7K Item 2

Item 0201 ballot draft rev 1
Potential working and test pressure mismatches on Flanges and Hammer Unions installed
on 7K hose assemblies
Dr Tibor Nagy
Z&N Technical Development Ltd.
for ContiTech Rubber Industrial Ltd.
20. 09. 2012.
Background information, NOT part of ballot draft

High pressure mud hoses according to API Spec. 7K 5th ed. 2010 (and former editions) shall
be pressure tested at twice of their maximum working pressure. (In the explanatory part of
this document DP stands for design pressure, identical to rated (or maximum) working
pressure, and TP stands for test pressure, BP for required burst pressure). In former editions
of API Spec. 7K (prior to Addendum 2 of API 7K was issued in 2005) rotary and vibrator hoses
were exempt of basic design and quality assurance requirements:
API Spec 7K 4th ed. section 9.10.3: “The requirements of 4.2.7, and all paragraphs of Clause
5, Clause 6, Clause 7, and Clause 8 shall not apply” to rotary hose. In addition to the above
there was no design validation requirement. Actually the 2xWP test pressure was the only
proof of the integrity of a particular design.
On the other hand in the presently valid API 7K 5th ed. all relevant design and quality
assurance requirements apply to high pressure mud and cement hoses.
The TP = 2XDP requirement occasionally does not match with the specification of the end
connector. Table 1 list some common, and some rarely used end connectors, and their test
pressure.

Table 1 End Connectors
Standard Design Ratio of TP
End connector Type or fig. Note
latest edition pressure to DP
4" 602 none 6000 psi 1,5
Hammer union 5" and 6" 1002 none 7500 psi 1,5
4" and 5" 1003 none 7500 psi 1,5
API LPT API Spec. 5B max. 5000 psi* 2,0
API Spec 6A various not specified usual API grades
ASME B16.5 various 1,5 non‐API grades
Flange
SPO Norsok L‐005 various 1,5 non‐API grades
ISO ISO 6164 various 1,5 non‐API grades
Hub API Spec. 16A various 1,5 usual API grades
*API Spec 7K allows LPT on HP mud and cement hoses up to 5000 psi, i.e. grade D

The vast majority of possible end connectors in Table 1 are rated to TP = 1,5 DP.
1

Other high pressure hoses e.g. cement hoses in API Spec 7K 5th ed. at and above 10 000 psi
DP, API 16C flexible choke and kill lines 10 000 to 20 000 psi, as well as API 17K bonded
flexible lines, or API 17J unbounded flexible lines all require 1,5XDP for test pressure. Of
course in line with present quality assurance principles, all these flexible lines have strict
design validation requirements.

In order to avoid test pressure mismatch, the test pressure for all mud and cement hoses
should be pressure tested 1,5xDP. It is not recommended to standardize different test
pressures for different end connectors.

The wording “Working Pressure” in API Spec. 7K 5th Ed. section 9.6. Table 9 and elsewhere is
misleading, thus the present draft proposes to change it to “Rated Working Pressure”. (The
same wording is applied in API Spec. 16C 1st Ed. see section 2.2)

2

Ballot draft
add to 3.1 rated working pressure
The maximum internal pressure equipment is designed to contain and/or control.

change “working pressure” to “rated working pressure” in the following sections: 9.6.2.1 c);
9.6.2.4; 9.6.2.5; 9.6.2.7; 9.6.7.2; 9.6.9.1; 9.6.10.1.3; 9.6.10.2 c); 9.6.10.3.1; 9.6.10.4;
9.6.10.5

change “specified working pressure” to “rated working pressure” in 9.6.5.2 and 9.6.5.3

change “working pressures” to “rated working pressures” in 9.6.6.2 (in two places)

change 9.6.7.1.1 Each high pressure mud and cement hose assembly shall be hydrostatically
tested to 1.5 times of the rated working pressure (see Table 9). Test pressure shall be held for
a minimum of 15 minutes. The test medium shall be water.

9.6.7.1.2 should be deleted

9.6.7.1.3 numbering should be changed to 9.6.7.1.2

change 9.6.8 Rated working pressure
The maximum working pressure of the hose assembly is specified in Table 9.Maximum surge
pressures encountered in the hose shall be included in the rated working pressure. The rated
working pressure is identical to design pressure.

3

Draft Table 9 - Rotary Drilling & Vibrator Hoses, Cement Hoses,
Mud Delivery Hoses Dimensions and Pressures
Rated MBR
Inside Diameter API Test Preesure Safety Minimal Burst Pressure
Working Pressure operational a Remark
mm (in.) Grade MPa (psi) factor MPa (psi)
MPa (psi) m (in.)
A 10.3 (1500) 15.5 (2250) 2,5 25.8 (3750) 0.9 (36)

B 13.8 (2000) 20.7 (3000) 2,5 34.5 (5000) 0.9 (36)
C 27.6 (4000) 41.4 (6000) 2,5 69.0 (10,000) 0.9 (36)
50.8 (2.0) D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 0.9 (36)
103.4
69.0 (10,000) 2,25 155.2 (22,500) 1.2 (48) Cement
(15,000)
103.4
155.1 (22500) 2,25 232.7 (33,750) 1.4 (55) Cement
(15,000)
A 10.3 (1500) 15.5 (2250) 2,5 25.8 (3750) 0.9 (36)
B 13.8 (2000) 20.7 (3000) 2,5 34.5 (5000) 0.9 (36)
C 27.6 (4000) 41.4 (6000) 2,5 69.0 (10,000) 0.9 (36)
D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 0.9 (36)
63.5 (2.5) E 51.7 (7500) 77.6 (11,250) 2,5 129.3 (18,750) 1.2 (48)
103.4
69.0 (10,000) 2,25 155.2 (22,500) 1.2 (48) Cement
(15,000)
103.4
155.1 (22500) 2,25 232.7 (33,750) 1.5 (60) Cement
(15,000)
C 27.6 (4000) 41.4 (6000) 2,5 69.0 (10,000) 1.2 (48)
D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 1.2 (48)
E 51.7 (7500) 77.6 (11,250) 2,5 129.3 (18,750) 1.2 (48)
76.2 (3.0) 103.4
69.0 (10,000) 2,25 155.2 (22,500) 1.5 (60) Cement
(15,000)
103.4
155.1 (22500) 2,25 232.7 (33,750) 1.6 (64) Cement
(15,000)
C 27.6 (4000) 41.4 (6000) 2,5 69.0 (10,000) 1.4 (55)
88.9 (3.5) D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 1.4 (55)
E 51.7 (7500) 77.6 (11,250) 2,5 129.3 (18,750) 1.4 (55)
C 27.6 (4000) 41.4 (6000) 2,5 69.0 (10,000) 1.4 (55)
D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 1.4 (55)
101.6 (4.0) E 51.7 (7500) 77.6 (11,250) 2,5 129.3 (18,750) 1.5 (60)
103.4
69.0 (10,000) 2,25 155.2 (22,500) 1.8 (72) Cement
(15,000)
C 27.6 (4000) 41.4 (6000) 2,5 69.0 (10,000) 1.5 (60)
127.0 (5.0) D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 1.5 (60)
E 51.7 (7500) 77.6 (11,250) 2,5 129.3 (18,750) 1.8 (72)
D 34.5 (5000) 51.7 (7500) 2,5 86.3 (12,500) 1.8 (72)
152.4 (6.0)
E 51.7 (7500) 77.6 (11,250) 2,5 129.3 (18,750) 1.8 (72)
NOTE see Figure 11 for illustration of symbols
a MBR is taken to the centre-line of each hose

4

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Item 0201 ballot draft rev 1

A 10.3 (1500) 15.5 (2250) 2,5 25.8 (3750) 0.9 (36)

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