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This presentation is about the design theory used by the Australian Piping Code AS 4041-1997. With a focus on facility piping and carbon steel piping which is the most commonly used pipe material in process plants. APIA publications have been referred for this presentation.
Qualifications & Approvals Design, Fabrication & Technical Specification Testing & Examination
The majority of the described aspects have been displayed as lists for better presentation
APPLICATION OF AS 4041
AS 4041 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. Along with specific requirements based on pipe material.
AS 4041 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. AS 4041 classifies piping into classes 1, 2A, 2B and 3 (as per service conditions)
APPLICATION OF AS 4041
Refer section 1 & table 1.4. Class 1 applies with no service limit. Class 2A applies up to 10 Mpag service pressure for any gas and any flammable liquid. Class 2A also applies with no service limit for combustible liquid.
Max. Temp.- no limit for Class1 & 400C for Class 2A. Min. Temp.- no limit (but >= MDMT) For Flange Ratings, refer to clause 3.24.4.2 & 3.2. Flange rating as per nominated standard (derating from T>38C for ASME B16.5 Group 1.1 or 121C for MSS SP-44). For control & sampling instrumentation, refer to clauses 3.25.3 Emphasis is placed on Design Approval rather than Designers Quals. AS 4041 requires design verification for Hazard Levels A & B
Welding Qualifications
For welding qualifications refer to AS 4458 & AS 3992 (and AS 4037 for NDE). For welder & welding procedure qualification refer to section 5.
Welding supervisor is required for option 2 but not option 1. Welder certification is required for option 1 but not for option 2. Welder qualification is required for both options Pre- qualified welding procedure is permitted subject to partial requalification Fit- up as per AS 4458 and within close limits for class 1 and medium limits for class 2A Weld Quality Criteria is very high for class 1 and high for class 2A Permanent backing ring is permitted for class 2A
Qualification of Materials
Refer to clause 2.2 for qualified materials & clause for 2.2.1 for materials allowed without qualifications
For qualified pipe materials refer to- API 5L and ASTM A53, A106 & A524. Additionally a few AS, ASTM & BS pipes and pipes fabricated to AS 1210. For Class 1piping refer to welded joint efficiency. For qualified fitting materials refer to- ASME B16.9, B16.11, B16.25, B16.28, A105, A234 & A420. BS 1640.3, 1640.4 & 3799. MSS SP-75. Plus other AS & BS standards.
For qualified flange materials refer to- ASME B16.5 & B16.21. BS 1560.3.1 & 1560.3.2. BS 3293. MSS SP 6 & 44. Also, AS 2129 & AS 4087.
Qualification of Materials
For qualified gasket materials refer to- ASME B16.20 & ASME B16.21
For qualified bolting materials refer to- AS 2528, 1111 & 1112. ASTM A193, A194, A307, A320, A325, A354 & A449. Also, BS 4882.
For materials for which no standards exist, refer to clause 2.2.3. Such materials are only permitted for components other than pipes subject to qualification.
Qualification of Materials
For reclaimed pipes, accessories, valves and fittings, refer to clause 2.2.6. They are permitted subject to qualification.
For material and components not fully identified, refer to clause 2.2.7. They are permitted subject to chemical composition and mechanical properties as specified in a nominated standard. For component identification, refer to clause 2.5. Also, refer to AS 4458. For unidentified materials and components, refer to clause 2.2.8. They are not permitted for containing pressurized fluid flows. For reclaimed corroded, deteriorated or untested components, refer to clause 2.2.9. They are not permitted for containing pressurized fluid flows.
ALLOWABLE STRESSES
As per Thin Wall Pipe Theory, Hoop Stress SH = PD / 2t, where P is internal pressure, D is Nominal Diameter and t is thickness
Refer to clause 3.27. AS 4041 applies design margins relative to material permanent deformation (SY or yield stress) and material failure (SU or ultimate stress)- SA = the lessor of SY / 1.5 and SU / 2.35. The allowable stress equations are similar to ASME B31.3 and the flexibility and stress intensification factors can be sourced from clause 3.27 & table 3.27.5. For earthquake loading refer to AS 1170.4. For wind loading refer to AS 1170.2. The following design details are same as for ASME B31.3 except for listed allowable stress value- sustained load stress limit, occasional load stress (including earthquake & wind), expansion stress range limit, expansion stress range limit at temperature close to ambient & low number of temperature cycles and expansion stress- range reduction factor f.
Sustained Load Stress is the sum of longitudinal pipe stresses due to pipe weight, pipe contents, internal pressure and external loads. A stress limit of M*F*SY is specified for normal operation conditions and another limit of 1.33*M*F*SY is specified for inclusion of occasional loads such as wind or earthquake. Expansion Stress Range is a stress value equivalent to the difference in pipe displacement or flexibility stress within the design temperature extremes from maximum to minimum. The displacement stress is defined as the combination of bending and torsion stresses using equation SE = (Sb2 + 4St2)
For piping systems that operate above the installation temperature, the expansion stress range value is calculated as the difference between the value for SE due to all design loads including pipe weight, pipe contents, internal pressure, external loads, displacement & differential temperature and the value for SE due to sustained loads. Otherwise use the method described above.
Group A1 (low strength) - 0C for t<=12 mm, 20C for 12< t<=25 mm & 40C for 25<t<=50 Group A2 (medium strength) - 20C for t<=12 mm, 50C for 12< t<=25 mm & 80C for 25<t<=50 Group A3 (high strength >=X52) - 0C for t<=12 mm, 25C for 12< t<=25 mm & 50C for 25<t<=50
Post- Welding Heat Treatment (refer to table 14.1 of AS 4458) Required for t>=32 mm at 580C to 620C for steel groups A1, A2 & A3. The duration varies between groups
Design of Bends
Continuous Curved Bends
As per clause 3.15.2.2 use same wall thickness as for straight pipe except where the pipe stress is time dependent then t is calculated using equations 3.15.4.2 or 3.15.4.3 (1) & (2) for all bend angles Ovality is referred to in clause 3.15.2.3 and usually set as 10% Hot or induction bends are allowed as per clause 3.15.2.1. Metallurgical properties variation not noted. For elbow wall thickness see clause 3.15.2.1. Temperature-pressure rating as per elbow material specification of manufacturer. Bends cut from forged bend or elbow are not mentioned Cold bends are permitted as per clause 3.15.2.1.
Refer to clause 3.15.4 permitted for any bend angle provided that (a) cut angle <= 15 for Class 1, and (b) pipe diameter to thickness ratio between 20 to 200 calculate t using equations 3.15.4.2 or 3.15.4.3 (1) & (2) for all bend angles
Design of Branches
Branch Connections (as per clause 3.19 & table 3.20)
The minimum included angle for Class 1 is 60 (or 45 subject to approval). For Class 2 it is 45.
Right angle branch followed by a bend is preferred where included angle < 90
Either run pipe D/t < 100 & Db/Dr <=1, or run pipe D/t > 100 & Db/Dr <=0.5 or design to be qualified For branch reinforcement & assessment method refer to clause 3.19.8 (ASME B31.3 method of reinforcement replacement equal to pipe area removed in branch opening) or alternatively as per BS 806 method described in Appendix L The axis of branch & run intersect
Design of Branches
Branch Connections (as per clause 3.19 & table 3.20)
To reinforce branch (a) use of thicker pipe, branch or both, (b) addition of reinforcement pad & (c) other approved, proven and qualified means For run pipe include weld joint efficiency E if branch intersects seam of welded pipe. For branch pipe E always include E to welded pipe. For un- reinforced branch, outer diameter distance from run seam or girth weld >= 4 * t run pipe External non- integral reinforcement method is not permitted without detailed analysis for Class 1 Partial penetration butt or fillet welding requires detailed analysis
Pressure & Temperature Variations above the Design Rating or Stress Limit
AS 4041 (similar to ASME B31.3) allows an over-pressure of 33% < 10 hrs at any event and < 100 hours total per year 20% < 50 hrs at any event and < 500 hours total per year
Over-pressure protection limit as per AS 4041 is Process pressure limited to 15% or 10% Thermal relief pressure limited to maximum safe working pressure of weakest component
WELD EXAMINATION
For weld inspection, refer AS 4458 & AS 3992 (and AS 4037 for NDE) AS 4041 requirements: NDE on 100% of pipeworks
Class 1- circumferential welds at nil for t<=20 mm & 20% for t>20 mm. Class 2A- nil. (Refer to AS 4037 Table 7.3)
Class 1- circumferential welds at 10% for t<=20 mm, 20% for 20 mm <t<=32 mm & 100% for t>32 mm, also longitudinal welds at 100% Class 2A- circumferential welds at 5% and longitudinal welds at 10%. (Refer to AS 4037 Table 7.3)
HYDROSTATIC TESTING
Test Pressures (refer to Clause 6.7 & Appendix U)
Minimum Strength Test Pressure the lesser of 0.83*SY*P/Sa, 90% of (2t*SY)/D & maximum permitted by component standard Maximum Strength Test Pressure 90% SY pipe hoop stress (use minimum purchase specification wall thickness) AS 4041 specifies 15 to 25 minutes Pneumatic test permitted with test pressure 90% of required hydrostatic test pressure Initial in- service test generally not permitted
Alternative Tests
HYDROSTATIC TESTING
Exemptions from hydrostatic testing
Butt, branch & flange welds including tie-in and cut-in welds subject to materials complying with a listed standard, 100% NDE & initial inservice test
Minor attachment such as temperature and pressure tapings <=DN 40 mm subject to 100% MP or DP and if failure not detrimental to piping in service