AS 2885.

5:2020 130

Appendix O
(normative)

Test header design

The test headers are classed as test equipment and not part of the permanent pipeline or
They shall meet the requirements of this appendix.

header integrity.
Test headers should be designed so that they can be fabricated from heavy wall line pipe supplied for
construction of the pipeline. This allows the project to take advantage of:
(a) high quality, high strength line pipe supplied to the project;
(b) the welding procedures developed and used on the project; and
(c) the maximum test header internal diameter to facilitate pig handling.

this appendix shall be used.

may be treated as listed for the purposes of this appendix.

Formal design calculations are not required where the following apply:
(a) The test header is manufactured from project line pipe (preferably heavy wall).
(b) The at the maximum pressure in the project is not more than
92.5 % of SMYS.
(c) The pipe is traceable to the pipe population.

manufactured from a material grade that will permit it to be welded to the header pipe in
accordance with the requirements of AS/NZS 2885.2.
(e) The header contains simple branch connections, designed as pipeline assemblies in accordance
with AS/NZS 2885.1.
(f) The header is simply supported and does not contain stress concentrators such as lifting lugs
or supports.

with .

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 131 AS 2885.5:2020

a new pipeline), a nameplate shall be used.

The nameplate shall include the following information:
(a) Date of manufacture.
(b) .
(c) Design temperature.
(d) Test pressure.
(e) Date of pressure test.
(f) Pipe number for material traceability.
(g) Pipe grade and carbon equivalent.

All test headers shall be hydrostatically pressure tested before being put to use. Test headers that are
designed in accordance with this document shall be pressure tested in accordance with this document.

Test headers shall be designed in accordance with one of the following:

(a) AS/NZS 2885.1 with a design factor for pressure containment not exceeding 0.925.
(b) The requirements of .
The test headers shall be designed by
intended to be used on multiple projects, consideration should be given to a more conservative design
that takes account of the needs of the multiple projects and the potential for degradation of the headers
between projects.

Test headers are not a permanent part of the pipeline; they are temporary works and will not form a
permanent part of the pipeline once pressure testing has been completed. This document recognizes
this and permits higher operating stresses for the test headers than it does for the operating stresses of
the pipelines because the latter are permanent works.

in accordance with the relevant requirements of this document.

Materials for pipe and heads may be supplied as proprietary with materials conforming to
the material requirements for of AS/NZS 2885.1. Materials and that conform
to the Standards nominated in AS/NZS 2885.1 shall be designated listed materials for the purposes of
this document.

designated unlisted materials.

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AS 2885.5:2020 132

The test headers shall meet the following minimum pressure and temperature requirements:
(a) Internal — The internal of any of the test
header shall be not less than the highest test pressure to which the attached pipeline is
subjected at the lowest point of the pipeline.
(b) Design temperature — The design temperature of the test header shall be not less than the
maximum temperature to which the test header will be subjected during the period it will be
connected to the pipeline while under pressure.

The design loads to which the test header will be subjected shall be determined by a
pipeline designer. The following causes of design loads shall be addressed:

.
(c) Thermal expansion.

(e) Seismic conditions.

(f) Loads from the pipeline connected to the header.
(g) Loads on nozzles from externally connected piping.
(h) Lifting of the header.

The wall thickness for design internal pressure shall be determined in accordance with AS/NZS 2885.1.
.
The internal pressure design wall thickness shall be calculated using a maximum allowable stress
in tension of 0.925 Y for listed materials. For unlisted materials, the allowable stress in tension for
internal pressure design shall be in accordance with

Allowances to be considered in the design of the test headers shall be in accordance with the following:
(a) Reduction in thickness during the fabrication process for unlisted , where a pipe,
head or other pressure-containing is manufactured from plate. Thinning during
the manufacturing process shall be addressed. An allowance equal to the full reduction in
thickness shall be included in the allowances.
(b) The required wall thickness (t ) of the shell or head is the internal pressure wall thickness
(tdp) plus the total thickness of all the allowances and manufacturing tolerances (where
relevant in accordance with AS/NZS 2885.1). The nominal wall thickness (tN) of pipes or
pressure-containing made from pipe or plate shall be not less than the required
wall thickness (t ) rounded up.

incorporate a corrosion allowance into the design.

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 133 AS 2885.5:2020

assessed under prior to re-use. This shall also apply at any time to any header
which shows signs of corrosion.

The basic allowable stress for listed materials is 0.925 Y.

Provided the wall thicknesses for pipe and for heads meet the requirements of , the stress
levels from internal pressure shall be deemed to meet the requirements of this document.

supports)

factor for the shell EG (EG = 1 for listed materials).

the shell EG (EG = 1 for listed materials).

The compressive stress limit at the saddle from bending shall not exceed the basic allowable tensile
stress.

The head (cap) shall be supplied as a standard dimensioned butt-welding cap manufactured from steel,
having at least the equivalent strength as the pipe used to manufacture the test header. Allowance shall

test header pipe.

produces an equivalent pipe cap. The membrane stresses in the head shall be substantiated.
Provided the calculation for wall thickness in has been carried out and the allowances
have been included, the stress levels in the head shall be deemed to be within allowable levels.

The allowable stress of the tangential shear stress in the plane of the saddle from self-weight is 0.6
times the basic allowable stress in tension or 0.56 Y.

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AS 2885.5:2020 134

The combined circumferential bending stress limit in the shell at the horn of the saddle from self-
weight is limited to the basic allowable stress in tension for the shell materials with equal tensile and
compressive yield strength.

The allowable limit for ring compressive stress from self-weight shall be Y/2 of the shell material.

The axial stress in the shell from thermal expansion shall be limited to Y/2.

Allowable design stresses for supports and miscellaneous structural items are as follows:
(a) Tension A = 0.6 Y.

(b) Shear A = 0.4 Y.

A = 0.66 Y.

method.
The maximum allowable stress in the shell and nozzle shall not be greater than the basic allowable
stress in tension.

The allowable limit for occasional loads such as wind, earthquake, and liquid surge shall not exceed
110 % of the allowable limit for the load type being considered.

summarizes the allowable stress levels of listed pipe materials (in accordance with Clause
) for the test headers of this document.
EG) adopted for design shall be .

Table O.3.1 — Table of allowable stresses for listed materials

Item Stress description Load type Limit
Shell and head Pressure 0.925 Y
Shell with saddle Combined tensile stress at midspan Pressure and bending 0.925EG Y
supports
Combined tensile stress at saddle Pressure and bending 0.925EG Y
Compressive stress at saddle 0.925 Y
Tangential shear stress in the shell in the plane 0.56 Y
of the saddle
Combined circumferential compressive 0.925 Y
bending at the horn of the saddle (ring bending
and direct stress)

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 135 AS 2885.5:2020

Table O.3.1 (continued)

Item Stress description Load type Limit
Ring compression in the shell over the saddle 0.5 Y
Axial stress in the shell from thermal Thermal expansion 0.5 Y
expansion

the allowable material stresses of the shell shall be limited to the following values:

(b) Allowable material stress in compression shall not exceed the allowable value in tension.
(c) Allowable shear stress shall not exceed 60 % of the basic allowable tensile stress.
(d) Stress limit for combined stresses shall not exceed the basic allowable stress.
(e) Allowable ring compressive stress and allowable axial thermal expansion stress shall not
exceed the basic allowable tensile or compressive stress.

allowable material stresses of the head shall be limited to the following values:

(b) Allowable material stress in compression shall not exceed the allowable value in tension.
(c) Allowable shear stress shall not exceed 60 % of the basic allowable tensile stress.

AS/NZS 2885.1 shall be considered to be

designed, fabricated, inspected, and tested in accordance with an Standard.

The test headers shall be adequately supported at all times.

shall be checked.

be used provided they meet the requirements of this document.

provided —
(a) the stress limits of are met;

welded to the reinforcing plate;

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AS 2885.5:2020 136

that are welded together; and

(d) there is no cracking in the weld metal, the support or the shell materials.

header. Full encirclement split sleeves with backing strips shall be attached to the body of the header by
welding and the lugs welded to these sleeves.

Test headers designed in accordance with AS/NZS 2885.1 shall be welded in accordance with
AS/NZS 2885.2.

with AS 1210.

headers shall be subjected to and pass an hydrostatic strength pressure test and be free of
leaks.
The test pressure shall be determined in accordance with the requirements of the relevant design
standard.
The pressure for test headers designed to of this appendix shall conform to
the following:
(a) The pressure shall be at least equal to the maximum pressure that it will be exposed to during
the .

SMYS of the standard wall pipe.

used in future projects, the test pressure factor shall not be less than 1.1.
(c) The test duration shall be not less than 30 min.
The minimum pressure of the test header shall be not less than that calculated from the
following —

where

ptmin = minimum pressure of the test header, in MPa gauge

pd = , in megapascal gauge of the test header, not less than the maximum
section test pressure

Ftp = test pressure factor

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 137 AS 2885.5:2020

= 1.0 min

tw = required wall thickness, in mm (the pressure containment wall thickness plus allowances)

tdp = wall thickness for internal pressure containment design, in mm (in accordance with the
relevant design standard)

(a) the of the header; or

(b) the pressure limit derived from the measured hydrostatic pressure divided
by the test pressure factor.

The re-use of existing headers for a new project is permitted by this document. Existing test headers
shall only be re-used provided the design standard of the test header is permitted by this appendix and
the following requirements are met:

nameplate, one shall be provided.

(b) Prior to re-pressure testing the test headers, they shall be examined for evidence of
deterioration including —
(i) internal and external corrosion;
(ii) wear or mechanical damage; and
(iii) cracking.
Should deterioration of the test header be found, a critical engineering assessment of the effect of the
deterioration shall be established and a new maximum safe test pressure established prior to retesting.

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