ABOUT THIS PRESENTATION

This presentation is about the design theory used by the Australian Piping Code AS 2885-1997. With a focus on facility piping and carbon steel piping which is the most commonly used pipe material in process plants. APIA publications have been referred for this presentation.

It will cover the following design aspects of these codes

Qualifications & Approvals Design, Fabrication & Technical Specification Testing & Examination

The majority of the described aspects have been displayed as lists for better presentation

ABOUT THIS PRESENTATION

The author of this document is Vivek Pandey B.E. (Mech.). Graduate of the University of Auckland. This document should be used only for selflearning and reference. Always consult the latest AS standard documents. Please do not use this document for commercial purposes. The author is not liable for the usage of this document.

APPLICATION OF AS 2885
AS 2885 is a set of codes which cover high pressure hydrocarbon piping AS 2885 PipelinesGas and liquid petroleum AS 2885.1: Design and construction (focus of this presentation) AS 2885.2: Welding AS 2885.3: Operation and maintenance
AS 2885 covers facility process piping under two headings a) pipeline assemblies such as mainline valves, isolation valves, scrapers and branch connections. b) station pipework such as piping within compressor, meter and regulation stations. For detailed reference for applications of this standard, see clause 1.1. Service Temp. in range of -30C & 200C

APPLICATION OF AS 2885
Always applicable for service pressure greater than 1050 kPag or for services with hoop stress greater than 20% of Yield Stress
For operation, inspection & maint. of in- service pipes, refer to AS 2885.3

For Flange Ratings, refer to clause 4.4.5 & 3.2. Flanges may be used without de- rating upto design temp. of 120C.
For control & sampling instrumentation, refer to clauses 4.3.5 & 4.4.4.1. Otherwise AS 4041 applies. Emphasis is placed on Design Approval rather than Designers Quals. AS 2885 does not specify design verification, however approval by operating authority or regulatory authority may be applicable

Welding Qualifications
For welding qualifications refer to AS 2885.2. For welder & welding procedure qualification refer to section 5.
Welding supervisor is required for prod. welding & qualification tests

Pre- qualified welder & welding procedure is permitted subject to documentary evidence proving previous qualification complies with this standard
Limited list of electrodes for SMAW and automatic processes Fit- up as per AS 4458 and within limits of qualified welding procedure Weld Quality Criteria

Each pipe length hydrostatically tested as part of manufacturing process Full length of welded seam subject to NDE

Qualification of Materials
Refer to clause 3.1 for qualified materials & clause for 3.1.2 for materials allowed without qualifications
For qualified pipe materials refer to- API 5L and ASTM A53, A106 & A524. Also, furnace welded pipe is not allowed. For qualified fitting materials refer to- ASME B16.9, B16.11, B16.25, B16.28, A105, A234 & A420. BS 1640.3, 1640.4 & 3799. MSS SP-75.

For qualified valve materials refer to- ASME B16.34. API 6D, 600, 602 & 603. ASTM A350. BS 5351. MSS SP 25 & 67.
For qualified flange materials refer to- ASME B16.5 & B16.21. BS 1560.3.1 & 1560.3.2. BS 3293. MSS SP 6 & 44.

Qualification of Materials
For qualified gasket materials refer to- ASME B16.21 & BS 3381.
For qualified bolting materials refer to- AS 2528. ASTM A193, A194, A307, A320, A325, A354 & A449.

For qualified pressure gauge materials refer to- AS 1349. For qualified welding consumables refer to- AS 2885.2. For qualified anti- corrosion coatings refer to- AS 3862.

Materials from standards not listed are permitted subject to qualification as equivalent to listed standard. Also, refer to clause 3.1.3.
For materials for which no standards exist, refer to clause 3.1.3. Such materials are only permitted for components other than pipes subject to qualification.

Qualification of Materials
For reclaimed pipes, refer clause 3.1.5. They are permitted subject to qualification.
For reclaimed accessories, valves and fittings, refer to clause 3.1.6. They are permitted subject to qualification. For material and components not fully identified, refer to clause 3.1.7. They are permitted subject to chemical composition and mechanical properties as specified in a nominated standard. For identification of components, refer to clause 3.1.8. Test certificates and full identification is not necessary provided item is marked with manufacturer name & nominated standard. For unidentified materials and components, refer to clause 3.1.9. They are not permitted for containing pressurized fluid flows. For reclaimed corroded, deteriorated or untested components, refer to clause 3.1.10. They are permitted subject to hydrostatic testing.

STRAIGHT PIPE WALL THICKNESS

Pipe wall thickness calculation as per AS 2885, t = PD / (2SYF), where P is internal pressure D is nominal outside diameter SY is Yield Stress F is a design factor (usually not more than 0.72)
Minimum Nominal Wall thickness = Calculated Thickness + Corrosion Allowance + Manufacturing Tolerance Corrosion allowance should not be less than 1 mm. Waive the manufacturing tolerance from the wall thickness calculation if it is less than 12.5%. Otherwise, apply the marginal difference above 12.5% if the manufacturing tolerance exceeds 12.5%.

ALLOWABLE STRESSES
As per Thin Wall Pipe Theory, Hoop Stress SH = PD / 2t, where P is internal pressure, D is Nominal Diameter and t is thickness
AS 2885 applies a design stress margin relative to material permanent deformation only (i.e. SY or yield stress)- SA = 0.6 * SY. Also refer to clause 4.3.6. The allowable stress equations are similar to ASME B31.4 and the code refers to AS 4041 for flexibility and stress intensification factors. The Ring Bending stress (transverse external loading) should be less than or equal to 90% of the Yield Stress. Occasional load stresses (including wind & earthquake) should be 110% of normal load stress For earthquake loading refer to AS 1170.4. There is no reference for wind loadings.

STRESS ASSESSMENT CRITERIA

The assessment criteria fall under two stress analysis load cases:

Sustained Load Stress is the sum of longitudinal pipe stresses due to pipe weight, pipe contents, internal pressure and external loads. A stress limit of M*F*SY is specified for normal operation conditions and another limit of 1.33*M*F*SY is specified for inclusion of occasional loads such as wind or earthquake. Expansion Stress Range is a stress value equivalent to the difference in pipe displacement or flexibility stress within the design temperature extremes from maximum to minimum. The displacement stress is defined as the combination of bending and torsion stresses using equation SE = (Sb2 + 4St2)

For piping systems that operate above the installation temperature, the expansion stress range value is calculated as the difference between the value for SE due to all design loads including pipe weight, pipe contents, internal pressure, external loads, displacement & differential temperature and the value for SE due to sustained loads. Otherwise use the method described above.

WELDING AS PER AS 4041 & AS 2885

Welding should be performed as per AS 2885.2.
Butt Welds Full- penetration butt welds are required & throat thickness is less than thickness of joined thinner part AS 2885 allows misalignment of the lesser of t/4 & 3.5 mm (as per figure 10.3). The wall thickness ratio limit for welding unequal thickness & equal OD pipes is not limited. Refer to clause 10.3 & figure 10.3 Socket Welds & Sleeve Welds are permitted. Fillet Welds Not to be used for services with corrosive conditions, cyclic stresses or thermal gradients that could overstress the attachment welds Size limited to 1.2*tpipe

WELDING AS PER AS 4041 & AS 2885

Stress Corrosion Cracking AS 2885 requires consideration in weld procedure qualification
Pre- Welding Heat Treatment As 2885 refers the pre-heat requirement to be determined by the welding procedure qualification or as per AS 2885.2 Section 3 Post- Welding Heat Treatment AS 2885 does not specify criteria or guideline to determine whether such heat treatment is necessary or not. As per AS 2885, components which comply with a nominated standard do not normally require heat treatment, but if necessary, the heat treatment shall be carried out in accordance with AS 1210 which refers to AS 4458.

Fracture Toughness & Low Temperature Service

Fracture Toughness & Low Temperature Service

Fract. toughness & low temp. service is referred in clauses 3.5 & 4.3.7.

AS 2885 requires that the design procedure should have a fracture control plan to limit propagation of rapid fracture unless the pipeline carries a stable liquid (low vapour pressure at atmospheric pressure) and the MDMT is above 0C
AS 2885 focuses on pipelines rather than station pipework (fracture arrest length as multiples of pipe joints, uniformity over the whole pipeline, methods of providing for crack arrest)

AS 2885 refers 'station pipework' to AS 4041

Design of Bends
Continuous Curved Bends

As per clause 6.5 use same wall thickness as for straight pipe Ovality is referred to in clause 6.4.2 and usually set as 5% Hot or induction bends are allowed as per clause 6.5.4. No penalty on thickness if max. thinning is 10% and constant material properties. As per clause 4.3.4.2 use same elbow thickness as for equivalent pipe Bends cut from forged bend or elbow are permitted as per clause 6.5.5 provided arc >= 4 t Cold bends are permitted if procedure is qualified as per clause 6.6 Mitre bends are permitted as a mitre butt-joint between two straight pipes and bend angle up to 3 as per clause 6.5.3

Mitre Bends

Cut & Shut Bends are not permitted

Design of Branches
Branch Connections (as per clause 4.3.9.5 & table 4.3.9.5)

For the following design details, refer to AS 4041: branch to header angle limit. (Presumed to be perpendicular). branch and header axis alignment. (Presumed to be aligned). design application limitations based on diameter to wall thickness ratio. AS 2885 is vague regarding fitting type and size limits when the fitting is not directly qualified AS 2885 permits branch fittings provided they have been qualified and reinforced. AS 2885 is specific and conservative for branch to run diameter ratios > 0.5 and run hoop stress greater than 50% SY AS 2885 refers to AS 4041 & AS 1210 for fitting assessments of pipeline assemblies in the aspects of allowable stress, required wall thickness, joint efficiency, manufacture tolerance, pressure testing and weld examination Vibration & ext. loading to be considered for thin walled header pipes

Design of Attachments
Pipe Attachments

Refer to clause 4.3.11.5

AS 2885 permits welding of attachments directly on the pipe when hoop stress is less than 50%
When hoop stress is greater than 50%, only a full encircling member may be welded to the pipe and attachments welded onto the encircling member

Pressure & Temperature Variations above the Design Rating or Stress Limit

Over- Pressure Allowances (refer to clause 4.2.6.4)

AS 2885 allows an over-pressure of 10% under transient conditions none under normal conditions

Over- Pressure Protection (refer to clause 4.2.6.4)

Over-pressure protection limit as per AS 2885 is Process pressure limited to 10% under transient conditions and to MAOP under normal conditions Thermal relief limit is not mentioned for blocked liquids

WELD EXAMINATION
There is a separate base standard for weld examination- AS 2885.2
AS 2885 requirements: NDE on 100% of station pipeworks AS 2885.1 Clause 4.4.4 Station Pipework refers the design to AS 4041 and specifies Clause 3.2 as an exception for flange ratings, but does not refer to AS 2885.2 Clause 16.5.1 (g) & (j) to emphasize the 100% NDE AS 2885.2 Clause 16.5.1 does not refer to the term pipeline assemblies, so maybe 100% NDE is not necessary unless the assembly forms part of the main piping in a station and this could exclude off-take branches and mainline valves

HYDROSTATIC TESTING
Test Pressures (refer to clause 7.4 & AS 1978)

Minimum Strength Test Pressure AS 2885 specifies 1.25 min. applied operating pressure (determined by operating authority) Maximum Strength Test Pressure AS 2885 specifies the lesser of 100% SY hoop stress or rated component test AS 2885 specifies 2 to 8 hours AS 2885 allows pneumatic tests if necessary for R1 & R2 location classes subject to risk assessment but not for location classes T1 & T2 AS 2885 does not permit initial in- service test

Strength Test Hold Period

Alternative Tests

HYDROSTATIC TESTING
Exemptions from hydrostatic testing

Refer to clause 7.4.2

Tie- in welds
Components with adequate design pressure manufactured to a standard Components for which strength is proven by experience