Pipe Hydrostatic Test Pressure Calculation Input Sheet

Revision 2 - December 2009

Only enter data values on light yellow blocks !!

Line Number
Line Class
Design Pressure
Design Temperature
Test temperature

O-7-596-1 1/2"-C & 007-O-496

C
1700 kPa
300 oC
572.00 oF
37.777 oC
100.00 oF

Pipe / Fittings Material

Pipe diameter
Pipe schedule
Measured wall thick
*
Measured pipe OD
*
Wall thick (less mill tol)
Pipe diameter used (OD)

Pipe / Fittings Inputs

A106 B
1
NPS
80
SCH thick
mm
mm
4.45 mm (per SCH)
48.26 mm (per SCH)

Y values:
Ferritic steel
Austenitic steel
Other ductile metal
Cast iron

Other Pipe Inputs

Mill tolerance
12.5 %
Mill tolerance
mm
Corrosion allow
1 mm
Joint Efficiency
1Y Coeficient
0.4 Test joint eff
1Type of pipe
Austenitic steel
Table 304.1.1 Y value (@ test temp)
0.40

A234 WPB
48.26 mm
5.08 mm

Hydrostatic Head

(if known)

(leave alone)
(No prob)

0m
0 kPa

PRINT

* Enter value here when using a measured pipe, leaving blank = new pipe
Yield and Allowable Stress Values - Pipe
Material Yield Stress
35 KSI
241.32 MPa
For design temperature
Stress at T1
0 oF
A106 B KSI
Stress at T2
600 oF
17.3 KSI
At test temperature
Stress at T1
0 oF
20 KSI
Stress at T2
100 oF
20 KSI
Test Calculations - Pipe
Minimum Test Pressure
kPa
Test Pressure Selected
7655 kPa
Maximum Allowable Stress
217.18 MPa
Stress in new pipe due to test pressure
38.4937 MPa
Stress in corroded pipe due to test press
50.5563 MPa

Date:
By:

18 November 2014

Per tables in ASME B31.3 - Hidden Database

Per SP 50-9 Round to nearest:

kPa

Acceptable
Acceptable

Yield and Allowable Stress Values - Fittings

Material Yield Stress
35 KSI
241.32 MPa
For design temperature
Stress at T1
500 oF
A234 WPB KSI
Stress at T2
600 oF
17.3 KSI
At test temperature
o
Stress at T1
20 KSI
F
o
Stress at T2
F
20 KSI
Test Calculations - Fittings
Minimum Test Pressure
kPa
Test Pressure Selected
7655 kPa
Maximum Allowable Stress
217.18 MPa
Stress in new fitting due to test pressure
38.4937 MPa
Stress in corroded fitting due to test press
50.5563 MPa

OD's

1
1
1
2
2
3
3
4
5
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48

SCH's
5S
10
10S
20
30
40
40S
STD
60
80
80S
XS
100
120
140
160
XXS

Per tables in ASME B31.3 - Hidden Database

Per SP 50-9 Round to nearest:

50 kPa

Acceptable
Acceptable

Inputs for determining acceptable test pressure for flanges (ASME B16.5)
51.1 bar
Acceptable
100oF rating for flange material group

Inputs for determining acceptable test pressure for valve bodies (ASME B16.34)
51.1 bar
Acceptable
100oF rating for Valve material group

Per tables in ASME B16.5

References
Pipe
ASME B31.3 para.345.4.2
ASME B31.3 para.345.4.3

Notes:

Flanges
ASME B16.5 para.2.5
Valves
ASME B16.34 Para 2.5.3
ASME B16.34 Para 4.3.3
ASME B16.34 Para 7.1

Hidden Calculations
Allow stress @ design temp
Allow stress @ test temp
Stress ratio (R)
Minimum Test Pressure
Maximum allowable stress
Corroded wall thick
Stress in corroded pipe
New wall thick
Stress in new pipe

Reference

Data / Pipe
KSI
20 KSI

MPa
137.90 MPa
SP50-9 -> max R=6.5
ASME B31.3 para.345.4.2

kPa
217.18 MPa
3.445 mm
50.556 MPa
4.445 mm
38.494 MPa

Acceptable
Acceptable

Calculate flange allowable stress

1111.71 PSI
1.5 times the 100 oF rating
Rounded up to next 25 PSI
1125 PSI
Max allow flange test pressure
7756.60 kPa

Reference
ASME B16.5 para 2.5
Acceptable

Calculate valve allowable stress

1111.71 PSI
1.5 times the 100 oF rating
Rounded up to next 25 PSI
1125 PSI
Max allow flange test pressure
7756.60 kPa

ASME B16.34 para.2.5.3

Acceptable

Note: Hydrostatic test pressure for new and corroded pipe

Allow stress @ design temp

Allow stress @ test temp
Stress ratio (R)
Minimum Test Pressure
Maximum allowable stress
Corroded wall thick
Stress in corroded pipe
New wall thick
Stress in new pipe

Reference

Data / Fittings
KSI
KSI

MPa
MPa
SP50-9 -> max R=6.5
ASME B31.3 para.345.4.2

kPa
217.18 MPa
3.445 mm
50.556 MPa
4.445 mm
38.494 MPa

Acceptable
Acceptable

Calculate flange allowable stress

1111.71 PSI
1.5 times the 100 oF rating
Rounded up to next 25 PSI
1125 PSI
Max allow flange test pressure
7756.60 kPa

Reference
ASME B16.5 para 2.5
Acceptable

Calculate valve allowable stress

1111.71 PSI
1.5 times the 100 oF rating
Rounded up to next 25 PSI
1125 PSI
Max allow flange test pressure
7756.60 kPa

ASME B16.34 para.2.5.3

Acceptable

Material Database
Row
2

Column
1
7

Yield

30
35
35
35
25
25
25
25
25
30

PIPES:
Material
0
Please Select
API 5LB
A106 B
A333 Gr 6
A333 Gr 3
A312 TP304L
A312 TP316L
A312 TP321H
A358 TP304L
A358 TP316L
A335 Gr P11

Allowable Stresses in kips/in2 at degF

100
200
300
20
20
20
21.7
16.7
16.7
16.7
16.7
16.7
20

20
20
20
19.6
16.7
16.7
16.7
16.7
16.7
18.7

20
20
20
19.6
16.7
16.7
16.7
16.7
16.7
18

400

500

600

650

700

750

800

850

900

950

1000

1050

1100

20
20
20
18.7
15.8
15.5
16.7
15.8
15.5
17.5

18.9
18.9
18.9
17.8
14.8
14.4
16.1
14.8
14.4
17.2

17.3
17.3
17.3
16.8
14
13.5
15.2
14
13.5
16.7

17
17
17
16.3
13.7
13.2
14.9
13.7
13.2
16.2

16.5
16.5
16.5
15.5
13.5
12.9
14.6
13.5
12.9
15.6

13
13
13
13.9
13.3
12.6
14.3
13.3
12.6
15.2

10.8
10.8
10.8
11.4
13
12.4
14.1
13
12.4
15

8.7
8.7
8.7
9
12.8
12.1
14
12.8
12.1
14.5

6.5
6.5
6.5
6.5
11.9
11.8
13.8
11.9
11.8
12.8

4.5
4.5
4.5
4.5
9.9
11.5
13.6
9.9
11.5
9.3

2.5
2.5
2.5
2.5
7.8
11.2
13.5
7.8
11.2
6.3

1.6
1.6
1.6
1.6
6.3
10.8
9.6
6.3
10.8
4.2

1 NA
1 NA
1 NA
1 NA
5.1
10.2
6.9
5.1
10.2
2.8

1150

1200
NA
NA
NA
NA

4
8.8
5
4
8.8
1.9

1250
NA
NA
NA
NA

3.2
6.4
3.6
3.2
6.4
1.2

1300
NA
NA
NA
NA

2.6
4.7
2.6
2.6
4.7
1.2 NA

1350
NA
NA
NA
NA

2.1
3.5
1.7
2.1
3.5

1400
NA
NA
NA
NA

1.7
2.5
1.1
1.7
2.5
NA

1450
NA
NA
NA
NA

1.1
1.8
0.8
1.1
1.8
NA

1500
NA
NA
NA
NA

1
1.3
0.5
1
1.3
NA

0.9
1
0.3
0.9
1
NA

*** Above table can be added to up to line above this line and formulas will still pick up the added information

Row
2

Column
1
7

Yield

30
35
25
25
25
30
35
35
35
40

FITTINGS:
Material

Allowable Stresses in kips/in2 at degF

0
100
200
300
Please Select
A234 WP11
20
18.7
18
A234 WPB
20
20
20
A403 304 WPS
20
20
20
A403 316 WPS
20
20
20
A403 WP 304L
16.7
16.7
16.7
A403 WPS 32
20
20
20
A420 WPL3
21.7 NA
NA
NA
A420 WPL3
21.7 NA
NA
NA
A420 WPL-6
20
20
20
A182 F 11 CL2
23.3
23.3
23.3

400

500

600

650

700

750

800

850

900

950

1000

1050

1100

17.5
20
18.7
19.3
15.8
20

17.2
18.9
17.5
17.9
14.8
19.3

16.7
17.3
16.4
17
14
18.3

16.2
17
16.2
16.7
13.7
17.9

15.6
16.8
16
16.3
13.5
17.5

15.2
13
15.6
16.1
13.3
17.2

15
10.8
15.2
15.9
13
16.9

14.5
8.7
14.9
15.7
12.8
16.7

12.8
6.5
14.6
15.5
11.9
16.6

9.3
4.5
14.4
15.4
9.9
16.4

6.3
2.5
13.8
15.3
7.8
16.2

4.2
1.6
12.2
14.5
6.3
11.7

2.8
1 NA
9.7
12.4
5.1
9.1
NA
NA
NA
2.8

NA
NA
20
22.5

NA
NA
18.9
21.7

NA
NA
17.3
20.9

NA
NA
17
20.5

*** Above table can be added to up to line above this line and formulas will still pick up the added information

NA
NA
16.8
20.1

NA
NA
13
19.7

NA
NA
10.8
19.2

NA
NA
7.8
18.7

NA
NA
5
13.7

NA
NA
3
9.3

NA
NA
1.5 HA
6.3

NA
NA
NA
4.2

1150

1200

1.9
NA
7.7
9.8
4
6.9
NA
NA
NA
1.9

1.2 NA
NA
6
7.4
3.2
5.4
NA
NA
NA
1.2

1250

1300
NA
NA

4.7
5.5
2.6
4.1

1350
NA
NA

3.7
4.1
2.1
3.2
NA
NA
NA

1400
NA
NA

2.9
3.1
1.7
2.5
NA
NA
NA

1450
NA
NA

2.3
2.3
1.1
1.9
NA
NA
NA

1500
NA
NA

1.8
1.7
1
1.5
NA
NA
NA

1.4
1.3
0.9
1.1
NA
NA
NA

RNE Engineering and Projects (Pty) Ltd

P.O. Box 1490 Sasolburg 1947
Tel: (016) 970 8100 Fax: (016) 970 8110
Date:

Tuesday, November 18, 2014

Designer:

Hydrostatic Test Pressure for New and Corroded Pipe

Line Design Data
Symbol

Value

Unit

1700 kPa

DT

300 oC

TT

37.777 oC

Pipeline Parameters
Line Class / Line Number

O-7-596-1 1/2"-C & 007-O-496

Nominal Line Size

NPS

Pipe Outside Diameter

OD

48.26 mm

Schedule as per line Class

SCH

80

Wall thickness as per Schedule

inch

5.08 mm

Mill Tollerance

12.5 %

Corrosion Allowance

Pipe Material

1 mm

A106 B
Sy

Pipe Material Yield Stress

Fittings Material

241.316495 MPa

A234 WPB

Fittings Material Yield Stress

Sy

Joint Efficiency

1.0

Y Coefficient

0.4

241.316495 MPa

References:
Using formulas from ASME B31.3 and other accepted engineering practices

St
Sd

Pt f Pt

S a 0. 9 S y E

Pressure Test Factor

Stress Ratio
Minimum Test Pressure

circ

P D P Y

2 E t
E

Symbol

Value

1.5

Unit

Result

St S d
Pt

Selected Test Pressure

kPa
7655

kPa

Checking stresses in pipe from selected hydro test pressure > corrected yield
Maximum Allowable Stress in Pipe / Fittings
Stress Induced in New Pipe / Fitt due to Test Pressure

Sa

circ t n

217.18

MPa

38.49

MPa

Acceptable

Stress Induced in Corroded Pipe / Fitt due to Test Pressure

circ tc

50.56

MPa

Acceptable

Check 1.5 x rating of flanges and valves @ test temperature > selected test pressure
For Flange Material Group

7756.60

kPa

Acceptable

For Valve Material Group

7756.60

kPa

Acceptable

Notes:

Hydrostatic Test Pressure:

7655 kPa

__________________________________________________

_________________________________________

CALCULATED BY:

CHECKED BY:

Result

Reference

1
SP 50-9

2
Acceptable

Acceptable

Acceptable

ASME B16.5

Acceptable

ASME B16.5

________________________