As 4041-1998 Amdt 1-2001 Pressure Piping

Title
AS 4041-1998/Amdt 1-2001 Pressure piping
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Licensed to on 18 Jan 2002
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AS 4041/Amdt 1/2001-04-05
STANDARDS AUSTRALIA
Amendment No. 1
to
AS 4041 — 1998
Pressure piping
REVISED TEXT
The 1998 edition of AS 4041 is amended as follows; the amendment(s) should be inserted in the appropriate
place.
SUMMARY : This Amendment applies to Preface, Clauses 1.1, and 1.2, Tables 1.3 and 1.4, Clauses 1.7.12,
1.7.39 (new), 1.7.40 (new), 1.7.41 (new), 1.11.1, 1.17, 2.2.1, 2.6.10, 2.6.11 (new), 2.11.6.3, 3.6.2, 3.11.7,
3.12.2 and 3.12.3, Table 3.14.2, Clause 3.15.2.2, Table 3.15.2.2, Clauses 3.19.7.3 to 3.19.7.7, 3.19.8.2,
Figure 3.19.8.2, Clauses 3.19.8.4, 3.19.9.2 to 3.19.9.5, Figure 3.19.9.2, Clauses 3.23.2.2, 3.23.2.3, 3.23.4,
3.24.3.5, 3.25.2.1, 3.25.5 (new), 6.5.1, 6.5.2 and 6.6 to 6.10 and Appendices A, D, G, J, L and U.
Published on 5 April 2001.
AMDT Page 2 Preface

No. 1
APR.
2001 Delete last sentence and substitute the following:
Licensed to on 18 Jan 2002. Single user licence only. Storage, distribution or use on network prohibited.
The traditional value of 1.5P applies for steam and water piping for steam boilers only.
AMDT Page 7 Clause 1.1

No. 1
APR.
2001 Add new second paragraph as follows:
The Standard makes extensive use of AS/NZS 3992, AS 4037 and AS 4458.

No. 1
APR.
2001 Item (e), delete ‘AS 3920.1’ and substitute ‘AS 4343’.
AMDT Page 9 Table 1.3

No. 1
APR.
2001 Delete Table 1.3 including Legend and Notes and substitute the following:
ISBN 0 7337 3577 0

AMDT TABLE 1.3
No. 1
APR.
2001 PIPING CLASSIFICATION (See Notes 1 and 2)
Limit or requirement
Description and Class 2
Item No. Class 1 Class 3
Clause reference piping
piping piping
2A 2P
1 MATERIAL - (See Section 2)
1.1 Steels designated for pressure Any C,
C,
purposes C-Mn
C-Mn,
austenitic and ferritic- C,
austenitic and
austenitic stainless steel, C-Mn
ferritic-austenitic
3½% Ni,
stainless steel
1Cr-½Mo
Ductile iron (Clauses 2.3.2,
See Table 2.6.3.4
2.6.3.4)
Non-ferrous metals
Any Any Not permitted Any
(Clauses 2.6.3.5 to 2.6.3.8)
Structural pipe and structural Any with
Not permitted Not permitted
steel (Clause 2.2.4) appropriate tests
1.2 Seamless, hot finished (HFS),
Both permitted
or cold finished (CPS)
1.3 Continuous welded (CW)
(In America this is called BW) Permitted to 260°C (see
Not permitted Permitted Permitted
(Clause 2.6.10)(Weld Joint Factor Clause 2.6.10)
Table 3.12.2)
1.4 Electric resistance welded (ERW) Permitted with weld joint factor listed in Table 3.12.2
Cold-drawn electric-resistance-
welded (CEW)
1.5 Welds with filler metal added Permitted with weld joint factor listed in Table 3.12.2
2 DESIGN (See Section 3)

2.1 Design temperature (excluding
material limitations) °C:
(a) Maximum None 400°C 99°C 180°C
(b) Minimum (MDMT see ≥ MDMT + 20°C;
≥ MDMT ≥ MDMT 0°C
Clause 2.11) and ≥ − 100°C
Determination (Clauses 3.3, 3.9.4,
3.9.5, 3.9.7, 3.9.8.3, 3.9.9)
2.2 Design pressure (excluding Pressure limits across classes depends upon the fluid type (see Table 1.4)
material limitations) Determination of design pressure (see Clauses 3.2, 3.9.1, 3.9.2, 3.9.3, 3.9.5, 3.9.6, 3.9.8.1)
2.3 Design strength at room Lower of: Lower of: Lower of:
temperature for C and C-Mn
Re Rm Re Rm 0.72 R e20 Re Rm
steels (See Note 5) or or or
(Clause 3.11) 1.5 2.35 1.5 2.35 1.5 2.35
2.4 Design factors

0.7 (see Item 7 in
Class design factor, (M) 1 1
this Table)
Weld joint factor, (e) 1.0 min. 0.6 min. 0.6 min. (See
(Clause 3.12) Clause 3.14.3(a))
2.5 Flexibility assessment Required Required
(Clauses 3.4 to 3.8 and 3.27.2.2)
Analysis (Clause 3.11 and 3.27) If required If required
2.6 Fatigue assessment (Clauses 3.4 Required Required
to 3.8) Not required
Analysis (Clauses 3.11.7, 3.11.8) If required If required
(See end of Table for Notes) (continued)
TABLE 1.3 (continued)
piping piping
2A 2P
2.7 Welded branch connection (Clauses 3.19, 3.20)
Minimum included angle 60° (or 45° when
45°
(Clause 3.19.1) agreed)
External non-integral
Not permitted without
reinforcement Permitted
detailed analysis
(Clause 3.19.8.1, 3.20.3)
Partial penetration or fillet weld Not permitted without Not permitted without Permitted by
Permitted
(Clause 3.20.3.2) detailed analysis detailed analysis agreement
2.8 Pipe joint (See Note 6) (Clause 3.24)
Butt weld (Clause 3.24.2.1) Permitted
Partial penetration butt welds
Not permitted Not permitted Permitted
(Clause 3.24.2.6)
Socket weld (Clause 3.24.2.3) Permitted below DN 65 Permitted
Sleeve weld (Clause 3.24.2.4) Not permitted Permitted
Bell and spigot (Clause 3.24.2.5) Not permitted Permitted
Permitted T ≤495°C
Threaded joints (Clause 3.24.3) Permitted by Permitted
agreement T >495°C
Flanged (Clause 3.24.4) Permitted
Flared, flareless and compression
Permitted when used within manufacturer’s recommendations, DN 25 practical upper limit
fittings (Clause 3.24.5)
Caulked (Clause 3.24.6) Not permitted Permitted
Permitted below
Soldered (Clause 3.24.7) Not permitted Permitted below 75°C Not permitted
75°C
Brazed (Clause 3.24.8) Permitted up to 200°C
2.9 Bend (Clause 3.15)
Mitre (Clause 3.15.4) Permitted cut ≤15° Permitted
Cut and shut (Clause 3.15.5) Not permitted Permitted
Wrinkle (Clause 3.15.3) Not permitted Permitted
Ovality (Clause 3.15.2.3) ≤10% ≤12%
2.10 Non-pressure attachment (Clause 3.23)
Not permitted without
Permitted by agreement
Partial penetration or fillet weld detailed analysis Permitted
T >250°C
T >250°C
3 WELDING (Includes brazing, see AS 4458, AS/NZS 3992 and Note 3)
3.1 Personnel requirements Option 1 or Option 2 Option 1 or Option 2
Welder certification (AS 1796) Required Not required Not required Required
Welder qualification
Required Required Required Not required
(Clause 6.3)
Welding supervisor (AS 1796) Not required Required Not required Not required
Welding procedure qualification
3.2 Required (except as provided for in Item 3.3)
(Clause 6.3)
Permitted but be subject to partial re-qualification
3.3 Prequalified welding procedure
e.g. welder qualification
Permanent backing ring
3.4 Not permitted Permitted
(Clauses 2.9.1, 3.20.3.4, 3.24.2.1)
3.5 Fit-up (AS 4458) Close limits Medium limits Wide limits
3.6 Criteria for weld quality Very high High Reduced
3.7 Dissimilar joints Permitted
(continued)
TABLE 1.3 (continued)
piping piping
2A 2P
4 EXAMINATION AND TESTING (See Section 6)
4.1 Visual 100%
4.2 Penetrant 0 to 100% 0 to 10% Not required
4.3 Magnetic particle 0 to 100% 0 to 10% Not required
20 to 100% 0 to 10%
4.4 Radiographic or ultrasonic Not required
(see AS 4037) (see AS 4037)
Alternatives to
Pressure tests: (Clause 6.6)
Item 4.5 include
4.5 Hydrostatic pressure test Normally required (for alternatives see Clause 6.8)
Items 4.6, 4.7 and
(Clause 6.7)
4.8)
Pneumatic pressure test
4.6 Permitted by agreement
(Clause 6.8.1)
Permitted in
Initial service leak test conjunction with other Permitted in conjunction with other tests
4.7 Permitted
(Clause 6.9) tests by agreement (Clause 6.8.2 and 6.8.3)
(Clause 6.8.3)
Required where Required where
4.8 Sensitive leak test (AS 4037) Not required
specified (Clause 6.8.3) specified (Clause 6.8.3)
4.9 Material test certificate Required Normally required Not required
4.10 Marking (Clause 8.3.2) Required Normally required Not required
5 INSPECTION (Depends on hazard Not normally
Required Normally required
level) (Section 8) required
6 CONTROLS
6.1 Pressure control tolerance +10% +15%

6.2 Design temperature control + Half the appropriate temperature + Double Class 1
tolerance (see Note 4 ) interval in Table D2 for the material and 2 entry, i.e.
100% of appropriate
temperature interval
7 COPPER PIPING For copper piping joined by brazing, refer to Ruling PE/1 update No. 1 (February 1999) to AS 4041 — 1998,
Enquiry No. 109/99
LEGEND:
MDMT = material design minimum temperature (see Clause 1.7)
Re = (see Clause 1.7).
Rm = (see Clause 1.7).
NOTES:
1 This Table outlines the basic difference between the classes, and reference should be made to the text for full details.
2 Materials, design, welding, examination and testing and inspection are shown as ‘permitted’ on the basis that such
items comply in all other respects with this Standard.
3 Welding is taken to include brazing and soldering unless otherwise specified. For detailed requirements, see AS 4458
and AS/NZS 3992.
4 Applies generally except as provided by Clauses 3.4, 3.9.5 and 3.10.3 for the creep range. Examples of the Class 1
upper temperature control tolerance for API 5L B pipe for the listed maximum temperatures are given below:
Maximum Class 1 tolerance

temperature, °C °C
75 +25
405 +5
475 +5
5 See Appendix D design strength and Appendix I determination of design strength.

6 See Clause 2.6.2 for possible effect of joint in corrosion performance.
AMDT Page 12 Table 1.4
No. 1
APR.
2001 Delete Table 1.4 including Footnote and Notes and substitute the following:
TABLE 1.4
APPLICATION OF PIPING CLASSES FOR SERVICE CONDITIONS
Service limits for following classes

Service conditions (see AS 4343) Class 3
Class 1 Class 2A Class 2P
(see Note 1)
Gas No service
1 Lethal Prohibited
Liquid limit
Design Very Gas No service 10 MPa max. Prohibited 2 MPa max.

pressure 2 harmful
Liquid limit 10 MPa max.
for fluid
type (see Gas 10 MPa max. Prohibited 4 MPa max.
Note 2 No service
3 Harmful
and Liquid limit No service limit No service limit
Clause
3.2) Prohibited
Gas No service limit
No service No service limit
4 Non-harmful
limit No service No service limit
Liquid
limit
Maximum No service
400°C 99°C 180°C
limit
Design temperature Minimum No service
(see Clause 3.3) limit (see No service limit (see −100°C (see Item 2.1 of
0°C
Item 2.1 Item 2.1 Table 1.3) Table 1.3)
Table 1.3)
No service limit except

Nominal size No service No service
All material No service limit DN 150 max. for Type 2
(see Clause 1.7.21) limit limit
fluid
Carbon steel
Low alloy
steel
No service
Max. High alloy See Table 3.14.2
limit
steel
Non-ferrous
metal
Nominal wall
Carbon steel
thickness (see
Low alloy
Clause 3.14.2)
steel
See Clause
High alloy See Clause 3.14.2(b)
3.14.2(a)
Min. steel
Non-ferrous
metal
Ductile &
Prohibited No service limit
cast iron
NOTES:
1 See Clause 3.24.2.6 for relaxation for low hazard service.
2 As an example, steam above 90°C is fluid No. 3.
AMDT Page 14 Clause 1.7.12
No. 1
APR.
2001 Delete ‘AS 3920.1’ and substitute ‘AS 4343’.
AMDT Page 17 Clause 1.7.39 (new)

No. 1
APR.
2001 Insert new definition as follows:
1.7.39 Assemblies — a collection of individual components joined together.

No. 1
APR.
1.7.40 Gas — a substance which is completely gaseous at 20°C and 101.3 kPa absolute
or at 50°C has a vapour pressure greater than 300 kPa.
For this Standard, gas also includes:
(a) Compressed gas which is entirely gaseous at 20°C and 101.3 kPa absolute.
(b) Liquefied gas which is partially liquid at 20°C.
(c) Refrigerated liquefied gas which is partially liquid because of its low temperature.
(d) Gas in solution which is a compressed gas dissolved in a solvent.
(e) Any liquid when it is above its atmospheric pressure boiling point, e.g. pressurized
high-temperature water which flashes to steam on release of pressure.
(f) Fluidized solids in compressed air or other gas.

No. 1
APR.
1.7.41 Liquid — any substance below its atmospheric pressure boiling point, e.g. water
<100°C. Liquid also includes solids fluidized in liquids, e.g. slurries.

No. 1
APR.
2001 Delete ‘AS 3920.1’ and substitute ‘AS 4343’.

No. 1
APR.
2001 Delete clause and substitute the following:
1.17 DIMENSIONAL AND MASS TOLERANCES Dimensional and mass
tolerances for pipe, components and assemblies shall comply with the tolerances —
(a) provided with the material component specification;
(b) according to AS 1210 for assemblies;
(c) specified in engineering drawings; or
(d) as otherwise agreed by the parties concerned.

No. 1
APR.
2001 Item (a), add new sentence as follows:
Pipes fabricated in accordance with AS 1210 or equivalent Standard.
No. 1
APR.
2001 Item (f), add new sentence as follows:
Fittings fabricated in accordance with AS 1210 or equivalent Standard.

No. 1
APR.
2001 Delete clause and substitute the following:
2.6.10 Limit of application of pipe made by the CW (BW) process Pipe made by
the CW (BW) process, i.e. continuous weld and furnace butt weld (see Table 1.3) is
limited by this Standard to Classes 2 and 3 and if the pipe is produced to AS 1074, only
Medium and Heavy pipes are permitted. The minimum thickness may be calculated using
the appropriate stress value from Table D2, a weld joint factor of 0.6 and a class design
factor selected from Table 1.3. Additionally, the maximum design condition that medium
and heavy pipe can be used for is 2.0 MPa and 260°C.

No. 1
APR.
2001 2.6.11 Limit of application of AS 1074 pipe Pipe to AS 1074 is limited by this
Standard to Classes 2 and 3. The minimum thickness may be calculated using the
appropriate stress value from Table D2, and a weld joint factor of 0.85 for ERW and a
class design factor selected from Table 1.3.
AMDT Page 47 Clause 2.11.6.3

No. 1
APR.
2001 Item (b), fourth paragraph, delete ‘nominal0’ and substitute ‘nominal’.

No. 1
APR.
2001 Delete ‘FEMA’ and substitute ‘FMEA’.

No. 1
APR.
2001 Delete from ‘F = stress range reduction factor . . .’ to end of Clause and substitute the
following:
F = stress-range reduction factor for the total number of displacement
cycles over the design lifetime. See Table 3.11 or calculate using
equation:
F = 6(N)−0.2 but ≤1.0
N = equivalent number of full displacement cycles during the
expected service life of the piping system
fc = design strength at the minimum metal temperature expected during
operation or shutdown, in megapascals (see Note)
fh = design strength at maximum metal temperature expected during
operation or shutdown, in megapascals (see Note)
fL = sustained longitudinal stress, in megapascals.
In the determination of fa, the value of the weld joint factor (e) shall be taken as unity.
Rm ReT
In no case shall the value exceed the minimum of and 2 at minimum metal
3 3
temperature (see Appendix D).
No. 1
APR.
2001 Item (d), delete piping class ‘3’ and substitute ‘2, 3’.
AMDT Page 60 Table 3.12.3

No. 1
APR.
2001 Delete class design factor ‘0.6’ and substitute ‘0.7’.
AMDT Page 61 Table 3.14.2
No. 1
APR.
2001 1 Steel group C, Class 3 piping, delete ‘10’ and substitute ‘0’.
2 Steel group E, Class 3 piping, delete ‘10’ and substitute ‘0’.

No. 1
APR.
2001 Item (b), third line, delete ‘thickness t1’ and substitute ‘thickness ti’.

No. 1
APR.
2001 In the first sentence delete ‘where the more’.
AMDT Page 64 Table 3.15.2.2

No. 1
APR.
2001 In heading to Columns 2 and 3, delete ‘tb = 1.25tf’ and substitute ‘tb = 1.125tf’.

No. 1
APR.
2001 First paragraph, delete ‘greater’ and substitute ‘smaller’.

No. 1
APR.
2001 First paragraph, delete ‘(see Appendix K)’ and substitute ‘(typically MSS SP97 and see
Appendix K)’.

No. 1
APR.
2001 First paragraph delete ‘The nominal size of a small bore branch’ and substitute ‘The
nominal size of small bore branch pipe, socket or coupling’.

No. 1
APR.
2001 Item (a), delete ‘DN 50’ and substitute ‘DN 25’.

No. 1
APR.
2001 Item (a), delete ‘50 mm and’ and substitute ‘DN 25 or’.
No. 1
APR.
2001 1 First paragraph, delete ‘the effects of corrosion, erosion and other items specified
in Clause 3.13, nor does it illustrate any’.
2 Notation for Do, delete notation and substitute the following:
Dob = outside diameter of branch pipe, in millimetres
‘ ’
3 Notation for d1, delete [Dob − 2(tb − G)]
sin α
‘ ’
and substitute [Dob − 2(tb − G b)] .
sin α
4 Notation for d2, delete ‘  ’

 d1 
(tb − G) + (th − G) 
 2
‘ ’
substitute (t − G ) + (t − G ) d1  .
 b b h h 
 2
5 Notation for L, delete ‘2.5(tb − G) + tr or 2.5(th − G)’ and substitute
‘2.5(tb − Gb) + tr or 2.5(th − Gh)’.
6 Notation for tn, delete ‘tn’ and substitute ‘th’.
AMDT Page 79 Figure 3.19.8.2

No. 1
APR.
2001 Delete Items (a) and (b) and Notes and substitute the following:
AMDT
No. 1
APR.
2001
NOTES:
1 Reinforcing saddles are to be used only on 90° branches.
2 When a ring or pad is added as reinforcement (see Figure 3.19.8.2(b)), the value of reinforcing area may
be taken in the same manner in which excess material in the main pipe is considered, provided a full
penetration weld is used between the branch, main pipe, and ring or pad.
3 The ratio of the width to thickness of a ring and a pad shall be as close to 4:1 as the available horizontal
space allows within the limits of the reinforcing zone along the main pipe and the outside diameter of the
branch allows, but the ratio shall be not less than 1:1.
FIGURE 3.19.8.2 (in part) REINFORCEMENT OF BRANCH CONNECTIONS

AMDT Pages 80 to 81 Clause 3.19.8.4
No. 1
APR.
2001 1 Delete Equation 3.19.8.4(1) and substitute ‘ A7 = (tmh − G h)d1 (2 − sin α) ’.
2 Delete Equation 3.19.8.4(2) and substitute ‘ A7 = 0.5(tmh − G h)d1 (2 − sin α) ’.
AMDT Pages 82 to 84 Clauses 3.19.9.2 to 3.19.9.5 including Figure 3.19.9.2:

No. 1
APR.
2001 Delete Clauses and Figure and substitute the following:
3.19.9.2 Notation The notation is as follows (see also Figure 3.19.9.2):
Dc = corroded internal diameter of main pipe, in millimetres
Doh = outside diameter of main pipe, in millimetres
dc = corroded internal diameter of extruded outlet measured at the level of the
outside surface of the main pipe, in millimetres
H = height of the reinforcement zone, in millimetres
= 0.7(DobTo)1/2
K = factor determined by the ratio of branch diameter to main pipe diameter
(see Clause 3.19.9.4)
tb = actual (by measurement), or minimum wall thickness of branch pipe,
permissible in the pipe specification, in millimetres
th = actual (by measurement), or minimum wall thickness of main pipe,
permissible in the pipe specification, in millimetres
To = corroded finished thickness of extruded outlet, measured to a point on or
beyond the outside surface of the main pipe, in millimetres

Dob = outside diameter of branch, in millimetres
d1 = corroded inside diameter of branch, in millimetres
ho = height of the extruded outlet, in millimetres
≥ ro, (except as shown in Figure 3.19.9.2(b))
r1 = half-width of reinforcement zone, in millimetres
= dc
ro = radius of external contoured portion of outlet measured in the plane
containing the axes of the main pipe and branch (see Clause 3.19.9.3), in
millimetres
tmb = required wall thickness of branch, in millimetres
tmh = required wall thickness of main pipe, in millimetres.
3.19.9.3 Radius of external contour The radius of the external contoured portion of an
outlet (see Figure 3.19.9.2) shall comply with the following:
(a) Minimum value of ro:
(i) For outlet outside diameter ≤760 mm . . . . . . . . . . . . 0.05Dob mm.
(ii) For outlet outside diameter >760 mm . . . . . . . . . . . . 38 mm.
(b) Maximum value of ro:
(i) For outlet outside diameter <190 mm . . . . . . . . . . . . 32 mm.
(ii) For outlet outside diameter ≥190 mm . . . . . . . . . . . . (0.10Dob + 13)mm.
AMDT (c) More than one radius:
No. 1
APR.
2001 Where the external contour contains more than one radius, the radius of best fit of
any arc sector of 45° shall comply with Item (a) and the radius at any point shall
comply with Item (b).
Machining shall not be employed to achieve compliance with the requirements of
Items (a), (b), and (c).
3.19.9.4 Required reinforcement area The required reinforcement area is defined as

equal to K(tmh − Gh) dc, where K shall be determined as follows:
(a) For Dob/Doh ≤ 0.15 . . . . . . . . . . . . . . . . . . . . . . K = 0.70.
(b) For Dob/Doh > 0.15 and ≤ 0.60 . . . . . . . . . . . . . . K = 0.60 + 2/3 × (Dob/Doh).
(c) For Dob/Doh > 0.60 . . . . . . . . . . . . . . . . . . . . . . K = 1.00.
3.19.9.5 Reinforcement area The area required for reinforcement (AR) shall be A1 + A 2
+ A 3,
where
A1 = area lying within the reinforcement zone resulting from any excess
wall thickness available in the main pipe
= dc(th − tmh)
A2 = area lying within the reinforcement zone resulting from excess wall
thickness available in the branch pipe
= 2H(tb − tmb)
A3 = area lying within the reinforcement zone resulting from excess

thickness available in the extruded outlet lip
= 2ro(To − tb − Gb)
AMDT
No. 1
APR.
2001
NOTES:
1 Taper bore ID (if required) to match branch pipe 1:3 maximum taper.
2 Corrosion and other allowances are shown at bores.
FIGURE 3.19.9.2 REINFORCED EXTRUDED OUTLETS

No. 1
APR.
2001 Delete Clause and substitute the following:
3.23.2.2 Elevated temperature piping A partial penetration weld to join an attachment
for Class 1 piping is not permitted without detailed analysis for design temperatures
above 250°C.
A partial penetration weld to join an attachment may be permitted, with agreement by
the parties concerned, for Class 2A piping for design temperatures above 250°C.

No. 1
APR.
2001 Second line, delete ‘Class 2’ and substitute ‘Class 2P’.

No. 1
APR.
2001 1 Equation 3.23.4(2), delete equation and substitute:
R 6 We
q = ±
L L2
2 Delete Note and substitute the following:
NOTES:
1 Other methods given in WRC 198 and BS 5500 are also acceptable.
2 Due consideration should be given to the level of stress already in the pipe due to other
loads.
AMDT Page 92 Table 3.24.3.5

No. 1
APR.
2001 Row 2, ‘T ≤ 260’, Column 3 ‘Size range’, delete ‘DN36’ and substitute ‘DN32’.

No. 1
APR.
2001 Delete ‘2.25.2.1’ and substitute ‘3.25.2.1’.
No. 1
APR.
2001 Add new Clause as follows:
3.25.5 Piping located below ground level
3.25.5.1 General Piping which is to be located below ground level shall also comply
with this Clause (3.25.5). Such piping includes that installed in basements, cellars,
mines, trenches or directly in the ground in order to provide services below ground, or to
facilitate traffic on roads, or within buildings, or to protect piping from fire, sun or
external interference.
In all cases, appropriate provision shall be made for —
(a) prevention or collection, drainage and removal of significant leaks from piping,
particularly lethal and very harmful fluids and gases heavier than air which may
seriously deplete oxygen levels in working spaces or form combustible mixtures;
and
(b) removal of ground water or other material (e.g. silt or debris in open or covered
trenches) which would seriously affect the performance or safety of the piping.
3.25.5.2 Buried piping Piping buried directly in the ground should, if practicable, be
avoided particularly where contents are at temperatures above 100°C or below 5°C.
The design shall consider, and when necessary, make provision for —
(a) the soil and surface loads on the piping, particularly for low thickness/diameter
ratio or vacuum piping;
(b) suitable support against ground settlement or conditions which could damage the
piping or its protection coating;
(c) protection against external corrosion by suitable material selection, corrosion

allowance, coatings, clean fill, drainage or cathodic protection (see Clause 7.4).
(d) protection against stray current corrosion;
(e) appropriate means for pressure testing, inspection, internal cleaning, isolation,
drainage (slope) and detection of leaks which could cause significant losses or
hazards to personnel, plant or environment;
(f) possible rotation of piping which will encounter selective bottom erosion; and
(g) suitable markers and location plans to avoid external damage when modifying or
adding services and to facilitate inspection.
See AS 2885 for further guidance applicable to buried piping.

No. 1
APR.
2001 1 Delete ‘for all liquids are’ and substitute ‘is’.
2 Item (e), delete ‘2000 kPa’ and substitute ‘2 MPa’.
3 Item (e), delete ‘400 kPa’, and substitute ‘0.4 MPa’.

No. 1
APR.
2001 1 Second line after ‘spot non-destructive examination’ add ‘(other than visual
examination).’
2 Delete ‘Classes 2 and 3’ and substitute ‘Classes 1 and 2’.
AMDT Pages 130 to 132 Clauses 6.6 to 6.10
No. 1
APR.
2001 Delete Clauses 6.6 to 6.10 and substitute the following:
6.6 PRESSURE TESTS
6.6.1 General Pressure tests shall be conducted in accordance with AS 4037 and this
Standard.
A pressure test on piping is used to achieve the following:
(a) Detect leakage at components and joints.
(b) Assist in assessing the adequacy of the piping system design, materials and
fabrication, e.g. that there is sufficient wall thickness, and material strength.
(c) Partially relieve residual fabrication stresses and sometimes modify shape.
6.6.2 Types of pressure tests Piping shall pass one of the following tests as
appropriate. More tests may be specified by the manufacturer:
(a) Hydrostatic test (see Clause 6.7).
(b) Pneumatic test (see Clause 6.8.1).
(c) Initial service leak test (see Clause 6.9 for method of application and Clauses 6.8.2
and 6.8.3 for circumstances in which they are used).
(d) Increased non-destructive examination and leak test (see Clause 6.8.3).
(e) Proof hydrostatic test (see Clause 6.8.4).
Alternatives to a hydrostatic test should be considered where any of the following apply:
(i) The mass of the water would damage the pipe or its supports.
(ii) The test fluid would damage linings or internal insulation.
(iii) Residual moisture would contaminate or cause failure of a process or cause
corrosion or other unacceptable hazard.
(iv) Low metal temperature during the test would cause risk of brittle fracture (see
AS/NZS 3788 and AS 4037 for information on MDMT).
(v) New piping isolated from existing systems by a valve, in cases where water from
the hydrostatic test, if leaked past the valve, would seriously contaminate the
existing system.
An alternative to pneumatic testing should be considered when it would introduce an
unacceptable hazard from the possible release of stored energy, particularly if low metal
temperature during the test would lead to the risk of brittle fracture.
6.7 HYDROSTATIC TEST

6.7.1 Application A hydrostatic test shall be made on all piping except when other
tests are permitted in lieu by AS 4037 or Clause 6.8.
6.7.2 Test pressure The hydrostatic test pressure shall be calculated in accordance
with Appendix U. The hydrostatic test pressure at any point in the piping system shall
comply with the pressures specified. Additionally, the minimum test pressure required
for any service or material is specified in Paragraph U1.
The test pressure at any point includes any static hydrostatic head due to the test fluid.
NOTE: For guidance on testing pressure vessels and piping together, see Paragraphs U5 and
U7 for testing jacketed piping.
6.7.3 Hold period The test pressure shall be held for the time specified in
Table 6.7.3. The pressure in the piping shall then be dropped to 85–90% of the test
pressure for visual examination.
AMDT TABLE 6.7.3
No. 1
APR.
2001 HOLD PERIOD FOR HYDROSTATIC TEST
Minimum hold period, minutes

Nominal size Test pressure, kPa
≤700 >700
≤DN 300 10 15
>DN 300 20 25
6.8 ALTERNATIVE TO HYDROSTATIC TEST

6.8.1 Alternative to hydrostatic test by use of pneumatic testing As an alternative
to hydrostatic testing, and where agreed by the parties concerned, a pneumatic test may
be used. The test shall be conducted in accordance with AS 4037. The test pressure shall
be 90 percent of that specified in Clause 6.7.2.
6.8.2 Alterative to hydrostatic test by use of initial service leak test At the owner’s
option, piping is exempt from hydrostatic test when each of the following apply:
(a) The pipe is certified by the pipe manufacturer to a listed Standard as leak tight by
hydrostatic test or non-destructive examination method.
(b) The piping is made from material groups A1, A2, A3, A4, B, C, E, K, M or non-
ferrous.
(c) The design temperature is less than or equal to 180°C and greater than −30°C.
(d) The design pressure is less than 2 MPa if the hoop stress ≤0.5f or 1 MPa if the
hoop stress >0.5f.
(e) The fluid is either —
(i) fluid types 3 and 4;
(ii) steam; or
(iii) caustic soda or sodium cyanide solutions as used in the mining industry.
In lieu of a hydrostatic test, each of the following shall be carried out:
(i) 100% visual examination of all welds (see Table 8.4 and AS 4037 for form and
working omissions).
(ii) An initial service leak test in accordance with Clause 6.8A.
6.8.3 Alternative to hydrostatic test by use of increased non-destructive
examination and leak test
6.8.3.1 General Increased non-destructive examination and leak tests may be used in
lieu of a hydrostatic test for butt welds, branch welds, flange welds and minor
attachments as given in this Clause 6.8.3. Leak tests should be used on mechanical
joints.
6.8.3.2 Butt welds, branch welds and flange welds For Classes 1 and 2 piping, butt
welds, branch welds, and flange welds, including tie-in and cut-in-welds, may be
exempted from hydrostatic testing where these welds comply with each of the following:
(a) The pipe is certified by the pipe manufacturer to a listed Standard as leak tight by
hydrostatic test or a non-destructive examination method.
AMDT (b) Butt welds are located in straight pipe and are not less than one pipe diameter from
No. 1
APR. any branch connection or bend. This requirement does not apply to butt weld
2001 fittings covered in Clause 2.2.1(f).
Branch welds are located in straight pipe and are not less than one pipe diameter
from any butt weld or bend.
(c) They comply with the ovality requirements of this Standard.
(d) They are subject to 100% visual examination.
(e) They comply with appropriate non-destructive examination Standards for —
(i) 100% radiographic examination, plus either magnetic particle testing or
penetrant examination; or
(ii) 100% ultrasonic examination, plus either magnetic particle testing or
penetrant examination.
(iii) Fillet welded pressure welds (e.g. slip-on flange or socket weld fittings)
either 100% magnetic particle testing or 100% penetrant examination in
accordance with AS 4037.
NOTE: When Items (i) and (ii) are not practical, refer to Clause 6.5.3.
(f) Examinations (d) and (e) have been carried out after any postweld heat treatment
has been carried out.
(g) They comply with the limits of surface imperfection for piping given in AS 4037.
(h) They pass an initial service leak test (Clause 6.8A) or the sensitive leak test
(AS 4037). For lethal fluids it shall be the sensitive leak test.
For Class 3 piping, butt welds, branch welds and flange welds (including tie-in and cut-
in welds) are exempt from hydrostatic testing where the welds comply with the initial
service leak test. Any longitudinal welds shall be subject to 20% radiograhic or
ultrasonic examination including either magnetic particle testing or penetrant
examination.
6.8.3.3 Mechanical joints Mechanical joints used within their pressure rating for the
service conditions (e.g. bolting and screwing) may be exempted from hydrostatic testing
provided that the completed piping is subjected to —
(a) 100% visual examination;
(b) a sensitive leak test (see AS 4037) where the contents are fluid Types 1 or 2;
(c) an initial service leak test for piping other than Item (b); and
(d) the components being joined have been hydrostatically tested at the time of
manufacture or its equivalent.
6.8.3.4 Minor attachments The welding or brazing of minor attachments, such as
temperature and pressure tappings (DN 40 and below) and minor structural attachments,
are exempt from hydrostatic provided —
(a) they are subject to 100% visual examination;
(b) the joint is subject to 100% magnetic particle or penetrant examination to
AS 4037; and
(c) failure will not be detrimental to the piping in service.
6.8.4 Proof hydrostatic test Where the strength of components cannot readily be
calculated, the design pressure may be determined in accordance with the proof
hydrostatic test specified in AS 1210.
AMDT 6.8A INITIAL SERVICE LEAK TEST The initial service leak test when used shall
No. 1
APR. be made during or prior to the initial operation and after taking all necessary precautions.
2001 The leak test shall be made with the service fluid at the operating condition of the piping
by examining for leaks at each joint and connection not previously pressure tested in
accordance with this Standard. Where the pressurized fluid is gas or vapour, a
preliminary leak test shall be made at one-quarter operating pressure but not more than
200 kPa. When the process fluid is Type 2 (very harmful), it is recommended that the
preliminary leak test be carried out using an inert medium. The pressure shall then be
increased gradually in steps until the operating pressure is reached, holding at each step
long enough to equalize piping strain and check for leaks.
6.9 TESTING PRESSURE-LIMITING DEVICES, RELIEF VALVES, PRESSURE

REGULATORS, AND CONTROL EQUIPMENT Pressure-limiting devices, relief
valves, pressure regulators, and control equipment shall be examined for the following:
(a) Good mechanical condition.
(b) Adequate capacity, effectiveness, and reliability for operation of the intended
service.
(c) Proper functioning at the correct pressure and temperature.
(d) Proper installation, and protection from foreign materials or condition that may
prevent proper operation.
(e) Compliance with the relevant product Standard.
6.10 REPORT After Class 1 or 2 piping has been completed and tested, the
fabricator or manufacturer shall add to the manufacturer’s data report that the piping has
been tested in accordance with this Standard.
AMDT Page 140 Appendix A

No. 1
APR.
2001 1 Insert new reference ‘4343 Pressure equipment — Hazard levels’.
2 Delete reference AS 4037, substitute ‘AS 4037 Pressure equipment — Examination and
testing’.
AMDT Page 154 Appendix D

No. 1
APR.
2001 Insert new last paragraph as follows:
Design strengths at intermediate temperatures may be obtained by linear interpolation.
AMDT Pages 157–160 Table D2

No. 1
APR.
2001 1 Column 7, delete ‘fe (max.)*’ and substitute ‘fc, fh (max.)*’.
2 Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)’.
3 Yield strength 200 MPa, first row:
Column 14, insert ‘86’.
AMDT Page 161 Appendix D

No. 1
APR.
2001 Second paragraph, delete ‘Re 250’ and substitute ‘Re 240’.
AMDT Page 161 Table D4
No. 1
APR.
2001 Title, delete ‘Re 250’ and substitute ‘Re 240’.

No. 1
APR.
2001 1 Column 7, delete ‘fc (max.)* and substitute ‘fc, fh (max.)*’.
2 Footnote, delete ‘fc (max.)’ and substitute ‘f c, fh (max.)’.

No. 1
APR.
2001 1 Column 10, delete ‘fc (max.)* and substitute ‘fc, fh (max.)*’.

No. 1
APR.
2001 1 Column 10, delete ‘fe (max.)* and substitute ‘fc, fh (max.)*’.

No. 1
APR.

No. 1
APR.
1 Column 11, delete ‘fc (max.)* and substitute ‘fc, fh (max.)*’.
2001

No. 1
APR.

No. 1
APR.
2 Footnote, delete ‘fe (max.)’ and substitute ‘f c, fh (max.)*’.
AMDT Page 184 Table G1
No. 1
APR.
2001 Delete the entries first 5 columns under ‘Material’ for type ‘carbon steels’ and type ‘low
alloy steels 1Cr-0.2Mo’ and substitute the following:
Material
Dia.
Type Specification Grade Temper or size (mm)
(Note 1)
CARBON STEELS AS/NZS 1110 4.6 All
AS B 148 Class 2 All
AS 2465 2 All
AS/NZS 1110 5.8 All
AS 2465 5 >24
AS/NZS 1110 8.8 All
AS 2465 5 ≤24
AS/NZS 1252 — All
LOW ALLOY ASTM A 320 L7, L7A, ≤63
STEELS L7B, L7C
1Cr-0.2Mo
≤63
ASTM A 193 B7
63<t≤102
AMDT Page 192 Appendix J

No. 1
APR.
2001 1 Paragraph J2, Equation J2, delete ‘p = rG(B)½ × 10’ and substitute
‘p = rG(B)½ × 10−6’
2 Paragraph J3, first line, after ‘4f ’ insert ‘(where 4f is the Darcy friction factor)’.
AMDT Page 197 Appendix L

No. 1
APR.
2001 Paragraph L1, second paragraph after ‘angle’ insert ‘, γ (see Paragraph L2),’.
AMDT Pages 199–200 Appendix L

No. 1
APR.
2001 1 Equation L5(7), delete equation and substitute:
2t a 2t a
ε = or
d1 t a D1 − t a
2 Equation L5(11), delete equation and substitute:
p (d1 + t a)
Y =
2f1 e1 t a
AMDT Page 204 Figure L3
No. 1
APR.
2001  − 0.16957’  − 0.19449’
f  f 
Curve c, delete ‘x 0.90216  1  and substitute, ‘x 0.90216  1 
p p
AMDT Page 206 Figure L5
No. 1
APR.
2001 1 Delete ‘Z n’ and substitute ‘Zn’.
2 Delete ‘Bu + Cu2’ and substitute ‘Bu + Cu2’.
AMDT Page 264 Appendix U
No. 1
APR.
2001 Delete Appendix U and substitute the following:
APPENDIX U
HYDROSTATIC TEST PRESSURE
(Normative)
U1 GENERAL
U1.1 Scope This Appendix sets out requirements for the determination of hydrostatic
test pressure for various materials and service conditions. It also contains examples of
the calculation of hydrostatic test pressure for various piping types. See Paragraph U8.
U1.2 Requirements for hydrostatic test pressure The hydrostatic test pressure for
any service and system shall be the minimum of Items (a), (b) and (c), but shall not
exceed Item (c) as follows:
(a) Phcalc (see Paragraphs U2, U3, U4 and U6).
(b) The maximum test pressure for any component or in-line equipment except
pressure vessels. For pressure vessels see Paragraph U5.
(c) Phmax as calculated from Equation U1.2(1).
2t
Phmax = f h × . . . U1.2(1)
D
where
Phmax = maximum pipe hydrostatic test pressure, in megapascals

fh = 90% specified minimum yield strength at test temperature, in
megapascals
= 0.9 Re . . . U1.2(2)
D = measured (or maximum per purchase specification) outside diameter
of pipe, in millimetres
t = measured (or minimum per purchase specification) wall thickness, in
millimetres
Re = specified minimum yield strength at test temperature, in megapascals
U2 FERRITIC, AUSTENITIC AND FERRITIC-AUSTENITIC STEEL PIPING,

CLASSES 1, 2A AND 3
U2.1 Steam and water piping associated with steam boilers The calculated
hydrostatic test pressure shall be determined from the following equation:
Phcalc = 1.5 × P . . . U2.1(1)
where
Phcalc = calculated hydrostatic test pressure, in megapascals
P = design pressure, in megapascals
AMDT U2.2 For all other piping services The calculated hydrostatic test pressure shall be
No. 1
APR. determined from the following equation:
2001
Re
Phcalc = 0.83 × × P . . . U2.2(1)
f
where
Re = specified minimum yield strength at test temperature, in megapascals
f = design strength at design temperature, in megapascals
and
Re
Maximum value of 0.83 × 3.5 . . . U2.2(2)
f
NOTE: Equation U2.1(1) is based on BS 806. Some values of R e and f are listed in
Appendix D.
U3 FERRITIC STEEL PIPING CLASS 2P The calculated hydrostatic test pressure

for piping to Class 2P is Phcalc = 1.25 × P . . . U3(1)
where
U4 NON-FERROUS METALS The calculated hydrostatic test pressure shall be

determined from the following equation:
ft
Phcalc 1.5P
f . . . U4(1)
ft
except that shall not exceed 6.5,
f
where
ft = design strength at test temperature, in megapascals
f = design strength at design temperature, in megapascals
U5 PIPING AND PRESSURE VESSELS TESTED TOGETHER For piping

attached to a pressure vessel where the test pressure is not more than the test pressure for
the vessel, the piping may be tested with the vessel at the test pressure of the piping.
Where the test pressure of the piping is greater than the vessel test pressure and it is not
practicable to isolate the piping from the vessel, the piping and the vessel may be tested
together at the test pressure of the vessel provided that —
(a) the owner agrees; and
(b) the test pressure of the vessel is not less than 77% of the piping calculated test
pressure adjusted for temperature (see Paragraphs U2, U3 and U4).
U6 PIPING SUBJECT TO EXTERNAL PRESSURE Piping subject to external

pressure in service shall be tested to an internal hydrostatic test pressure of the maximum
of Items (a) and (b) but shall not be less than Item (b) as follows:
(a) Phcalc = 1.5 Pdiff . . . U6(1)
AMDT where
No. 1
APR.
2001 Pdiff = differential design pressure, in megapascals
(b) 100 kPa.
U7 JACKETED PIPING The test pressure for internal piping of jacketed piping
shall be determined according to the internal or external design pressure, whichever is
critical using Paragraph U1. The test shall, if necessary, be performed before completion
of the jacket so that any joints of the internal piping can be visually inspected.
The test pressure for the jacket shall be determined in accordance with Paragraph U1 and
according to the design pressure of the jacket, unless otherwise limited in the
engineering design.
U8 EXAMPLES
Example 1: Paragraph U2
Service = other than steam or water
Pipe specification = API 5L B
Class = 1 or 2A
Temperature = 50°C
Design life = indefinite
Size = 273 × 4.8
Max. OD = 273 mm
Min. thickness = 4.8 mm

Re = 241 MPa (from Table D4 or material specification)
Rm = 413 MPa (from Table D4 or material specification)
 
 Re 
f = 160 MPa depends on 
 1.5 
P = 5.62 MPa
2t
Phmax = fh ×
D
= 7.63 MPa
Re
Phcalc = 0.83 × P
f
Re
= 1.25 P NOTE: 0.83 × < 3.5
f
= 7.03 MPa
Re
(whenever f = , P h = 1.25 P )
1.5
Since Phcalc < Phmax hydrostatic test pressure is 7.03 MPa.
For steam or water service:
Phcalc = 1.5 P
= 8.43 MPa
Since Phcalc > Phmax hydrostatic test pressure is 7.63 MPa.
AMDT Example 2: Paragraph U2.
No. 1
APR.
2001 Service = other than steam or water
Pipe specification = API 5L X42
Class = 1 or 2A
Temperature = 50°C
Size = 273.1 × 4.8
Max. OD = 273.1 mm
 
 Rm 
f = 176 MPa depends on 
 2.35 
P = 6.2 MPa
2t
Phmax = fh ×
D
= 9.15 MPa
Re
Phcalc = 0.83 × P
f
Re
= 1.36 P NOTE: 0.83 × < 3.5
f
= 8.45 MPa
Phcalc = 1.5 P
= 9.30 MPa
Example 3: Paragraph U2.

Pipe specification = ASTM A 106B
Class =1
Temperature = 450°C
Design life = 150 000 hours
Size = 168.3 × 21.95 (XXS)
Max. OD = 169.9 mm
f = 56 MPa
P = 14.25 MPa
AMDT
No. 1 2t
Phmax = fh ×
APR. D
2001
= 48.84 MPa
Re
Phcalc = 0.83 × P
f
Re
= 3.56 P NOTE: 0.83 × > 3.5
f
= 3.5 P
= 49.88 MPa
Phcalc = 1.5 P
= 21.38 MPa
Example 4: Paragraph U3.

Pipe specification = API 5L X42
Class = 2P
Temperature = 99°C

Size = 273.1 × 4.8 (Class 2P)
Max. OD = 273.1 mm
f = 208 MPa (0.72 × Re)
P = 7.3 MPa
2t
Phmax = fh ×
D
= 9.10 MPa
Phcalc = 1.25 P
= 9.13 MPa
NOTE: 1.25 × 0.72 = 0.9

As 4041-1998 Amdt 1-2001 Pressure Piping

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AS 4041-1998/Amdt 1-2001 Pressure piping

Published on 5 April 2001.

AMDT Page 2 Preface

AMDT Page 7 Clause 1.1

AMDT Page 8 Clause 1.2

AMDT Page 9 Table 1.3

ISBN 0 7337 3577 0

2 DESIGN (See Section 3)

2.4 Design factors

6.1 Pressure control tolerance +10% +15%

Maximum Class 1 tolerance

5 See Appendix D design strength and Appendix I determination of design strength.

Service limits for following classes

Design Very Gas No service 10 MPa max. Prohibited 2 MPa max.

No service limit except

AMDT Page 17 Clause 1.7.39 (new)

AMDT Page 17 Clause 1.7.40 (new)

AMDT Page 17 Clause 1.7.41 (new)

AMDT Page 18 Clause 1.11.1

AMDT Page 18 Clause 1.17

AMDT Page 19 Clause 2.2.1

AMDT Page 27 Clause 2.6.10

AMDT Page 27 Clause 2.6.11 (new)

AMDT Page 47 Clause 2.11.6.3

AMDT Page 51 Clause 3.6.2

AMDT Page 57 Clause 3.11.7

AMDT Page 60 Table 3.12.3

AMDT Page 63 Clause 3.15.2.2

AMDT Page 64 Clause 3.15.2.2

AMDT Page 64 Table 3.15.2.2

AMDT Page 71 Clause 3.19.7.3

AMDT Page 72 Clause 3.19.7.4

AMDT Page 72 Clause 3.19.7.5

AMDT Page 72 Clause 3.19.7.6

AMDT Page 72 Clause 3.19.7.7

4 Notation for d2, delete ‘  ’

AMDT Page 79 Figure 3.19.8.2

FIGURE 3.19.8.2 (in part) REINFORCEMENT OF BRANCH CONNECTIONS

AMDT Pages 82 to 84 Clauses 3.19.9.2 to 3.19.9.5 including Figure 3.19.9.2:

beyond the outside surface of the main pipe, in millimetres

3.19.9.4 Required reinforcement area The required reinforcement area is defined as

(a) For Dob/Doh ≤ 0.15 . . . . . . . . . . . . . . . . . . . . . . K = 0.70.

(c) For Dob/Doh > 0.60 . . . . . . . . . . . . . . . . . . . . . . K = 1.00.

A3 = area lying within the reinforcement zone resulting from excess

FIGURE 3.19.9.2 REINFORCED EXTRUDED OUTLETS

AMDT Page 86 Clause 3.23.2.3

AMDT Page 86 Clause 3.23.4

AMDT Page 92 Table 3.24.3.5

AMDT Page 107 Clause 3.25.2.1

(c) protection against external corrosion by suitable material selection, corrosion

AMDT Page 129 Clause 6.5.1

AMDT Page 129 Clause 6.5.2

6.7 HYDROSTATIC TEST

Minimum hold period, minutes

6.8 ALTERNATIVE TO HYDROSTATIC TEST

6.9 TESTING PRESSURE-LIMITING DEVICES, RELIEF VALVES, PRESSURE

been tested in accordance with this Standard.

AMDT Page 140 Appendix A

AMDT Page 154 Appendix D

AMDT Pages 157–160 Table D2

AMDT Page 161 Appendix D

AMDT Pages 162–163 Table D5

AMDT Pages 164–168 Table D6