minimum test pressure calculation design guide

8/13/2019 Minimum Test Pressure Calculation Design Guide

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PROCESS TECHNOLOGY PROCEDURES

PREPARED BY

Edited from existi!do" #$ %.R. B&r'&rt

DATE

A(ri) *+, +++

DEPARTENT/ PROCESS ENG0NEER0NG

APPROED BY

%RB

SUB%ECT/ 0N0U TEST PRESSURE CA2CU2AT0ON DES0GNGU0DE

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1.0 SCOPE

This design guide1presents the procedures for calculating minimum test pressure forpiping subjected to internal or external pressures.

2.0 RESPONSIBILITIES

The process engineer is responsible for calculating the minimum test pressure for linesshown on the piping and instrumentation diagrams (P&IDs) and in the line summar.

The line summar will print the minimum test pressures based on the information pro!idedfor each line. The basis for calculations are standard piping material specifications andthe codes and standards identified in "ection #.$ of this document. The test pressures inthe line summar should be the calculated test pressures rounded to the nearest highest% pounds per suare inch gage (psig).

3.0 CODES AND STANDARDS

The latest issue of the following codes and standards are referenced in this design guide.

1. '"*'merican +ational "tandards Institute ('+"I),#1.1 Power Piping

,#1.- uel /as Piping

,#1.# 0hemical Plant and Petroleum efiner Piping

,#1.2 3iuid Transportation "stems for 4drocarbons5 3iuidPetroleum /as5 'nhdrous 'mmonia5 and 'lcohols

,#1.% efrigeration Piping

,#1.6 /as Transmission and Distribution Piping "stems

,#1.7 ,uilding "er!ices Piping,#1.11 "lurr Transportation Piping "stems

Table 1 cross references the pipe classification standards with nine different ser!ices.

1Re4. + of t'e Desi! G5ide 6&s &d&(ted 6it' miim&) "'&!es from & P&s&de& do"5met, DSG-P1*, 113


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Table 1 8 Pipe 0lassification 0ross eferences

"er!ice Pipe 0lassification

,uilding ser!ices piping '"*'+"I ,#1.7

0hemical plant and petroleum refiner piping '"*'+"I ,#1.1

uel gas piping '"*'+"I ,#1.-

/as transmission and distribution piping sstem '"*'+"I ,#1.6

3iuid transportation sstems for hdrogen5 liuid

petroleum gas5 anhdrous ammonia5 and alcohols

'"*'+"I ,#1.2

Power piping '"*'+"I ,#1.1

efrigeration piping '"*'+"I ,#1.%

"lurr transportation piping sstems '"*'+"I ,#1.11

4.0 TEST PRESSURE

In accordance with '"*'+"I ,#1 (.15 .-5 .#5 .25 .%5 .95 .65 .75 and .11)5 the test pressuresetting falls into two main categories:

1. Internal Pressure

Internal pressure includes hdrostatic testing and pneumatic testing.

-. xternal Pressure

xternal pressure includes hdrostatic testing and pneumatic testing.

4.1 Internal Pressre Test Pr!"e#re

The following guideline shall be used to calculate the minimum test pressure subject tointernal and*or external pressure.


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2.1.1 Power Piping

In accordance with '"*'+"I ,#1.15 the following reuirements of hdrostatic testingappl to power piping:

1. The hdrostatic test pressure at an time shall not be less than 1.% times thedesign pressure for design temperature at or below the test temperature.

-. or design temperature abo!e the test temperature5 the minimum test pressure

shall be calculated b uation %825 except that the !alue of "*" shall not exceed9.% (for the !alue of "5 see '"*'+"I ,#1.15 "tress Table '81).


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2.1.- Pneumatic Testing

Pneumatic testing shall not be used unless the Purchaser specifies pneumatic testing orpermits its use as an alternati!e. Pneumatic testing is recommended for use onl whenone of the following conditions exists:

1. ;hen piping sstems are designed so that the cannot be filled with water

-. ;hen piping sstems are to be used in ser!ices where traces of the testingmedium cannot be tolerated


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The pneumatic test pressure shall not be less than 1.- times the design pressure. Thetest pressure shall not exceed the maximum allowed test pressure of an nonisolatedcomponent in the sstem (see uation %8-).

Test temperature must be considered when the designer chooses the constructionmaterial.

2.1.# uel /as Piping


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In accordance with '"*'+"I ,#1.-5 hdrostatic test pressure and pneumatic testing forfuel gas piping shall meet the following reuirements:

1. or hdrostatic test pressure5 see Paragraph 2.1.1. 4owe!er5 the test pressure!alue shall not be less than # psig.

- or pneumatic testing and test pressure5 see Paragraph 2.1.-. The test pressureshall not be less than # psig.

2.1.2 0hemical Plant and Petroleum efiner Piping


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In accordance with '"*'+"I ,#1.#5 hdrostatic test pressure and pneumatic testing forchemical plant and petroleum refiner piping shall meet the following reuirements:


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1. or hdrostatic test pressure5 see Paragraph 2.1.1. 4owe!er5 if the test pressure asdefined in that paragraph would produce a stress in excess of the ield strength attest temperature5 the pressure ma be reduced to the maximum pressure that willnot exceed the ield strength at test temperature (see '"*'+"I ,#1.# anduation %82).

or pneumatic testing5 see Paragraph 2.1.-. The test pressure !alue shall be 11$percent of the design pressure (see uation %81).

2.1.% 3iuid Transportation "stems for 4drocarbon5 3iuid Petroleum /as5 'nhdrous'mmonia5 and 'lcohols


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In accordance with '"*'+"I ,#1.25 the hdrostatic testing (for liuid onl) and theproof test for liuid transportation sstems for hdrocarbons5 liuid petroleum gas5anhdrous ammonia5 and alcohols shall meet the following reuirements:

1. The portion of piping to be operated at a hoop stress of more than -$ percent ofthe specified minimum ield strength of the pipe shall be subjected at an point to ahdrostatic proof test not less than 1.-% times the internal design pressuremultiplied b the lowest ratio of the permissible stress intensit !alue (see uation%8#). This reuirement pertains to those piping sstems that are !isuall inspected.


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-. or piping sstems that are not !isuall inspected5 the proof test shall be followedb a reduced pressure lea< test of no less than 1.1 times the internal designpressure for not less than 2 hours (see uation %81).

2.1.9 efrigeration Piping

In accordance with '"*'+"I ,#1.%5 the hdrostatic test pressure and the pneumatictesting for refrigeration piping shall meet the following reuirements:

1. or hdrostatic test pressure5 see paragraph 2.1.1. 4owe!er5 if the test pressuredefined in that paragraph would produce a stress in excess of the ield strength at


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test temperature5 the pressure ma be reduced to the maximum pressure that willnot exceed the ield strength at test temperature (see '"*'+"I ,#1.#).

-. or pneumatic testing5 see Paragraph 2.1.-. The test pressure !alue shall be 11$percent of the design pressure (see uation %81).

2.1.= +uclear Power Piping

In accordance with '" ,#1.=5 the hdrostatic test pressure and pneumatic testing for

nuclear power piping shall meet the following reuirements:


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1. xcept as otherwise permitted in '" ,#1.15 Paragraphs 18=#=.1 and 18=#=.2.=5piping sstems shall be subject to a hdrostatic test pressure at e!er point in thesstem that is not less than 1.-% times the internal design pressure multiplied bthe lowest ratio of the permissible stress8intensit !alue (see uation %8#).

-. or pneumatic testing and test pressure5 see Paragraph 2.1.-.

2.1.6 /as Transmission and Distribution Piping "stem

In accordance with '"*'+"I ,#1.6 and Table -5 the testing of gas transmission anddistribution piping sstems shall meet the following reuirements:


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1. 4drostatic testing is reuired for piping sstems operating at hoop stress of #$percent or more of the specified minimum ield strength of the piping material.

-. Pipeline and mains located in 0lass 1 locations shall be tested either with gas orair or hdrostaticall tested at 1.1 times the maximum operating pressure.

#. Pipeline and mains located in 0lass - locations shall be tested either with gas orair or hdrostaticall tested at 1.-% times the maximum operating pressure.

2. Pipeline and mains located in 0lass # and 2 locations shall be testedhdrostaticall at 1.2 times the maximum operating pressure.


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%. >ffshore platform piping and prefabricated portions of offshore platform risers shallbe tested hdrostaticall at 1.2 times the maximum operating pressure.

2.1.7 ,uilding "er!ices Piping

In accordance with '"*'+"I ,#1.75 hdrostatic testing and test pressure andpneumatic testing and test pressure for building ser!ices piping shall meet the followingreuirements:

1. or hdrostatic testing and test pressure5 see Paragraph 2.1.1.


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-. or pneumatic testing and test pressure5 see Paragraph 2.1.-. The followingexceptions to Paragraph 2.1.- appl:

a. The piping sstem should not contain cast iron piping.

b. The piping sstem should not contain soldered joints o!er - inches in diameter.

c. The test pressure should not exceed 1%$ psig.

d. If the piping sstem is nonmetallic5 it should not be larger than - inches +ationalPipe Threads (+PT).

2.1.1$ "lurr Transportation Piping "stems


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In accordance with '"*'+"I ,#1.115 hdrostatic and lea< testing for slurrtransportation piping sstems shall meet the following reuirements:


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1. The portion of piping to be operated at a hoop stress of more than -$ percent ofthe specified minimum ield strength of the pipe shall be subjected at an point to ahdrostatic proof test not less than 1.1 times the internal design pressure multipliedb the lowest ratio of the permissible stress intensit !alue (see uation %81).

-. ;hen lines are tested at a pressure that de!elops a hoop stress based on nominalwall thic


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2. or piping sstems that are not !isuall inspected5 the proof test shall be followedb a reduced pressure lea< test of no less than 1.1 times the internal designpressure for not less than 2 hours.

%. ' 18hour hdrostatic or pneumatic lea< test ma be used for piping sstems that willbe operated at a hoop stress of -$ percent or less of the specified minimum ieldstrength of the pipe. The hdrostatic test pressure shall not be less than 1.-% timesthe internal design pressure. The pneumatic test pressure shall be 1$$ psig or apressure that would produce a normal hoop stress of -% percent of the specified

minimum ield strength of the pipe5 whiche!er is less.


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4.2 H$#r!stat%" Test%n& !' E(ternal Pressre P%)%n&

3ines in full or partial !acuum ser!ice shall be tested at a minimum internal pressure of?1% psig5 unless limited to a lower pressure b design. @ac


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The following euations are used in minimum test pressure calculation:

1. Pneumatic Testing

1.1T

PSP x

S

= (. %81)

-. Pneumatic Test Pressure


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1.-T

PSP x

S

= (. %8-)


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Table - 8 Test euirements for Pipelines and ains To>perate at 4oop "tresses of #$ Percent or ore of the

"pecified inimum Aield "trength of the Pipe

0lass 3ocation Permissible Testluid

Pressure Test Prescribed

aximum 'llowable>perating Pressure5 the

3esser or

inimum(x mop)

aximum


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1 ;ater 1.1$ +one tp B 1.1$'ir 1.1$ 1.1 x dp or

/as 1.1$ 1.1 x dp dp

- ;ater 1.-% +one tp B 1.-%'ir 1.-% 1.-% x dp or

dp

# ;ater 1.2$ +one tp B 1.2$or


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dp

2 ;ater 1.2$ +one tp B 1.2$or

dp

"ource: '"*'+"I ,#1.65 621.#--%

mop C maximum operating pressure (not necessaril the maximum allowable operating pressure)

dp C design pressuretp C test pressure


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This table brings out the relationship between test pressures and maximum allowable operating pressuressubseuent to the test. If an operating compan decides that the maximum operating pressure will be lessthan the design pressure5 a corresponding reduction prescribed test pressure ma be made as indicated inthe Pressure Test Prescribed5 inimum5 column. 4owe!er5 if this reduced test pressure is used5 themaximum operating pressure cannot later be raised to the design pressure without retesting the line to thetest pressure prescribed in the Pressure Test Prescribed column.

#. 4drostatic Testing

1.-%TPS

P xS

= (. %8#)


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2. 4drostatic Test Pressure

1.%T

PSP x

S

= (. %82)


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where:

PT C minimum hdrostatic gage pressure

P C internal design pressure" C allowable stress at test temperature" C allowable stress at design temperature '+"I ,#1.#5 Table '81. or high

pressure (abo!e -5%$$8pound flange rating)5 use '+"I ,#1.65 Table E81.

%. 4oop "tress


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-

PD

t = (. %8%)

where:

P C design pressureD C internal diametert C wall thic


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minimum test pressure calculation design guide

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