Engineering and

Pressure Testing

Nothing is more important than

safety
 What can go wrong ! - Background
KT Test plug sheared out of its threads
while testing at 22,500psi.
Threads on the KT ring were sheared as it
was made of weaker material.

This was the second KT ring built the

first one passed tests.
Damage to the floor of the test bay as
result of the failure
No Injuries were sustained and the
test was conducted in a test bay under
the correct procedures.
What can go wrong! Design Calculations

Force On Plug : 635,748 lbf

Stress on Threads : 49,660 psi
Min yield strength of Male Plug : 100,000 psi
Min yield strength of Female KT Ring: 80,000 psi (per specification)

Design Factor on Female Thread : 0.934 ( Min yield per spec)

Design Factor based upon KT Material Cert : 1.08 (92,800psi)
 What can go wrong !
Calculations
Design of the components was not thorough enough.
Calculations for the test plug showed that the original design was dependant upon
the individual material certificate of the component made, not the minimum yield of
the material specification
It is suspected that the design calculation was done after material was delivered
and therefore the calculation was adjusted to use that material.
Design Code was API 16A states that stress under Hydrostatic Proof Testing can
be 90% yield or Design Factor 1.11.
ASME and API 6A states that for similar Hydrostatic Proof Testing stresses should
not exceed 83% of yield or design factor of 1.20
For this component it should have been designed to API 16A and not exceeded
90%
In both cases the design factor was insufficient
The minimum yield per specification( 80,000psi) should have been used
NOT the material cert. As no account was made for future manufacture!
Lessons Learned
Calculations for Test Equipment
Strength of material should always be based upon minimum yield specified
by the specification for normal verification of design.
The design factors should be based upon ASME 8/API 6A unless it is for
riser components then API 16A can be used.
Calculations for Test Tools must be as thorough as the Primary Operating
components
Assessment must be made of Test Components on whether their operating
pressure will be regularly at the Hydrostatic Pressure Test Pressure, as in
the case of Permanent Test Components for the Workshop , in which case
their Design Operating Pressure (Maximum Working Pressure) should be
the Hydrostatic Test Pressure of the equipment they are testing, and their
primary stresses should not exceed 67% of yield at that maximum working
pressure.
Reference to TOPPS tutorial ENGDES 3.06
FAT and SIT test procedures will reference Safety Management Systems
Procedure SMS 7.20.12 Safe Systems of Work Pressure Testing
Test Equipment Design Guide
You are responsible for checking your work!
Designer/checker/engineer
Make sure there are independent checks on your work, three
signatures for release.

Design requires all deliverables to be verified and all test

components, in-house or third party.
Calculations are required up front, test components should not be
left to the last minute, particularly so that you cannot change the
design if required!
Design review if necessary, make sure related parts are checked i.e.
female and male components.
If necessary use the generic risk assessment VG GRA 0008 to guide
you on the assessment of the risk, or seek guidance from you safety
coordinator Neil Birnie.
Test equipment is safety critical
Test Equipment useful info
Pressure Test Safety
The stored energy in a hydro test is a 100 times less than the equivalent
gas test.
All gas tests must be in a pit and submerged in water
Per the HSE calculations,
Pressure vessel 1m dia , 20 mm thick, 80 mm thick end caps
weighing 1716 kg for the cylinder, 490 for the end caps
Fails during hydro test at 1000 bar (14,600 psi)
17kg fragment needs 13.4 mm steel to stop it.
340kg fragment needs 33mm steel to stop it.
490 kg end cap needs 15.1 mm steel to stop it.
Equivalent gas test:
17kg fragment needs 57mm steel
340kg fragement needs 141 mm steel
490 kg end cap needs 65mm steel