Piping Pressure Testing 386055

Piping Design Submissions What not to Forget / Omit Presented by: Djordje Srnic Design Survey Manager

ABSA

the pressure equipment safety authority

Objectives

™ Code requirements ™ Submission requirements ™ What not to forget / omit

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Hierarchy of Act and Regulations Safety Codes Act Regulations

Ministerial Orders

’s Directives and Interpretations CSA B51 ASME Boiler and Pressure Vessel Codes

ASME Piping Codes

Other codes and Standards

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Alberta regulatory requirements ™ Safety Codes Act (Section 40) – Pressure Equipment Safety Regulation (Alta Reg 49/2006) – Pressure Equipment Exemption Order (Alta Reg 56/2006)

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Owner’s Responsibilities ™

PESR 37 – Do you ever ask yourself what your responsibilities as a Plant Owner are under the Safety Codes Act and the Pressure Piping Codes that have been declared to be in force under the Act? –

Do you rely exclusively on your piping Contractor to meet all regulatory and Code requirements because he has the Certificate of Authorization from ABSA? If so, read the article PLANT PIPING – OWNER’S RESPONSIBILITIES in ABSA’s The Pressure News, Volume 5, Issue 4, Dec. 2000.

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Information Bulletins and “The Pressure News” ™

Information Bulletins - may issue – Directives – Variances – Interpretations – Alerts

™

The Pressure News – ABSA’s publication that – Informs public – Provides interpretations & clarifications – Alerts public 1/19/2009

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CSA B51 – Boilers, Pressure Vessels and Pressure Piping Code ™ Clause 4.1 provides general requirements for registration of designs (including pressure piping designs).

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ASME Code for Pressure Piping ™ Collectively under ASME B31 – B31.1, Power Piping – B31.3, Process Piping – B31.5, Refrigeration Piping and Heat Transfer Components – B31.9, Building Services Piping

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Interpretations and Code Cases ™ Neither Interpretations nor Code Cases are mandatory parts of the Codes. Before trying to apply an Interpretation or Code Case, ensure that ABSA is amenable to its use.

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Design Registration Requirements ™ PESR Sections 4, 14 & 16 – Section 4 provides partial exemptions for piping systems. It is not applicable for boiler external piping. – Section 14 provides general requirements for design registrations and exemption for piping systems with Volume<500 l (0.5 m3) – Section 16 provides requirements for piping design registration. 1/19/2009

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Piping Design Requirements ™ PESR 16(2) - The information referred to in subsection (1) must bear the stamp or seal of a professional engineer and the name of: a) the owner of the design ; or b) the person who will be the manufacturer of the pressure piping system.

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Special design requirements ™ If piping design includes special design requirements, the submission needs to include them:

– – – – –

Nonmetallic piping materials Category M Fluid Service High Pressure Piping Safeguarding Metallic Bellows Expansion ts 1/19/2009

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Fittings in Pressure Piping Systems ™ PESR 16 & 17 – Fittings must be ed (See Line 8 in AB-96, General Engineering Requirements for Design & Registration of Pressure Piping Systems). – Only fittings that are within the scope of registration may be used. – Modifications or alteration of fittings is not allowed without re-registration of fitting design. 1/19/2009

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Safety Valve Requirements ™

PESR Section 38(3) An owner of pressure equipment must ensure that the overpressure protection system is designed and maintained so that the maximum pressure in the pressure equipment does not exceed the prescribed limit of overpressure allowed in the applicable code declared in force by this Regulation. PRD to open before pressure exceeds MAWP. See section 38(2). 1/19/2009

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Safety Valve Requirements (cont’d) ™ PESR Section 38(1) An owner of pressure equipment must ensure it has overpressure protection that is (a) a pressure relief valve that meets the requirements of the ASME Code; (b) other means of overpressure protection acceptable to the .

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Safety Valve Requirements (cont’d) ™ Other means of overpressure protection acceptable to the –

Rupture discs. Rupture disks must be UD Stamped.

–

Code Case 2211 (moved in Section VIII, Div. 1 UW140). Protection by system design is not recommended because the Safety Codes Act and Regulations do not allow for this type of protection.

–

Allowance for occasional variations above design conditions (Section 102.2.4 of B31.1 or Section 302.2.4 of B31.3) is not in line with PESR 38(2).

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Safety Valve Requirements (cont’d) ™ Proposal for the use of other means of overpressure protection must – – – –

–

Include technical justification for the use of the Code Case. Demonstrate compliance with the Code Case. Include the acceptance from the owner. Provide proposal for adding a warning plate on a vessel protected by CC-2211. It needs to state that vessel is ƒ Protected by Code Case 2211 ƒ Designed for specific operation condition and any change in operating conditions require the owner’s and ABSA’s acceptance. Vessel drawings submitted for registration need to include ƒ Code case number ƒ note that the MDR will include CC-2211 under “Remarks” ƒ Warning plate information. 1/19/2009

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Safety Valve Requirements (cont’d) ™ Different requirements for safety valves in – ASME BPVC, Section I and ASME B31.1. See PG67 through PG-73 of Section I and 107.8 and 122.1.7(D) of B31.1. – ASME BPVC, Section VIII, Div.1 and ASME B31.3. See UG-126 through UG-133 of Section VIII and 322.6 of B31.3.

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Safety Valve Requirements (cont’d) ™ PESR Section 16(1)(c) Piping design submission must include – A list of pressure relief devices. – The pressure relief set pressures. ™ PESR Section 16(1)(i) Additionally, design surveyors may ask for: – Drawing (flow or line diagram) number that shows the safety valve. – A list of pressure vessels protected by this safety valve. 1/19/2009

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Hydrostatic Test ™

PESR Section 30 (1) All pressure piping leak tests must be conducted using the hydrostatic method. (2) Despite subsection (1), the may accept, for a specific pressure piping system, alternative test methods that are allowed in a code or standard that is declared in force. (3) A pressure piping system shall not be tested at a temperature that is colder than its minimum design temperature. (4) When conducting pressure tests, the ductile-to-brittle transition temperature and the possibility of brittle fracture must be considered by the contractor. 1/19/2009

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Hydrostatic Test (cont’d) ™ Hydrostatic testing of pressure piping systems is – – – –

to the integrity and leak tightness of the piping system (purpose). The last physical quality test in the fabrication process to the system is safe to operate. Performed prior to placing the system in service. Preferred mainly due to safety considerations and for ease of finding leaks. Should a component fail during a hydrostatic test, the energy stored in the water is quickly dissipated.

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Hydrostatic Test (cont’d) ™ Requirements for Boiler External Piping (BEP) – BEP shall be hydrostatically tested in accordance with PG-99 of ASME BPVC, Section I

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Hydrostatic Test (cont’d) ™ Alternative test Methods – – – – –

Pneumatic test Hydrostatic-Pneumatic Test Initial Service Leak Test Sensitive Leak Test Alternative Test Methods in Lieu of Hydrostatic Leak Testing for a Closure or Tie-In Welds 1/19/2009

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Hydrostatic Test (cont’d) ™ Alternative test Method Procedures Must – –

–

–

Provide technical justification for not completing the hydrostatic pressure test. Provide a written test procedure that will fully address the technical and safety considerations for the test. Be acceptable to the owner. The owner of the piping system must review the circumstances and decide to accept the risk of not hydrostatically testing the piping system Be reviewed and accepted by ABSA. 1/19/2009

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Hydrostatic Test (cont’d) ™ Do not forget that – – –

– –

Hydrostatic test is mandatory according to Section 38(1) of PESR 49/2006. Piping system shall be tested to ensure system integrity and tightness. When considering any alternative to the hydrostatic test prescribed under the Safety Codes Act, all risks and consequences must be carefully and thoroughly evaluated. If alternative test method is proposed, it must be acceptable to the owner & ABSA Alternative tests shall be performed by personnel other than those performing the production work. 1/19/2009

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Piping Modules, Closure Welds and Tie-in Welds ™

Submissions to Design Survey must have the following: – – –

– – –

List of all of the identified welds Description of the procedure Acceptance Criteria per ASME B31.3 344.7.1 and additionally a. misalignment tolerances b. gap tolerance c. preheats (if applicable) d. any additional NDE (MP, LPI) e. any other acceptability criteria for inspectors to ensure weld is properly constructed Full Radiography requirements (or phased array in lieu of – Code Case 181) per 345.9.1 Hydrostatic testing requirements for all connection modules before the start of welding. Statement by Professional Engineer on the submission that flexibility analysis per B31.3 345.9.2 has been addressed. 1/19/2009

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Piping Modules, Closure Welds and Tie-in Welds ™

Field inspection requirements include the following: – The final Closure weld acceptance in the field must be pre-determined on a travel sheet with set acceptance criteria prior to making the closure weld. – The closure welds must be kept away from high stressed locations. – Each side of the closure weld MUST be hydrostatically tested – Start-up procedure must take into that you have welds which have not been hydrostatically tested. Caution is requested here. 1/19/2009

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Impact Testing requirements ™ Section 323.2.2 of ASME B31.3 specifies the lower temperature limits for listed materials. ™ Section 323.2.3 of ASME B31.3 specifies requirements for unlisted materials. ™ Section 323.3 of ASME B31.3 specifies Impact testing Methods and Acceptance Criteria. 1/19/2009

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Impact Testing requirements Example of pipe calculations: Pipe: NPS 10 Sch 80, material A106-B (curve B - Table A-1) P=1480 psi T=100 deg. F MDMT = -20 deg. F S=20000 psi CA=0.125” tnom = 0.594” tmin=0.519” treq={(1480)*(10.75)/[2*(20000+(0.4)*(1480)]}+0.125 treq =0.386 +0.125 = 0.511” Calculated stress in pipe is Sp=19598 psi Per table 323.2.2A, MDMT is -2.5 deg.F for Tnom= 0.594” Stress ratio r=19598/20000=0.98 Per table 323.2.2B temperature reduction is 2 deg.F The adjusted MDMT is -2.5 -2 = -4.5 deg. F Impact testing is required. 1/19/2009

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Use of Unlisted Materials ™ ASME B31.1 – Unlisted materials can not be used for boiler external piping (BEP) according to section 123.1.2. – For non-BEP, unlisted materials may be used if they satisfy all five requirements (A through E) of section 123.1.2. – ABSA will require the owner’s acceptance for use of unlisted materials in accordance with 123.1.2(D). 1/19/2009

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Use of Unlisted Materials (cont’d) ™ ASME B31.3 – Allows the use of unlisted materials according to section 323.1.2. – The allowable stresses of unlisted materials shall be defined in accordance with section 302.3.2.

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Skid Packages not shown in the Piping Design Submission ™ Submissions to Design Survey must have the following: – Scope of registration – Information who will skid packages if they are not shown in the submission. – Who is responsible for the ts between skid lines and the rest of the piping.

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Where do things go wrong?

™ ™ ™

™ ™

Incomplete information in the submission No P. Eng. stamp on piping designs Improper application of - Pressure relief devices - Pressure piping testing requirements - Material specifications and flange classes - the low temperature rules Manual changes on drawings – improper revision practice Client’s failure to respond in a timely fashion 1/19/2009

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How can ABSA help?

™ We encourage pre-job meetings with EPC’s, owners, and suppliers for major projects to iron out areas that may be unclear (2 – 3 hours at ABSA’s head office) ™ We are happy to answer phone or e-mail questions

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How can you help?

™ Inform your vendors of the Alberta requirements. ™ Keep in with your vendors to ensure that they are doing what they need to do to get their designs ed. ™ Don’t permit shipment from the Manufacturer’s facility if there is no registration in place.

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Selected Articles to Pressure Piping from “The Pressure News” ™

http://www.absa.ca/newsletter/default.aspx – – – – – –

Piping Systems Constructed Outside Alberta, Volume 7, Issue 3, Sep. 2002 Pressure Piping Construction Documents, Volume 9, Issue 3, Sep. 2004. Permit Requirements for the Construction of Instrumentation Tubing Systems, Volume 13, Issue 3, Sep. 2008. Correction/Clarification Pressure Piping Systems (Threaded piping is treated similar to welded piping), Volume 7, Issue 3, Sep. 2002. Pressure Piping Not Over 0.5m3 In Capacity, Volume 8, Issue 2, June 2003. Plant Piping – Owner’s Responsibilities, Volume 5, Issue 4, Dec. 2000. 1/19/2009

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Selected Articles to Pressure Piping from “The Pressure News” ™

http://www.absa.ca/newsletter/default.aspx – – – – – –

Owner s Inspector must Inspect & Certify Piping Data Report, Volume 13, Issue 3, Sep. 2008. Failure of Low Pressure Piping, Volume 9, Issue 1, Mar. 2004. Special Considerations for Alternative Leak Testing for Closure Welds of Pressure Piping Fabricated to ASME B31.3, Volume 9, Issue 3, Sep. 2004. Installation of Pressure Relief Valves , Volume 13, Issue 3, Sep. 2008. Isolation Valves In A Pressure Relief Path, Volume 10, Issue 3, Sep. 2005. Flare Lines and Flare Knockouts, Volume 9, Issue 3, Sep. 2003. 1/19/2009

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Selected Articles to Pressure Piping from “The Pressure News” ™

http://www.absa.ca/newsletter/default.aspx – Requirements for Boiler External Piping on ASME Section I Power Boilers, Volume 10, Issue 3, Sep. 2005 – Pneumatic Test, Volume 7, Issue 2, June 2002. – Failure of 2˝ Y Strainer under Pneumatic Test, Volume 10, Issue 1, June 2005. – Warning – Water Hammer Hazards, Volume 12, Issue 2, June 2007. – Alert-Use of ed Fittings, Volume 5, Issue 2, June 2000. – Alteration of Fittings, Volume 3, Issue 3, Sep. 1998. 1/19/2009

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Selected Articles to Pressure Piping from “The Pressure News” ™

http://www.absa.ca/newsletter/default.aspx – On Stream Leak Sealing of Flanges, Valves, Volume 2, Issue 1, Feb. 1997 – Positive Material Identification, Volume 11, Issue 4, Dec. 2006. – Alerts (Brass Valve Failure and Rig Boiler Fatality), Volume 9, Issue 1, Mar. 2004. – Flange Gaskets (Incorrect specification and installation), Volume 8, Issue 1, Mar. 2003. – Hydrostatic Testing can be Dangerous Too, Volume 13, Issue 3, Sep. 2008.

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Selected Information Bulletins & Alerts to Pressure Piping ™

http://www.absa.ca/IBIndex/default.aspx – Interpretation - Random Radiography for designated lot of ASME B31.3 Piping, IB07-002 – Pipe Nipple Failure, IB02-001 – Brass Valve Failure in Power Boiler Service, IB04002 – Alert to Pressure Equipment Owners and Operators - Rig Boiler Fatality, IB04-003 – Valve Failure (Stem came off due to improper installation), IB04-005

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