PLANT PIPING PRESSURE TESTING

(EXAM FOR INSPECTORS PERFORMING TEST PKG & SIS SHEET CALCULATION REVIEWS)

1. In pressure testing, what piping system component (pipe, fitting, flange, valve) is usually the
limiting factor in a Pressure Test? Choose the correct element from the four choices given!

Answer: The “flange” is the correct answer.

Note: Valves have flanges … When a Valve is included in the test package, valve is also correct.

2. Match the piping system component to the correct ASME standard for pressure test “ratings”:
 Flanges ASME B16.5
 Large flanges above 24” ASME B16.47
 Valves ASME B16.34
 Piping ASME B31.3
 Fittings ASME B31.3

3. Plant piping (API spec 5L) comes from the manufacturer in different forms, True or False …
Name at least two forms of API 5L Pipe

Answer: True … Seamless pipe and rolled / welded plate

4. When calculating required test pressure for a given piping diameter, the calculation for both
Seamless piping and welded plate is the same … True or false? Why?

Answer: False
Reason: Value “t” in the pressure test Formula is represented as follows:
Note 1: This is nominal wall thickness less 12.5 % mill tolerance for seamless pipe
Note 2: This is nominal wall thickness less 0.10” tolerance for welded plate
Example 1: 24 inch standard wall seamless pipe (.375”) less 12.5% = .328” = “t”
Example 2: 24 inch standard welded plate (.375”) less 0.10” = .365” = “t”

5. Formula for determining test pressure when checking “limiting factor” for all piping diameters
to be tested in a given test package (ASME B31.3 Plant Piping) and listed in the SIS sheet is:

P = t x 2S (0.9) (E) / D … True or False?

Answer: True

Using the Saudi Aramco pressure testing Formula above:

A) What does “S” represent (what value is used?)

Answer: S = Stress Values from ASME B31.3 Table A-1

Example: API 5L Gr. B has a SMYS of 35,000, therefore S = 35,000
Example: API 5L Gr X-60 has a SMYS of 60,000, therefore S = 60,000

B) What does “E” represent (what value is used?)

Answer: E = Quality Factor from Table A-1A or Table A-1B
Example 1: Quality factor for API 5L Gr. B Seamless Pipe is 1.00, therefore E = 1.00

C) Suppose your piping is API 5L Spec “Welded Pipe” … not seamless pipe!
What quality factor “E” would you use in your formula and where can this be found?

Answer: This is found on the mill test certificate (Longitudinal Weld Joint, etc)

Also, this is found in Table 302.3.4 of ASME B31.3

Generally, we will use 1.0 for this value, but NEVER Assume this!

D) API Pipe has tolerances for wall thicknesses. Below is Table 9 from API Spec 5L

What value would be used for calculations where “ t ” = … Assume API X60
1. .500” … 48 – inch pipe SAW
2. .375” … 24 – inch pipe Seamless
3. .250” … 12 – inch pipe Seamless
Answers:
1. .460”
2. .338”
3. .219”
Example 1: A typical Carbon Steel Class 150 # system (Proposed for Hydrotest at 450 psi,
limiting factor = flange)
1. A test proposes isolation against a closed valve (gate, ball or plug type). Valve has passed a
body & seat test.
2. Calculations are made to determine if a test against the valve seat is allowable per SAES-A-
004, Section 7.3
• A 150 # steel gate valve (Refer to ASME B16.34, Group 1.1 Materials tables & Section 7
Pressure Testing & API 598 Table 3 & Table 4) has working pressure design rating of 285 psi.
• Determine Valve body Hydrotest value. Design x 1.5, round up to next 25 value (285 x 1.5 =
427.5 = 450 psi)
• Determine Valve Seat/Closure Test pressure. Design = 110% or 1.1 per API 598 Table 3 (285 x
1.1 = 313.5 psi).
• Determine hold time for seat test. Refer to API 598 Table 4. Closure test = 1 minute (valves to
12” NPS)
Result … Do not allow a 30 minute Hydrotest at 450 psi against the valve seat (because over
pressurization results).
6. Sample Hydrotest calculation (package review)
CS Class 150 # Raw Water 12LEOU (hydro test at 450 psi per SIS, limiting factor = flange)
System has Fusion-bonded epoxy (FBE) internally coated piping & valves (check & gate) for corrosive
water service. System (ISOs & SIS information match) Design Pressure = 190 psi at Design temperature of
100F. Piping is shown on drawings to be API 5L, Gr B seamless pipe 24” Standard or .375” nominal wall,
also 12” Standard or .375” Pipe flanges are ASTM A 105, forged CS, per ASME 16.5. A 150 # gate valve
in this service is Ductile iron ASTM A395 epoxy lined body, Bolted Bonnet, ASTM B61/B62 bronze trim.
A 150 # check valve in this service is Ductile iron ASTM A395 epoxy lined body, Bolted Cover, ASTM
B61/B62 bronze trim. Note: The system test will cover three open gate valves, one check valve (internals
removed for test), and one closed gate valve at the outer test limit.

Quick Calc Steps:

1. Do not accept a test in 150# system against a closed 150# valve (typical)
Do not accept the proposed test against a closed gate valve. Perform thorough review even after finding an
error.
2. Determine Flange Pressure ratings as follows:
• Pipe flg limiting factor per ASME B16.5 (Table 1-A, Mat'l Group 1.1 = ASTM A 105) Press Temp
Rating Table 2-1.1
• Working pressure rating for Class 150 systems @ temp of 100 F = 285 psig (multiply value by 1.5 per
Section 8.3)
• 285 x 1.5 = 427.5, round up to next increment of 25 = 450 psig (acceptable, as our listed limiting factor is
450 psi)
3. Determine Valve Pressure ratings by checking ASME B16.34 OR API 598 Table 2 & 3
Note: Class 150 Ductile Iron = 400 psig per Table 2 (shell test) & 250 psig (high pressure seat closure test)
ACTIONS: Do not accept 450 psig test pressure. Class 150 valves (ductile iron) are tested to 400 psig (250
at seat).
B) Request a test pressure reduction to 400 psig and test limit revision & proceed with review, even after 2
errors.
4. Determine piping Pressure ratings as follows in the following code formula based on 90% SMYS (per
SA):
Use ASME B31.3 code formula t = PD / 2SE & SA requirement of 90% SMYS values for strength test
calcs.

Formula for pressure is P = t x 2S (0.9) (E) / D

S = Stress Values from ASME B31.3 Table A-1 (API 5L Gr. B has a SMYS of 35,000) therefore S =
35,000
t = pipe thickness (nominal less 12.5 % mill tolerance for seamless pipe, less 0.10”, welded plate)
Therefore .375” x 87.5%, t = .328” for both 12” & 24” seamless pipe
P = unknown & E = Quality Factor from Table A-1A or Table A-1B (Quality factor for API 5L Seamless
Pipe is 1.00), therefore E = 1.00
D = outside diameter of piping (all sizes are considered in calcs), therefore 2 calcs will be performed, one
for 24” and the other for 12”
Calc for 12” pipe ... P=.328 x (2)(35,000)(0.9) / 12 = 1,722.66 or 1,723 psi is rating for limiting factor for
12” pipe
Calc for 24” pipe ... P=.328 x (2)(35,000)(0.9) / 24 = 861.33 or 861 psi is rating for limiting factor for 24”
pipe
Notice how pipe diameter affects pressure! Neither pipe size is near our 400 psi limiting factor
5. Check FBE internal coating spec (APCS 101) pressure rating of 5,000 psi per SAES-H-002, OK!
ACTION: Review Complete. Return test package to Engineering.
Test pressure and arrangement are unacceptable:
1. Test pressure of 450 psig is unacceptable as Ductile Iron Valves are rated for 400 psig.
2. Use of a closed ductile iron valve at test limits is unacceptable.
Recommendation: Reduce Test pressure to 400 psig. Test valves in open position with blind at test limit.