SABS 087-1:1999 Annex E (informative) Testing of the high pressure Stage of an installation E.1 Testing of system (see figure E.1) E.1.1 Close off the low pressure line, E.1.2 Break the Pigtail joint of container A, and couple a pressure Seuge between the pigtail and th, Waive Of the container. (The gauge shoud have a range of 0 to 600 kPa and a eer of diameter at lee 100 mm.) E.1.4 Close the valve of container A and allow the system to stand for 5 min for equalization of temperature, E.1.5 Note the Pressure on the pressure gauge. E.4.6 Allow the System to stand for a further 10 ‘min: if the gauge pressure does not drop, the installation is sound. E.1.7 ifthe pressure drops, test individual Joints, using soapy water to detect leaks, For installations {hat incorporate non-retum valves, the torr Should be cartied out with the ‘auge attached to each Container (in turn), E.2 Testing of valves With the pigtails disconnected, test the container valves for leakage, using soapy water, Change-over valve Wall block — -— Container S485 087-3 — Container g Brg t6767-EC/00-2 Figure E.1 — High pressure leakage tost 40SABS 087-1:1999 Annex F (informative) Testing the system performance of low pressure regulators F.1 Connect a water manometer to some convenient point in the low pressure system as close as possible to the regulator outlet. F.2. Turn on the gas supply and purge the air from the system. F.3 Check and note the gas pressure with a) all the burners alight, ) only the smallest burner in the installation alight, and o) all the burners turned off. F.4. The type and size of the regulator and the performance of the system can be regarded as satisfactory if there is no fluctuation of pressure in F.3(a) and F.3(b) above, and if the pressure a) does not fall lower than 2.7 kPa in F.3(a) b) does not exceed 3,4 kPa in F.3(b), and c) does not exceed 4,0 kPa in F.3(c) at42 SABS 087-1:1999 Annex G (informative) G.3 Repeat 6.2 al the regulator. G4 The piping can be regarded as adequate in size if in neither Of the above tests the gas pressure is less than 2,5 kPa,SABS 087-1:1999 Annex H (informative) Testing the adjustment of burners H.1 Check the operation of each burner of each appliance and ensure that the aeration controls are correctly adjusted and locked H.2 Check the performance of the thermostats on ovens, et. with a suitable thermometer. H.3 Ensure that the pilot lights and flame failure devices function correctly. H.4 Check all water heaters for water discharge temperature and ensure that their adjustments are correctly set. 43SABS 087-1:1999 Annex J (normative) In-situ container filling requirements u filling Containers can be illed in situ subject to the following conditions: a) containers should have a water capacity in excess of 120 f+ ) each container should be fitted with an approved pressure relief device: and ) each container should 1) have an automatic shutoff valve which should operate at the maximum allowed liquid level applicable to the container being filed (This should be complied with when the containers being filled are on @ manifold with a single filing connection,), or 2) be fitted with a permanent fixed liquid level gauge device so that itis ensured that the relevant mass fill ratio is not exceeded for the particular container size. MoT iis ing method can be alowed subject o 2 quantified assessment ofthe vapour release and tosubsequent ‘approval of the local authority. 44SABS 087-1:1999 Annex K (normative) Piping design and fabrication of pipe systems for liquefied petroleum gas installations in critical locations K.1 General K.4.4 This annex details the design, construction and inspection requirements for LP gas pipework in'safely critical areas and is limited to critical sections of LP gas (not liquid) pipework where a greater than standard integrity is required, K.4.2. It imposes stringent material specifications and construction restraints on the designer! fabricator of LP gas piping and therefore ensures the integrity of the piping covered by this annex K.2 Design K.2.1 Design code Pipework should be designed in accordance with the requirements of ANSI/ASME 631.3. K.2.2 Design conditions The following design requirements should be applied to piping covered by this annex: a) design pressure 1 000 kPa: b) working pressure ‘100 KPa to 150 kPa ©) design temperature 60°C; and d) working temperature 0 °C to 20°C. K.2.3 Corrosion allowance Since LP gas is non-corrosive, a nominal corrosion allowance of 1 mm should be included for the design and selection of components, K.2.4 Overpressure protection Provision shall be made to safely release excessive developed pressures in the piping system before the piping is welded K.2.5 Flexibility “The piping system should be routed with suficient natural flexibility to safely absorb piping movements due fo thermal growth and building settlement. Flexible couplings should not be used, K.2.6 Supports K.2.6.1 Maximum spacing of supports “The spans for straight steel piping should not exceed the values given in table K. 1. (For caloulations see BS 3974-1.) 45SABS 087-1:1999 Table K.1 — Pipe spans Dimensions in milimetres i 2 Size of pipe [Maximum horizontal span 5 7200 20 2.400 25 2400 40 3.800 20 4550 80 5400 100 6750 150 7-900 K.2.6.2 Support design Supports should be so designed that under the maximum expected design load of the piping, the support deflection is limited to 15 mm, K.3 Piping components K.3.1 Piping material and components All piping material and components should be as given in table K.2. K.3.2 Bends and elbows For changes in direction, long radius, one and a half times the Pipe diameter, butt weld elbows are preferred. Piping smaller than 25 mm can be cold bent (smooth and not deformed) (minimum bend radius to be three times the pipe diameter). K.3,3 Branch connections Branch connections should be forged tees or forged reducing tees, K.3.4 Buttweld fittings [ee8, reducers, caps and long radius elbows should be seamless forged fitings that comply with ANSI B16.9. K.3.5 Flanges 3.5.1 Flanges should not be used on pipelines installed in erica! locations K.3.5.2 ANSI Class 150, raise face butt weld flanges should be used. K.3.5.3 Flanges should comply with ANSI B16.5. 46SABS 087-1:1999 K.3.5.4. The surface finish of flanges should be suitable for use with compressed asbestos fibre (CAF) gaskets, Gaskets to be 6,3 ym Ra, (See ISO 468 for surface finish.) K.3.5.5 CAF gaskets for RF flanges should be flat rings that comply with ANSI 816.21 K.3.6 Valves K.3.6.1 The use of valves in critical LP gas pipework is not recommended K.3.6.2 If valves have to be used, they should be welded into position and should be of a fire safe construction. (A fire resistance of 1 h is required.) K.4 Fabrication K.4.1 Drawing requirements Al LP gas pipework should be included on plant and building layout drawings. K.4.2 Construction of pipework K.4.2.1 Fabrication, assembly and erection of pipework should be in accordance with chapter 5 of ANSUASME B31.3. K.4.2.2 All erlical LP gas piping should be a fully welded construction K.4.2.3. All welding should be performed by coded welders using a certified welding procedure specification (WPS) that has been prepared and qualified by a responsible, recognized organisation, with expertise in the field of welding K.4.2.4 The pipe and fitting manufacturer should bevel and prepare joints for field welding. K.5 Non-destructive examination and testing K.5.1 General K.5.1.1 All material used in construction should be strictly in accordance with the material specification (see table K. 2). K.5.1.2 All fabricated piping should be protected for transport or storage if not installed immediately. Protection should include but not be limited to the following a) the manufacturer should provide flange protectors to prevent damage to flange facings during handling, storage and installation; and b) the bevelled ends of open pipe should be protected with metal caps secured in place by double wrapped duct tape K.5.1.3 Welds that are to be subjected to non-destructive testing should be selected in accordance with the requirements of this annex K.5.1.4 The manufacturer should use a quality contro! system that allows traceability of production welds and weld repairs. 47SABS 087-1:1999 K.5.1.5 All non-destructive testing shall be performed to writen Procedures in line with the requirements of chapter VI of ANSHASME B31.3, K.5.1.6 Except for visual examination, all non-destructive ‘esting should be performed by qualified personnel, K-5.1,7 Allresults of non-destructive testing should be reported and Copies of the reports should be included in the hand-over documentation to the owner 1.5.1.8 Allinspection documentation ofthe piping system should be included in the project archive documentation, K.5.2 Examination The following non-destructive tests are required for LP gas, critical ipework. Acceptance criteria for all examinations isto be extracted from table 341.3,2A from ANSIIAGHIE Bay 5 kK. -1 Visual examination ‘8 100 % shop and field visual examination is required Visual examination shauld be performed in accordance with an approved code. Results of visual examination should be documented, K.5.2.2 Pressure test requirements EY Initial operation, each piping system should be pressure tested to ensure the integrity of the toate des empraferred method of pressure testis @ pneumatic fest using on-flammable and non- toxic gas other than air, subject to the following conditions ®) Pneumatic testing involves the hazard ofthe potential release of stored energy in a compressed ges; should a failure occur. The possibilty of brittle fracture occurs at ¢ temperature below the Guctle-britle transition temperature for the piping material. Thus procera testing should not be Performed below 0 °C; 5) @ pressure reliet device should be provided, having a set pressure of 10 % above the test pressure: ©) the test pressure should be 110 % of the design pressure: and 4) the test procedure should be as follows: The Oak test should be maintained for at least 10 min. During this ime the system should be checked for leaks and no drop in pressure should be permitied K.5.2.3 Progressive sampling for examination When a required spot or random examination reveals a defect: 3) two additional samples of the same kind (if welded, by the same welder, or operator) should be Subjected to the same type of examination: and 48SABS 087-1:1999 b) if the items examined as required by (a) above are acceptable, the defective item should be repaired or replaced and re-examined as specified in the appropriate of K.5.2 and all items represented by these two additional samples should be accepted; but 6) if any of the items examined as required in (a) above reveals a defect, two further samples of the same kind should be examined for each defective item found by that sampling; and ¢) if all the items examined as required in (c) above are acceptable, the defective item(s) shall be repaired or replaced and re-examined as specified in the appropriate of K.8.2 and all items represented by the additional sampling shall be accepted; but ©) if any of the items examined as in (c) above reveals a defect, all items represented by the progressive sampling shall either be: 4) repaired or replaced and re-examined as required; ar 2) fully examined and repaired or replaced as necessary, and re-examined as necessary for compliance with the requirements of this part of SABS 087 and ANSI/ASME 631.3 K.5.2.4 Repairs after pressure testing If repairs are made following a pressure test, the pressure test is to be redone K.5.2.5 Test records Records should be made of each system subjected to pressure testing, including the following: a) date of test; b) identification of piping system; ©) test fluid d) test pressure; and €) certification of results by examiner. K.5.3 Post-commissioning inspection and testing K.5.3.1 Pressure tests To ensure the continued integrity of the piping system, the system should be pressure tested at twice the operating pressure at intervals not exceeding 5 years. ‘These pressure tests should be in accordance with the general requirements of K.5.2.4 K.5.3.2 Visual inspection The entire piping system should be visually inspected at intervals not exceeding 5 years. If any mechanical or corrosion damage has occurred, such damage should be assessed and remedial work should be undertaken to ensure that the system's integrity is maintained. Records of these inspections should be included in the data packs for the installation 49SABS 087-1:1999 38d GSW AUS Sx aaIN ‘oid s sony SHOE ALS Us 44 0S1 S980 Nm OH soLy 9-2 SHOE GIS Us 44 Ost S829 mg OH wA-% SoBuey adig ’ 9-9 nz SOLGISNY Jag: oBuey o:nesoig unm 9- 09.91.9. 0: e6uby oimeeduiel aoe e0es pose 05) 98615 reais vogue wim sonjon, e Bath 262 Us 1M ais p= SAM Peay USM GUS — suod seonpou Sd vezy Us uM ais vo) BM ve2v US LM Gis aL SAM VEZY USIMGS seiBeq sy 95 ‘O] Gat ¥628 1s 1M ais en 801899 06 13 SOLVUS GHI Peay exenbs Ghia s01n05 SOLWTLS 188 000 € ssei0. 33L, SOLWILS MS 000 € 882:9 aL SOLVUSMs 000 € SSkI9 BaLBaq gp 34 SOLVUSMS 000 € 852 seiisq Ob Ts omedd seq 47 séunny z {BUS stwOl Add :8uI0 Iv (b'2'9 268) pamaios. ENS-IdV US M3 OF HOS adig 9-2 99 424) ul Ze Burprcu pus a dn e260 sod 8 toe SSidv US SINS 08 HOS adi 9-4 Od ‘ S0}0N uondussag "ON “bog SIeua}eW 404 seag — zy oiqey 502 & 8 SABS 087- your xu8y0 au @12 VON sears eLR puE spuepUEN neue Jed ase SeqUAlA}a: pUB LONE OSeP ayy 'seaLE pads pve ie zoe 1 ry 6, Sy eprera ung ssejo aun | 123us neu 4a eG ‘uoneoyaeds jean —se9 a7 ouemoje uoIEOneD So10u uonsnsueS je1suen | suojsiney S9IBISNY Ba 9.09019, 0: 6uey eunjasadwie] ‘9084 pastels OS| SEI) aGuey einssaig jeaig voaeg epjam ung steep uononaisueg ONN £9 $9 S81 GW3H XBH MaHOS dvo SUNN H2 WO P61 WM 28 BD E61 LiOs-aNLS Suniog 8 MHL S't ONIY ASV OS! S581 LISD e-2 sisxse9) L ypomedd sep 37 Jean 399 dM YO vEZS “US Sx 903 BBeng BG GAM YO veZS 118 Sx BUD aBemg oo10g sajddin oBems, 8 s210N, uondusseg “on "bas (pepnjouoa) 2° age, 5tSABS 087-1:1999 Bibliography ANSI B16.5:1996, Pipe flanges and flanged fittings. ANSI B16.9:1993, Factory-made wrought steel butt welding fittings ANSI B16.21:1992, Non-metallic flat gaskets for pipe flanges. ANSV/ASME B31.3:1998, Code for chemical plant and petroleum refinery piping. API 5L:1997, Specification for line pipe. ASME PV CODE 7:1998, Recommended guidelines for care of power boilers. SABS 0140-3:1992, Identification colour markings ~ Part 3, Contents of pipelines. SABS 199:1972, Cylinder shut-off valves for LPG. SABS 1091:1989, National colour standards for paints. SABS 1186:1997, Symbolic safety signs. sabs pla 52