Piping at Offshore Jacket ASME B31.3 .pptx

Piping For process piping.

1. Process Piping ASME Code for Process Piping, B31.3 Muhammad Bilal June 01 , 20 13 1

2. Contents Objective History & Scope Code Development History Organization of Code Scope Exclusions Design Design Conditions Design Criteria Design for Internal Pressure (Para 304) Fabrication, Assembly & Erection Inspection, Examination & Testing

3. Objective To provide the participant with a good basic understanding of the design, fabrication, erection and inspection rules and requirements of the ASME B31.3 Code. At the conclusion of the session, the participant will understand: Development history of the Code How the ASME B31.3 is Organized Design Conditions & Criteria Fabrication , Assembly & Erection Inspection , Examination & Testing

4. History & Scope Code Development History Organization of Code Scope Exclusions 4

5. In 1926 the American Standards Association (ASA) initiated the B31 Project at the request of the American Society for Mechanical Engineers (ASME). Members were required to be selected from engineering societies, industry, government bureaus, institutions and trade associations. Initial publication in 1935 was entitled the “American Tentative Standard Code for Pressure Piping”. This edition was directed toward power plant and industrial installations. 1942 Edition of “Code for Pressure Piping” added a new section for refrigeration piping & contained the following sections: Power Piping Systems Gas & Air Piping Oil Piping Systems District Heating Piping Systems Refrigeration Piping Systems Fabrication Details Materials – Their Specifications and Identification The “combined” edition of the code was published until 1955 History & Scope

6. Due to the size and complexity of trying to cover growing number of industrial applications in one book, the Code was broken into separate documents. In the 1960's, the Book Sections were formed and consisted of the following: B31.1 Power Piping B31.2 Fuel Gas Piping B31.3 Petroleum Refinery Piping B31.4 Liquid Petroleum Transportation Piping Systems B31.5 Refrigeration Piping B31.7 Nuclear Power Piping B31.8 Gas Transmission and Distribution Piping Systems B31.9 Building Services Piping B31.10 Cryogenic Piping Systems The B31.3 Code was first published in 1976 and represented a combined effort of two Committees, the old B31.3 which addressed petroleum refineries and related facilities and the B31.6 which dealt with chemical plant piping. A draft code of the B31.6 was completed in 1974 but it was decided to publish one joint code, titled Chemical Plant and Petroleum Refinery Piping. The first edition was published as ANSI B31.3-1976. History & Scope

7. The 1984 contained the integration of the B31.10 cryogenic requirements, a new stand alone chapter on high pressure piping was added to the code. The 1990 and 1993 Editions added requirements for bellows expansion joints and aluminum flanges. The 1996 Edition contained significant changes to the introduction and scope statements to clarify the application of all B31 sections, which also revised their scope sections. The title of the code was changed to Process Piping. The 1996 Edition also contains SI metric units and are designated as standard. Instructions for conversion are given where metric data are not available or it was not possible to complete all the metric conversions to date. By agreement, either system may be used. In 2000 Edition, SI metric units are given first with US customary units in parentheses. (Tables H, X, Tables of Appendices A & K and Tables C-1, C-3 and C-6 in Appendix C are not converted into SI units). Values in metric units are to be regarded as the standard, unless otherwise agreed between the contracting parties. History & Scope

8. Organization of B31.3 CODE FOR E W O RD INTRODUCTION C H APT E R I CHAPTER I I PAR T 1 PAR T 2 PAR T 3 PAR T 4 P ART 5 PART 6 C H APT E R III C H APT E R IV C H APT E R V CHAPTER VI C H APT E R VII PAR T S 1-6 PART 7 PART 8 P ART 9 PAR T 10 C h apte r VIII PAR T S 1-10 PART 11-20 C H APT E R IX PAR T S 1-10 SCOP E AN D DEFINITIONS DESIGN CONDITI O N S AN D C R ITERIA PRES S U R E DESIG N O F PIPI N G COMPONENTS FLUI D SERVIC E REQUIRE MEN T S FOR PIPING COMPO N EN T S FLUI D SERVIC E R EQU IREMENT S FO R P I PI N G J O I N TS F LE X I B I L IT Y AND S U PPO RT S Y S T EMS M ATERI ALS S T ANDARD S FO R PIPING COMPONEN TS FABRICATION, A S SEMBLY AND ER E CTION INSPECTION, EXAMINATION AND TESTING NONM E T A L LI C PIPING & : PIPING LINED W I TH NONMETALS(Prefix-A) T o p i c s same as parts for C h a p ter II MA T E R I ALS PIPING C O MPON E N T S S T ANDARDS FABR I CA T ION, ASSEMB L Y A N D ERE C T I ON IN S PECTIO N , EXAMI N ATIO N A N D TESTI N G PIPING FO R CAT E G O R Y M FLUID SERVIC E (Pref i x-M) To p i c s same as parts for C h a p ter VII Correspon d i ng t o Chapter VII H I GH PRESSURE PIPING (Pref i x-K) To p i c s same as parts for C h a p ter VII

9. Fluid Service Categories Category D All discussions in B31.3 is based on this category Non toxic, non hazardous, non corrosive fluid below 150 psig pressure and at a temperature between -20 ~ 300 deg F Category M Special requirements of chapter 8 to be fulfilled Hazardous, harmful in small dozes to human beings, pressure and temperature non falling in category D Normal Fluid not falling in above two categories High Pressure piping The pressure exceeds the limits of B16.5 class 2500 flange at temperature B31.3 Chapter 9 details additional requirements

10. Scope of B31.3 (Para 300.1) This Code prescribes requirements for the materials, design, fabrication, assembly, erection, examination, inspection, and testing of piping. This Code applies to piping for all fluids: Raw, intermediate, and finished chemicals; Petroleum products; Gas, steam, air, and water; Fluidized solids; and Refrigerants This Code covers all piping within the property limits of facilities engaged in the processing or handling of chemical petroleum, or related products. Examples are a chemical plant (including non-radioactive fluids in a nuclear fuel reprocessing plant), petroleum refinery, loading terminal, natural gas processing plant (including liquefied natural gas facilities), bulk plant, compounding plant, and tank farm. Packaged Equipment Piping - Piping which interconnects individual pieces or stages of equipment within a packaged equipment assembly shall be in accordance with B31.3, except that packaged refrigeration piping may conform to either B31.3 or B31.5.

11. Exclusions (Para 300.1.3) The B31.3 Code excludes the following (Para. 300.1.3) Piping systems designed for internal pressures 0 to 15 psi with design temperatures - 20°F to 366°F. (- 6.6°C to 185°C) Power Boilers in accordance with ASME BPV Section I and boiler external piping which is required to conform to B31.1; tubes, tube headers, crossovers, and manifolds of fired heaters, which are internal to the heater enclosure; pressure vessels, heat exchangers etc., pumps, compressors, and other fluid handling or processing equipment, including internal piping and connections for external piping; piping located on company property which has been set aside for pipelines conforming to B31.4, B31.8, or B31.11, or applicable governmental regulations; plumbing, sanitary sewers, and storm sewers; and fire protection systems constructed in compliance with insurance underwriters' or other recognized fire protection engineering standards. (Requirements in NFPA Codes)

12. Exclusions (Para 300.1.3) The B31.3 Code excludes the following (Para. 300.1.3) Piping systems designed for internal gage pressures at or above zero but less than 105 kPa (15 psi), provided the fluid handled is nonflammable, nontoxic, and not damaging to human tissues as defined in 300.2, and its design temperature is from −29°C (−20°F) through 186°C (366°F) Power boilers in accordance with BPV Code2 Section I and boiler external piping which is required to conform to B31.1 Tubes, tube headers, crossovers, and manifolds of fired heaters, which are internal to the heater enclosure Pressure vessels, heat exchangers, pumps, compressors, and other fluid handling or processing equipment, including internal piping and connections for external piping

13. Design Design Conditions Design Criteria 13

14. Design Conditions Design Pressure (Para 301.2) Design Temperature (Para 301.3) Ambient Effects (Para 301.4) Dynamic Effects (Para 301.5) Weight Effects (Para 301.6) Thermal Expansion & Contraction Effects (Para 301.7) Effects of Support, Anchor and Terminal Movements (Para 301.8) Reduced Ductility Effects (Para 301.9) Cyclic Effects (Para 301.10) Air Condensation Effects (Para 301.11)

15. Design Pressure (Para 301.2) The pressure design of a piping system is based on determining the thickness of each piping component considering the following: Design pressure of each component in the piping system shall not be less than the pressure at the most severe condition of coincident internal or external pressure and temperature expected during service . Design to achieve the greatest component thickness or highest flange rating required Consider all pressure-temperature conditions and variations Consider any exceptions to the Code requirements by particular attention to all statements in the subject paragraph. Para. 302.2.4 specifies the allowances for Pressure and Temperature Variations.

16. Design Pressure (Para 301.2) Provisions must be made to safely contain or relieve any pressure to which the piping system may be subjected (Para. 301.2.2 ). Provide relief valving Provide ability for isolation or Design the system to withstand the highest pressure that can be developed . Consider oscillations, surges, control failures and improper operation effects the piping system.

17. Design Pressure (Para 301.2) Consider that the allowances of Para. 302.2.4(f) are permitted provided the other requirements of Para. 302.2.4 are also met. Para.302.2.4 addresses allowances for Pressure and Temperature Variations, it is a very detailed paragraph and should be studied carefully before applying. subject to owner's approval operation in excess of pressure rating or the allowable stress for pressure design at the temperature 33 % for no more than 10 hours at anyone time and no more than 100 hours/year or 20 % for no more than 50 hours/year at anyone time and no more than 500 hours/year evaluation by the designer over the service life of the piping system variations which are self-limiting

18. Design Temperature (301.3) The design temperature of each component in a piping system is the temperature at which, under the coincident pressure, the greatest thickness or highest component rating is required. Coincidental with pressure, the most severe condition is to be considered. Consider the fluid temperature, solar radiation, heating or cooling temperatures. Consider the material requirements and the minimum temperature expected in service. Consider insulated and uninsulated piping requirements. For insulated piping, consider the effects of external insulation versus internal insulation. Consider effects of heat tracing piping components .

19. Ambient Effects (Para 301.4) Cooling Effects on pressure Cooling effects of gas or vapor may reduce pressure to cause a vacuum. Consider external pressure caused by cooling effects Provide a vacuum break or design piping to withstand external pressure. Expansion Fluid expansion effects Make provisions to withstand or to relieve increased pressure effects due to heating of static fluid. (Thermal relieving) Icing Atmospheric icing effects Systems operating below 32 of may result in moisture condensation Make provisions to avoid buildup of ice Consider this condition applying to shut off, control, relief valves. Low Ambient Temperature Consider for displacement stress analysis

20. Dynamic Effects (Para 301.5) Impact External - jet impingement Internal - water hammer (any liquid), liquid or solid slugging, flashing Wind Minimum design loads for buildings and structures Uniform Building Code, ASCE 7 (ANSI 58.1) Earthquake ASCE 7 Uniform Building Code

21. Dynamic Effects (Para 301.5) Vibration Design to reduce excessive vibration consider implementing studies to determine if resonance will occur in some part of the system. Consider use of pulsation-reducing devices (accumulators, surge drums etc.) Supports Adequate foundations, especially at pumps and compressors strategic location of guides and supports avoidance of small branch connections Impact, pressure pulsation, resonance wind loads Discharge Reactions design, arranged and supported let down loads relief valve discharge loads

22. Weight Effect (Para 301.6) Live Loads Medium weight - service or test Environmental - ice & snow Dead Loads Piping component weight Piping insulation Other superimposed permanent loads

23. Thermal Expansion and Contraction Effects (301.7) Thermal Loads Due to Restraints Thermal expansion thrust and moments Restraints and anchors Equipment connections - pump, tank connections Loads Due to Temperature Gradients Unequal temperature distribution (dead leg) High heat flux Two phase flow (condensate line) Loads Due to Differences in Expansion Characteristics Bimetallic piping (differences in thermal expansion) Lined piping Jacketed Metallic-non metallic piping

24. Other Conditions EFFECTS OF SUPPORT, ANCHOR AND TERMINAL MOVEMENT (Para. 301.8) Piping flexibility Settlement Wind sway REDUCED DUCTILITY EFFECTS (Para. 301.9) Welding Heat treating Forming, bending or low temperature operation Chilling effect (evaporation of volatile liquid) CYCLIC EFFECTS (Para. 301.10) (Thermal or Pressure) Fatigue effects Cyclic loadings AIR CONDENSATION EFFECTS (Para. 301.11) At operating temperature below -3 12° F (-191° C) in ambient air, condensation and oxygen enrichment occur. Materials selection Include insulation and adequate shielding and/or disposal

25. Design Conditions Appendix F Good reference in the form of precautionary considerations relating to particular fluid services and piping applications The designer is referred to Appendix F of ASME B31.3 for guidance in the form of precautionary considerations relating to particular fluid services and piping applications. These are not Code requirements but should be taken into account as applicable in the engineering design. Appendix F provides further information and references in the following areas: Design Conditions Ambient Effect (fluid entrapment) Dynamic Effects Thermal Expansion and Contraction Effects (bowing during cool down) Pressure Design Pressure Design of other Metallic Components (Expansion Joints) Valves extended bonnets are recommended to establish a temperature difference between valve packing and fluid.

26. Design Conditions APPENDIX F (Cont’d) Flanges and Gaskets Spec i f ic Flange s (ra i se d fac e flanges) Gas k et s (ful l fac e typ e) Bolting - u s e o f controlle d b olt i n g procedures . The most widely used b o l t i n g materials in proces s plan t d esig n a r e A S TM A19 3 Gr ade B7 Stud b o lts with ASTM A194 Grade 2H heavy hex nuts. These mater i als ar e accep t abl e from - 50 ° F to 1O00° F. Flanged Joints - s election/ d esign , installation Design Considerations for Specific Systems Sto p Valve s i n Pressu r e Rel i e f Pi p ing ! S a f e gua r d i ng

27. Design Conditions APPENDIX F (Cont’d) Materials General Con s idera t ions - s uch as expo s ure to f i re and melti n g p o i n t s s u s c eptib i l i ty to br i t tle f r a ctu r e i n sulat i o n protect i o n o f p i p i n g mater i al un d e r f i re expo s ure s u s c eptib i l i ty to c orro s i on a d v erse electrolyti c effects compati b i l ity of lub r icants or sealants for threads compati b i l ity of p a c k i n g s eals, O- r ings Spec i f ic M a t er i a l Conside r a t i on s (M e t als) cast iro n /lack of duc t i l ity, sen s i t ive to therma l an d m echanica l shock s . c onver s ion of car b ides to grap h i t e dur i n g lo n g -te r m e x p o s ure abov e 800° F for carbon s teels hydrogen exposu r e pos s ibi l ity o f stres s corro s io n cracking su s c eptibil i ty o f hig h allo y (st a i n les s steels ) in inter-gr a nula r c orro s i o n comments and co ns iderations in the use of: Nicke l an d Nicke l Base d Alloys Alumi n um and Alumi n um Allo y s Coppe r a n d Coppe r Alloys T i tan i um a n d T i t a nium Alloys Z i r c o n i u m Alloys Tantalum

28. Design Criteria General Pressure Temperature Design Criteria Allowable Stresses and Other Stress Limits (Para 302.3) 28

29. Design Criteria General Pr ess ur e -T e mperature rati n gs can b e u se d f or p i p i n g com p onent s l i sted i n T a b l e- 326-1 T h e s t an da rd s lis t th e d i mensiona l r equ i rement s fo r pi p i n g components Appendix-A o f th e Co d e is a r equ i re m en t also Allowances for Pressure & Temperature variations Va r i ation s occu r o n occ a sions Us e thes e va r i ation s to de t e rmin e th e d esig n conditions Rating at Junctions of Different Se r v ices S e parating valve rated at h i ghes t servic e (mos t sever e servic e condition) Des i g n eac h s i d e to servic e cond i tio n applicable

30. Allowable Stresses and Other Stress Limits Determine stresses in accordance with Code Rules unless modified by other provisions of this Code Tension - The basic allowable stress S in tension is listed in Table A-I of this code. Table A-I is used to determine the allowable stress in tension for a number of metallic components at various temperatures. When using Table A-I take care to read any notes which may apply to the specific material. When the term SE appears in an equation, the stress value S is multiplied by a manufacturing quality factor E. The term E will have a subscript c or j. Subscript c means that the component has a casting quality and subscript j relates to weld quality. The values of Ec and Ej are found in Code Tables A1-A and A1-B respectively. Shear and Bending - The allowable stress in shear shall be 0.80 of the basic allowable stress in tension from Table A-l or A-2. Bearing - The allowable stress in bearing shall be 1.6 times the basic allowable stress in tension Compression -The allowable stress in compression shall be no greater than the basic allowable stress in tension. Structural stability shall be considered. Design Criteria

31. Design Criteria Basic Allowable Stresses used for Internal & External Pressure S =basic allowable stress from Table A-1at minimum metal temperature considered safe when wall thickness meets the requirement of para . 304 (for internal pressure) and ASME BPV Code, Section VIII, Div. 1 (for external pressure) Basic Allowable Stresses used for Fatigue or Cyclic Loads Sc =basic allowable stress at minimum metal temperature expected during the displacement cycle under analysis Sh = basic allowable stress at maximum metal temperature expected during the displacement cycle under analysis The above basic stresses are used to calculate the allowable displacement stress range, SA, which is used for fatigue analysis Bases for Allowable Stresses(other than Bolting, Cast & Malleable Iron) Allowable stress for a pipe or component is based on a function of the yield or tensile strength of the material, or the creep rate at temperature or stress for rupture at elevated temperature. Reference Para. 302.3.2. Allowable stress for material at ambient or cold condition is given the term Sc. Allowable stress for material at the design temperature is given the term Sh. Sc and Sh values are tabulated in Table A-I. The basis of Sc and Sh values at temperatures below the creep range are the lowest of 1/3 of the specified minimum tensile strength at room temperature. 1/3 tensile strength at temperature. 2/3 minimum yield strength at room temperature. 2/3 yield at temperature.

32. Design Criteria Who Can Establish Allowable Stresses The user can not establish or calculate the allowable stresses. Only the ASME Code Committees can establish allowable stresses. For a user to use a new material, he/she needs to provide to ASME the necessary material data, i.e. tensile strength and yield strength at various temperatures, creep data and stress-strain curves. Appendix 3 of Section-II Part D describes the complete information that ASME requires.

33. Pressure Design (Para 304) Straight Pipe (Para 304.1) Branch Connection (Para 304.3 ) Calculation

34. Wall Thickness for Internal Pressure (Para 304.1) For (t < D/6) c = Corrosion Allowance P = Internal design pressure D = Outside diameter of pipe S = Stress Value from Table A-1 Y = Stress Temp compensation factor from Table 304.1.1 E = quality factor from Table A-1A or A-1B Mill tolerance 12.5% T = t + c + mill tolerance   For t ≥ D /6 or for P/SE > 0.385 calculation of pressure design thickness for straight pipe requires special consideration of factors such as theory of failure, effects of fatigue, and thermal stress.

35. Branch Connection (Para 304.3) Reinforcements to be added based on geometry of area . Not required when connections are taken using listed/listed unrated components Conditions 1. Centre line of branch pipe intersects that of run 2. Angle of intersection is between 45 and 90 deg 3. For run pipe 4. Branch to run dia ratio  

36. Branch Connection (Para 304.3) Integrally reinforced branch fittings which abut the run pipe above 4 inch dia are not permitted if d/D exceeds 0.8 or run pipe is less than sch 40 or run pipe thickness is less than 0.74 where pipe size exceeds 36 inch Pad reinforced braches where temp exceeds 800°F are not permitted Branch connections 1.5 inch or lesser can be made using half coupling or pipe nipple 160 sch .

37.   Branch Connection Calculations 37

38. Pipe Material: Seamless, A106 Gr. B for branch and header S = 16,500psi Design Conditions : 550 psig @ 700°F c = 0.0625in Mill Tolerance = 12.5% NPS Header : 0.562in Branch : 0.375in Required Pipe thicknesses Header : 0.395in Branch : 0.263in Branch Angle = 90° Sample Problem – Branch Reinforcement 38

39. Sample Problem – Branch Reinforcement 39 Calculate Required Reinforcement Area  

40. Sample Problem – Branch Reinforcement 40 Calculate Excess Area Available in Header  

41. Sample Problem – Branch Reinforcement 41 Calculate Excess Area Available in Branch  

42. Sample Problem – Branch Reinforcement 42 Calculate Other Excess Areas Available  

43. Sample Problem – Branch Reinforcement 43 Reinforcement pad: A106, Gr. B, 0.562 in. thick Recalculate Available Reinforcement  

44. Sample Problem – Branch Reinforcement 44 Calculate additional reinforcement required and pad dimensions:  

45. Fabrication, Assembly & Erection 45

46. Fabrication Welding/ Requirements Preheating/ Heat Treatment Bending and Forming

47. Assembly & Erection Alignment Flanged Joints Threaded Joints Tubing Joints Cleaning of Piping

48. FABRICATION, ASSEMBLY & ERECTION WELDING Welding procedure & Performance qualification as per Sec. IX with some exceptions as defined in para . 328.2.1 (b) to (f) Welding Procedure Qualification by others (other than owner) maybe used provided that the conditions of para 328.2.2 (a) are met. Performance Qualification by others maybe acceptable as per para 328.2.3 Welding joints & alignment of joints

49. FABRICATION, ASSEMBLY & ERECTION WELDING REQUIREMENT Welding shall be made by qualified welders by qualified procedure Tack welds at the root shall be made with filler metal equivalent to that used in the root pass Peening is prohibited Welding shall not be performed if there is impingement on the weld area of rain, snow, sleet or excessive wind or if the weld area is frosted or met. FILLET WELDS

50. Branch Connection

51. FABRICATION, ASSEMBLY & ERECTION PRE-HEATING Pre-heating is used to minimize the detrimental effects of high temperature & severe thermal gradients inherent in welding Required & recommended minimum heat temperatures are given in Table 330.1.1 If the ambient is below 0°C, the recommendations become requirements HEAT TREATMENT Heat Treatment is used to avert or relieve the detrimental effects of high temperature & severe gradients inherent in welding & to relieve residual stresses created by bending & forming Heat treatment shall be in accordance with the material grouping & thickness ranges as defined in Table 331.1.1 Governing thickness criteria is defined in para . 331.1.3 Fillet welds also required heat treatment as per para . 331.1.3 (b). Heat treatment is required when the thickness through the weld in any plane is more than twice the min. material thickness requiring heat treatment Hardness tests of production welds & of hot formed piping are intended to verify satisfactory heat treatment

52. FABRICATION, ASSEMBLY & ERECTION BENDING & FORMING Pipe maybe bent & components maybe formed by any hot or cold method suitable for the service. The finished surface shall be free of cracks & buckling. Thickness after bending shall be not less than that required by the design. Both hot & cold bending is allowed provided that the heat treatment is carried out as per para . 332.4

53. FABRICATION, ASSEMBLY & ERECTION ASSEMBLY & ERECTION Alignment Piping Distortion - Any distortion of piping to bring it into alignment for joint assembly which introduces a detrimental strain in equipment or piping components is prohibited Cold Spring - To be discussed during PEP session on Flexibility Analysis Flanged Joints - Before bolting up, flange faces shall be aligned to the design plane within 1mm in 200mm measured across any diameter; flange bolt holes shall be aligned within 3mm maximum offset. Flanged Joints Tightening of bolts to a predetermined torque is recommended Bolts should extend completely through their nuts. Any which fails to do so are considered acceptably engaged if the lack of complete engagement is not more that one thread No more that one gasket shall be used between contact faces in assembling a flanged joint Threaded Joints Sealing compound used on threads shall be suitable for the service conditions & pipe material Joints to be seal welded shall be made up without sealing compound A leaking threaded joint maybe seal welded provided all compound is removed from exposed threads

54. FABRICATION, ASSEMBLY & ERECTION ASSEMBLY & ERECTION (Cont’d) Tubing Joints Both flared & flareless (compression type) tubing joints are permitted Cleaning of Piping Refers appendix-F, para . F335.9 (Appendix-F is for guidance)

55. Inspection, Examination & Testing 55

56. INSPECTION, EXAMINATION & TESTING B 31.3 distinguish between Examination & Inspection Examination Applies to quality control functions performed by the manufacturer (for components only), fabricator or erector. Responsibility for Examination Providing materials, components, and workmanship in accordance with this code Performing all required examinations Preparing suitable records of examinations & tests for the Inspector’s use Inspection Applies to functions performed for the owner by the owner’s Inspector or the Inspector’s delegates. Responsibility for Inspection It is the owner’s responsibility, exercised through the owner’s Inspector Verify that all required examinations & testing have been completed Inspect the piping to the extend necessary to be satisfied that it conforms to all applicable examination requirements of the Code and of the engineering design Qualification of Owner’s Inspectors Defined in para . 340.4

57. INSPECTION, EXAMINATION & TESTING INSPECTION & EXAMINATION (Cont’d) Examination Requirements Prior to initial operation each piping installation, including components & workmanship shall be examined (in accordance with para 341) Extent of Required Examination Visual Examinations Sufficient materials & components, selected at random, to satisfy the examiner that they conform to specifications and are free from defects At least 5% of fabrication for welds, each welder’s work shall be represented 100% of fabrication for longitudinal welds except those in components made in accordance with a listed specification Random examination during erection of piping including checking of alignment, supports & cold spring Examination of erected piping for evidence of defects that would require repair or replacement and for other evident deviations from the intent of the design Other Examinations Not less than 5% of circumferential butt & miter groove welds shall be examined fully by random radiography or ultrasound The welds to be examined shall be selected to ensure that the work product of each welder doing the production welding is included

58. INSPECTION & EXAMINATION (Cont’d) Examination - Severe Cyclic Conditions More stringent inspection requirement (refer para . 341.4.3) Acceptance Criteria For welding, refer Table 341.3.2. For others, as per engineering design INSPECTION, EXAMINATION & TESTING

59. Testing Requirements for Leak Test Preparation of Leak Test Test Fluid Test Pressure Hydrostatic Testing of Piping with Vessel as a System Pneumatic Leak Test

60. INSPECTION, EXAMINATION & TESTING TESTING Required Leak Test Prior to initial operation, each piping system shall be tested to ensure tightness. The test shall be hydrostatic leak test in accordance with para . 345.4. Where the owner considers a hydrostatic leak test impracticable, either a pneumatic test or a combined hydrostatic-pneumatic test maybe substituted. Where the owner considers both hydrostatic & pneumatic leak testing impracticable, the alternative specified in para . 345.9 maybe used Para. 345.9 - Alternate Leak Test 100% Examination of longitudinal, circumferential & spiral groove welds by radiography 100% Examination of structural attachment welds by PT or MP Carry out formal flexibility analysis General Requirement for Leak Test Test pressure should not exceed beyond Yield Strength Precaution should be taken for over pressurization due to fluid thermal expansion Test shall be maintained for atleast 10min. for leak detection Piping sub-assemblies may be tested either separately or as assembled piping A flanged joint at which a blank is inserted to isolate other equipment during a test need not be tested Piping subject to external pressure shall be tested at an internal gage pressure 1.5 times the external differential pressure, but not not less than 15 psi.

61. INSPECTION, EXAMINATION & TESTING TESTING (Cont’d) General Requirement for Leak Test (Cont’d) Jacketed Lines - The internal line shall be leak tested on the basis of the internal or external design pressure, whichever is critical. The jacket shall be leak tested separately. If repair or additions are made following the leak test, the affected piping shall be retested, except that for minor repairs or additions the owner may waive retest requirements when precautionary measures are taken to assure sound construction Preparation for Leak Test All joints to be leak tested are to be left un-insulated & exposed for examination during the leak test Piping designed for vapor or gas shall be provided with additional temporary supports, if necessary, to support the weight of test liquid Equipment which is not to be tested shall be either disconnected from the piping or isolated by blinds or other means during the test. A valve maybe used provided the valve (including its closure mechanism) is suitable for the test pressure Test Fluid The fluid shall be water unless there is the possibility of damage due to freezing or to adverse effects of water on the piping or the process (see para . F345.4.1 ). In that case another suitable nontoxic liquid may be used. If the liquid is flammable, its flash point shall be at least 49°C (120°F), and consideration shall be given to the test environment.

62. INSPECTION, EXAMINATION & TESTING TESTING (Cont’ d ) Test Pressure Shal l no t b e les s tha n 1. 5 time s th e tes t p r essur e a t a n y poin t in th e system Fo r desig n tempe r at u r e a b ov e th e t es t t e mpe r at u r e , th e mi n i mu m tes t p r essu r e shall be calculated by eqn-24, page-83. T es t p r essur e shoul d no t ex ceed beyond Yield Strength Hyd r ostatic Test of Piping w i th Vessels as a System W h ere the t es t p r ess ure o f p i p i n g att a ched to a vessel is t h e same as or less than th e t es t pressu r e fo r th e vessel , th e pip i n g may b e tes t e d w i th th e vesse l a t the pi p i n g tes t pressure W h e r e t h e t es t p r essu r e o f th e pi p in g excee d s th e vesse l tes t pressure , an d i t is not cons i d e r e d p r acticabl e to i s ola t e th e pipi n g from th e v esse l, th e p i p i n g an d the vessel may b e t e sted together at t h e v e sse l tes t pressure , prov i d e d th e owner approve s an d th e v esse l tes t p r essu r e i s no t les s th a n 77% o f th e pipin g tes t pressu r e calculat ed i n b y eqn-24 , page- 83.

63. INSPECTION, EXAMINATION & TESTING TESTING (Cont’ d ) P n euma t ic Le a k Test Pneuma t ic tes t i n g in v o lves the hazard of released energy s t ored in c ompressed gas. A pressur e rel i e f devic e shal l b e pro v i d e d , hav i n g a se t pressur e no t highe r than th e t es t pressu r e plu s th e lesse r o f 50ps i o r 10% o f th e t es t pressu r e T es t Flu i d - Th e g a s , i f no t a i r , shal l b e nonflammabl e an d nontoxic T es t P r essur e - 1 1 0% o f th e d esig n pressu r e

64. QUESTION Why is “B31.3” called B31.3? In 192 6 th e A m erica n S t an da rd s Assoc i atio n (ASA ) i n it i a t e d th e B3 1 Pro j ec t a t the r eques t o f th e America n Soc i et y fo r Mec hanical Engineers (ASM E ) . A t that time, there were 31 known formulae for the calcula t ion of p ipe t h i c knesses. On e o f th e pr i me tas k o f B3 1 pro j ec t team was to analy z e/ t e st these formulae to establis h th e mos t appropr i ate / accep t abl e formul a fo r th e pip e thi c kness calculation