendix H Loads Longitudinal stress, occasional loads 3.5 3.11.6 Longitudinal stress, sustained 3.11.5, 3.11.6 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Low temperature (see Materials for low temperature service) New designs 1.16 fabrication methods 1.16 materials 1.16 Nominal sizes of pipe Appendix B Non-metallic piping 1.14 Notation Machining allowance 3.13.4 Manufacturing tolerance 3.13.2 Operation Manufactuer’s data report 1.11.1 Outside diameter of pipe Opening, reinforcement 1.8 Appendix L 9.2 Appendix B Material properties Appendix D reference thickness 2.11.5 tensile strength Appendix D Owner 1.7.22 Parties concerned 1.7.23 Materials brazing corrosive service dissimilar identification limitations (see Limitations components) low temperature service alloy steels bolting cast iron groups A1 and A2 non-ferrous metals non-metallic materials pipes, thin tubes, thin Pipe 1.7.24 properties mechanical Poisson ratio thermal expansion weldability Young Modulus qualification of (see components) on 3.24.8 2.7 2.8 4.5 materials and Qualification of 2.11.2.3 2.11.2.6 2.11.2.5 2.11.2.2 2.11.2.3 2.11.2.7 2.11.2.4 2.11.2.4 2.4.2 2.4.5 2.4.3 2.4.6 2.4.4 materials and May 1.7.17 Mechanical strength, allowance 3.13.5 Minimum operating temperature 2.11.3 Mitre bend 1.7.18, 3.15.4 Mitre joint www.standards.com.au 1.7.19 Pipe bends continuous wrinkle crease mitre cut-and-shut gusseted 3.15.2 3.15.3 3.15.3 3.15.4 3.15.5 3.15.5 Pipe support 1.7.25, 3.28, 9.1.6 Piping class fast track selection 1.5.3 mixing classes 1.5.2 selection 1.5 Piping control instrument sampling joints brazed caulked compression expansion flanged flared flareless propriety soldered special threaded welded protection 1.7.26.1 1.7.26.2 1.7.26.3 3.24.8 3.24.6 3.24.5 3.24.9 3.24.4 3.24.5 3.24.5 3.24.10 3.24.7 3.24.10 3.24.3 3.24.2 4.3.6 © Standards Australia AS 4041 — 1998 276 Clause Clause Plastic strains Pneumatic testing Q4 6.8.1 Report 1.11, 6.10 Required material design minimum temperature 2.11.4 7.2 Responsibilities 1.2 Pressure design (see Design pressure) regulator 6.9, 9.1.4 Risk analysis 3.6 Pressure control systems Safety valve discharge piping 3.9.8 Pressure-limiting devices 6.9, 9.1.4 Pressure relief systems Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Pressure relief valve discharge piping 7.3 3.25.4 Safety valve discharge piping, design pressure Appendix J Sampling piping 3.25.3 Pressure tests 6.6 Scope Pressure tests, alternatives 6.8 Service conditions 1.7.29 Proof hydrostatic test 6.8.4 Shall 1.7.30 Proprietary components 1.7.28 piping joints 3.24.10 Shear stresses 3.11.3 Should 1.7.31 Protection 4.3.2 Shut down systems 9.1.3 Size of pipes basis for determining 3.1.1 Qualification of materials and components alternative product form complying with nominated Standards complying with Standards not nominated for which there are no Standards not fully identified reclaimed components specially tested structural 2.2.3 2.2.1 2.2.2 2.2.3 2.2.7 2.2.6 2.2.10 2.2.4 Sleeve joint Appendix P Socket fillet-welded Appendix O welded joint 1.7.32 Soldered piping joints Special piping joints Quality assurance 1.1 3.24.7 3.24.10 8.8 Specified minimum tensile strength 1.7.33.1 Radiography, exemption Reactions 6.5.1 3.27.6, Q3 Specified minimum yield strength 1.7.33.2 Standard piping design Appendix T Reduced pressure systems 3.9.1.3 Static loads and forces Reducers 3.16 Steam piping design temperature 3.9.4 drainage 3.25.1 main 3.9.1 Referenced documents 1.10, Appendix A Reheat piping 3.9.2 Strength Reinforcement branch connection and openings 3.19.8 of a branch Appendix L of an opening Appendix L Relief valves 6.9, 9.1.4 © Standards Australia 3.5 1.7.33 Stress analysis 3.27, 3.27.3, Appendix Q Stress calculation in a piping system Appendix S Stresses in a piping system Q3 www.standards.com.au 277 AS 4041 — 1998 Clause Clause Support attachments Temperature control systems design, definition design (see Design temperature) material design minimum maximum operating minimum operating 3.28.4 7.2 1.7.34.1 1.7.34.2 1.7.34.3 1.7.34.4 Tensile strengths of materials Appendix D Testing 1.7.35 Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Thermal effects insulation Thickness actual design pressure nominal required 3.7 4.4 1.7.36.1 1.7.36.2 1.7.36.4 1.7.36.3 Wall thickness of straight pipe cast pipe external pressure internal pressure nominal required 3.14.5 3.14.4 3.14.3 3.14.2 3.14.1 Weld details Appendix N joint factor 3.12.2 joint factor, definition 1.7.38 Welded branch connections 3.20 Welded piping joints bell and spigot butt fillet welds partial penetration sleeve socket welded stress corrosion cracking 3.24.2.5 3.24.2.1 3.24.2.2 3.24.2.6 3.24.2.4 3.24.2.3 3.24.2.7 Welding backing rings permanent 2.9.4 temporary 2.9.5 fusible inserts 2.9.3 Threaded allowance 3.13.4 protection 4.3.6 joints 3.24.3 Welds, branch Appendix M Tolerances, dimension and mass 1.17 Wrinkle pipe bends Verification Young modulus www.standards.com.au 1.7.37 3.15.3 Appendix F © Standards Australia Standards Australia Standards Australia is an independent company, limited by guarantee, which prepares and publishes most of the voluntary technical and commercial standards used in Australia These standards are developed through an open process of consultation and consensus, in which all interested parties are invited to participate Through a Memorandum of Understanding with the Commonwealth government, Licensed to LUU MINH LUAN on 26 Feb 2002 Single user licence only Storage, distribution or use on network prohibited Standards Australia is recognized as Australia’s peak national standards body Australian Standards Australian Standards are prepared by committees of experts from industry, governments, consumers and other relevant sectors The requirements or recommendations contained in 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A A A A A 53 106 135 178 179 199 209 210 213 ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM A A A A A A A A A A A A A A A A A A A A A... 369 376 423 430 452 524 587 672 688 691 789 790 ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM B B B B B B B B B B B B B B B B B B B B B... 3672 AS 3673 AS 3688 A1 ASTM ASTM ASTM ASTM A B B B Forgings AS 1448 (f) 479 160 164 166 ASTM ASTM ASTM ASTM Castings AS AS AS AS (e) AS 4041 — 1998 ASTM A 182 ASTM A 234 ASTM A 403 BS BS BS BS