PIPE FABRICATION
MATERIALS, DRAWING AND FABRICATION METHODS
METALS AND ENGINEERING
ENG2068
Pipe fabrication
ENG2068
Materials, drawing and fabrication methods
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Training Sector Services
Telephone: 08 6212 9789
Email: sectorcapability.ip@dtwd.wa.gov.au
Website: www.dtwd.wa.gov.au
First published 2013
ISBN 978-1-74205-902-0
© WestOne Services 2013
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted in any form or by any means, electronic, mechanical, photocopying,
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Published by and available from
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Website: www.westone.wa.gov.au
This product contains various images ©Thinkstock 2013, used under licence. These
images are protected by copyright law and are not to be reproduced or re-used in other
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Data Chart at Appendix 1 has been reproduced with the permission of MRC Global
Australia.
Contents
Chapter 1 – Introduction to pipe fabrication
5
About pipe fabrication.......................................................................................................5
Codes and standards.......................................................................................................6
Approval of piping systems..............................................................................................7
Pipe fabrication abbreviations..........................................................................................8
Chapter 2 – Materials
13
Piping systems...............................................................................................................13
Pipe................................................................................................................................16
Pipe fittings.....................................................................................................................18
Flanges...........................................................................................................................29
Gaskets..........................................................................................................................37
Valves.............................................................................................................................40
Bolts...............................................................................................................................54
Brackets and hangers (support).....................................................................................58
Identification of piping.....................................................................................................73
Chapter 3 – Drawing
75
Types of drawings..........................................................................................................75
Types of projection.........................................................................................................82
Parallel line.....................................................................................................................92
Piping symbols...............................................................................................................98
Dimensioning and line types........................................................................................107
Chapter 4 – Fabrication methods
115
Pipe fabrication.............................................................................................................115
Preparing for fabrication...............................................................................................116
Fabrication process......................................................................................................123
Welding process...........................................................................................................129
Appendix 1 – MRC Data Chart
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Chapter 1 – Introduction to pipe
fabrication
About pipe fabrication
Pipelines are used to transport fluids, including vapours, gases, slurries and powders
which flow through pipes at various pressures and temperatures. The transmission of
these materials invariably subjects the pipe to intense stresses and strains and this
demands the highest possible performance from the pipe.
All pipework must be designed and fabricated in a way that ensures the safety of plant
operators, the plant, the public and the environment.
The fabricator is responsible for the quality of the pipework and pipe fabrication must
be carried out in accordance with all relevant standards and specifications. One faulty
weld could lead to damage costing millions of dollars, personal injury and in serious
cases even death. Welded pipe systems demand the highest degree of excellence in
materials and quality of work.
Because high standards are required, the cost of pipework is extremely high. Typical
costs for pipework in a manufacturing plant are shown in Table 1.1.
Field labour costs 47%
Material costs 23%
Design engineering costs 20%
Table 1.1: Fabrication costs
It is essential that pipework is fabricated by suitably trained and competent
tradespersons.
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Codes and standards
To ensure the highest standards of uniformity, safety and work quality, most piping
systems are designed, welded, installed and tested to rigid specifications or codes. The
most commonly used codes for welded pipework in Australia are as follows.
Standards Australia International Limited (SAI)
● AS/NZS 3992:1998/Amdt 1:2000 Pressure equipment – Welding and brazing
qualification
●
AS/NZS 4645.2:2008 Gas distribution networks - Steel pipe systems
●
AS 2885.4-2010 Pipelines - Gas and liquid petroleum - Submarine pipeline
systems
●
AS 1796-2001 Certification of welders and welding supervisors
●
AS 1074-1989 Steel tubes and tubulars for ordinary service
●
AS 4458-1997 Pressure equipment – Manufacture
●
AS 4041-2006 Pressure piping
American Society of Mechanical Engineers (ASME)
● ASME IX Piping systems in connection with power boilers, nuclear vessels and
unfired pressure vessels
American Petroleum Institute (API)
● API Std 1104 (R2010) Welding of Pipelines and Related Facilities – 20th Edition,
includes Errata 1 (2007) and 2 (2008)
American National Standards Institute (ANSI)
● ANSI/ASME B31.3 Chemical plant and petroleum refinery piping
●
ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe
Some insurance companies, manufacturers and the military forces set up their own
codes to cover the fabrication and welding of pipeline systems.
All codes are developed to establish uniform minimum standards for:
●
piping material
●
fabrication and welding procedures
●
quality of work
●
qualification of personnel
●
inspection and testing.
These standards ensure that there is maximum protection against accidents
occurring when the piping is in service.
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Approval of piping systems
There must be a high degree of quality control when high-pressure pipe systems are
being fabricated to ensure that they meet the specifications of the relevant codes.
The inspecting authority may be the machinery inspection branch of the state
or territory government, the insurance company underwriting the job or the
representatives of the client for whom the pipework is being fabricated.
The quality control program includes the following steps.
1.
Approval of the design of the pipe system.
2.
Approval of the fabricator who may have to prove that there is adequate equipment
and expert personnel to successfully meet the requirements of the relevant
code(s).
3.
Frequent checks to ensure that the specified material is being used.
4.
Approval of welding procedures and regular inspections to ensure that these
procedures are being followed.
5.
Qualification of welders who are tested to ensure that they are capable of carrying
out the approved procedures successfully.
6.
Non-destructive testing as required by the code(s).
7.
Post-weld heat treatment as required by the code(s).
8.
Final hydrostatic testing or alternative testing method.
Fabricators are responsible for the quality of the work they perform and for the
coordination of all inspection and testing procedures as required by the relevant
code(s).
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Pipe fabrication abbreviations
Abbreviation
Definition
ANSI
American National Standards Institute
ASME
American Society of Mechanical Engineers
ASTM
American Society for Testing and Materials
API
American Petroleum Institute
AWS
American Welding Society
ASSY
assembly
BB
bolted bonnet
BC
bolt circle
BE
bevelled ends (for welding)
BF
blind flange
BM
bill of material
BOP
bottom of pipe
BLDG
building
BW
butt weld
˚C
degrees Celsius
centre-line
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CH. OP.
chain operated
CI
cast iron
CO2
carbon dioxide
COND
condensate
CORR
corrosion or corrosive
CONC
concentric
CPLG
coupling
CS
carbon steel, cast steel or cold spring
Ø
diameter
DIA or D
diameter
DF
drain funnel
DWG
drawing
ECC
eccentric
EFW
electric fusion welded
EL
elevation
ELL
elbow
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Abbreviation
Definition
ERW
electric resistance welded
FF
flat faced or full faced
FFW
field fit and weld
FIG
figure or figure number
FLG
flange
FOB
flat on bottom
FW
field weld
GA
general arrangement
GALV
galvanised
GJ
ground joint
GR
grade
HC
hydrocarbon
HDR
header
ID
inside diameter
IDD
inside depth of dish
INS
insulate
INV
invert (inside bottom of pipe)
LC
lock closed
LO
lock open
LR
long radius
M&F
male and female
MFG
manufacture or manufacturing
MI
malleable iron
MIN
minimum
MW
mitre weld
NC
normally closed
NO
normally open
NS
nominal size
OD
outside diameter
plate
PCD
pitch circle diameter
PE
plain end (not bevelled)
P&ID
Pipe and instrument diagram
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Abbreviation
10
Definition
PFD
Process flow diagram
PI
point of intersection
PR
pair
RED
reducer
REINF
reinforce
RF
raised face
RTJ
ring type joint (sometimes just designated RJ)
SCH
schedule
SCRD
screwed
SMLS
seamless
SO
slip on
S.O.
steam out
SPEC
specification
SQ
square
SR
short radius
SS
stainless steel
STD
standard
STL
steel
STM
steam
SW
socket weld
SWG
swage
SWP
standard working pressure
SC
sample connection
TC
test connection
TE
threaded end
TEMP
temperature
T&C
thread and coupled
T&G
tongue and groove
TOC
top of concrete
TOS
top of steel
TYP
typical
VET
vertical
WB
welded bonnet
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Abbreviation
Definition
WE
weld end
WN
weld neck
WT
weight
XH
extra heavy
XXH
double extra heavy
XS
extra strong
XXS
double extra strong
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Chapter 2 – Materials
Piping systems
There are three common methods of joining piping, each with its own advantages and
disadvantages.
Butt welded piping systems are used for most process, utility or service piping. Butt
welding is the most practicable way of obtaining strong, leak-proof joints; especially
on larger piping. The pipe and fitting used have, or are prepared with, standard weld
preparation. They require high levels of workmanship in their assembly and welding.
B
Detail B
Scale 1/2
Fig 2.1: Butt welded piping system
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Socket-welded piping systems are used for lines of small diameter which carry
flammable, toxic or expensive materials where no leakage is permitted. They are easier
to assemble and weld than butt welds and no weld metal can enter the bore. The
pipe end is finished square and fitted into the fittings, usually with a 1.5 mm gap. This
gap sometimes pockets liquids and is not recommended if severe erosion of crevice
corrosion is anticipated.
C
Detail C
Scale 1/2
Fig 2.2: Socket-welded piping system
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Screwed piping systems are used for small lines, usually of 50 mm diameter and are
easily assembled using standard fittings. The removal of metal to create the thread is a
disadvantage and fatigue strength is poor. There is no need for coded welders when a
screwed pipe system is used except where seal welding is undertaken.
Only butt welded and socket welded systems will be dealt with in this text.
A
Detail A
Scale 1/2
Fig 2.3: Screwed piping system
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Pipe
Pipe is specified by stating its nominal size (NS), which is only approximate. Nominal
size is neither the inside nor the outside diameter and it is necessary to use standard
tables or manufacturers’ tables to ascertain these two dimensions exactly.
Pipe thicknesses are often described as ‘standard’ (STD), ‘extra strong’ (XS) and
‘double extra strong’ (XXS). However, most manufacturers have adopted the American
piping code classification which classifies pipes into a schedule system. The mass
of the pipe is referred to as the schedule of pipe, and may vary from Schedule 10 to
Schedule 160.
As the schedule number increases so does the wall thickness, and as a consequence
the inside diameter reduces. The outside diameters remain constant enabling
standardisation of pipe brackets or threading. The exact wall thickness can be
determined from standard tables.
Pipe nominal size versus actual
outside pipe diameter
Schedule pipe wall thickness
NS 100 pipe
SCH 10
SCH 40
NS 100
114.3
(+14.3)
NS 150
168.3
(+18.3)
NS 200
219.1
(+19.1)
NS 250
273.1
(+23.1)
Nominal
pipe size
3.05
6.02
SCH 80
8.56
SCH 160
13.49
Pipe wall
Outside diameter
Fig 2.4: Comparison of nominal size and schedule for 100 NS pipe
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Pipes are sometimes referred to as tubes. The primary difference is in how they are
measured, Boiler tubes and tubing are known by their outside diameter and their wall
thickness. Both dimensions are required when ordering.
Carbon steel pipe
Carbon steel (CS) pipe is by far the most common pipe used and it is supplied to
strict specifications.
Straight seam-welded and spiral-welded pipe is made from plate, and seamless pipe
is made by piercing solid billets.
CS pipe is strong, weldable, durable, ductile, machinable and cheaper than most
other materials.
If CS pipe can meet the requirements of pressure, temperature, corrosion, resistance
and hygiene, it is a cost effective choice.
CS pipes in common use are manufactured to the following standards:
●● ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe
●● AS 1074-1989 Steel tubes and tubulars for ordinary service
●● BS 1387:1985 Specification for screwed and socketed steel tubes and tubulars
and for plain end steel tubes suitable for welding or for screwing to BS 21
pipe threads.
Dimensions for pipes covered by these standards are, for practical purposes,
the same.
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Pipe fittings
A pipe fitting may be defined as any type of pipe connector that is used to:
●●
make a connection
●●
change the size or direction of pipes or
●●
change the pipe specification from one material to another.
Fittings are classified by the method of end fixing, eg. butt welding, socket-welding,
screwed or flanged and by name, eg. 90° and 45° elbows, reducing elbows, short and
long radius bends, equal and unequal tees, concentric and eccentric reducers and
stub ends.
How are fittings rated?
Fittings are rated by nominal working pressure in cold, non-shock conditions.
Pressure rating
Manufacturer’s
weight
Schedule no.
Pressure rating
PSI
kPa
2000
13 790
STD
40
3000
20 670
XS
80
6000
41 340
XXS
160
Table 2.1: Relationship between PSI, kPa and the schedule
Socket weld fittings are not manufactured in 2000 PSI (13 790 kPa).
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Butt welded fittings
Butt welded fittings have a 30° truncated edge with a designed weld preparation
consisting of a root gap and landing that is welded. Types in common use are shown in
Figure 2.5.
180o Long radius Weld ELL
90o Short radius
Weld ELL
Straight
tee
180o Short radius Weld ELL
90o Long radius
Weld ELL
Reducing
tee
90o Reducing long
radius Weld ELL
Concentric
reducer
Cap
45o Long radius
Weld ELL
Eccentric
reducer
Fig 2.5: Butt welded fittings
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Preparation for butt welds
Unless the piping system is of a large enough diameter to permit internal access,
butt welds must possess sound and smooth root penetration when welded from the
outside.
To achieve this, the weld preparation requires careful attention and the root face, root
gap and root alignment are all critical. A single-Vee preparation is most common with
the dimensions as shown in Figure 2.6.
300
+7½
-0
1.5 mm
2 - 3 mm
Fig 2.6: Preparation for butt weld
Butt weld elbows
Elbows are fittings which are used to change the direction of flow. They are available
for changes in direction of 180°, 90° and 45°. The 180° elbow is also referred to as a
‘return bend’. All butt weld elbows are supplied with bevelled ends.
The 90° butt weld elbow is used to make a 90° offset-in any direction. It is available
in short and long radius. The radius of the fitting is important when calculating cutting
sizes as it must be subtracted in order to achieve correct centre line dimensions.
The long radius elbow is most common, and equals one-and-a-half times the nominal
pipe diameter from the face of the weld preparation to the elbow’s centre-line. Unless
otherwise specified long radius elbows will always be supplied.
1½ × NPS
90o Long radius weld ELL
1 × NPS
90o Short radius weld ELL
Fig 2.7: Short and long butt welding elbows
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When an offset is required where the angle is not than the standard fitting, it is
customary to use a 90° or a 45° elbow and cut to the desired angle.
Critical dimensions of elbows and other fittings can be obtained from standard tables.
Reducing elbows
Reducing elbows facilitate a change in line size along with a 90° change in direction.
The centre-line radius is one and a half times the nominal size of the larger end.
Fig 2.8: Reducing elbow
Return bends
Return bends are used to change the direction of piping through 180°. Long radius
returns have a radius of 1½ × NS, ie centre to centre distance of 3 × NS.
3 × NS
2 × NS
180o Long radius weld ELL
180o Short radius weld ELL
Fig 2.9: Return bends
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Lap joint stub ends
Lap joint stub ends are flared pipes that accommodate slip on flanges. They are
supplied mainly in material other than carbon steel, eg stainless steel.
As an economic measure carbon steel flanges are used as an alternative to stainless
steel flanges. The flanges are allowed to float free and can swivel which is useful when
pipes are being aligned.
Fig 2.10: Lap joint stub end
Reducers
Reducers are used to join a smaller pipe to a larger one. Reducers are available in two
types – eccentric and concentric. Eccentric reducers are used when the top or bottom
of the line needs to be kept level.
Fig 2.11: Concentric and eccentric reducers
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Butt welding tees
Butt welding tees are used to make 90° branches from the main run of pipe and may be
either straight or reducing. Reducing tees have a 90° branch smaller than the main line.
Tees with branches larger than the main line are seldom used, as they must be made
to order.
Fig 2.12: Straight and reducing tees
How to specify tees
Equal tees are abbreviated, eg a NS 150 mm straight tee = NS 150 EQ tee.
Reducing tees are specified in the following order:
Run inlet
Run outlet
Branch
NS 100
NS 100
NS 80
Specified red tee: 100 × 100 × 80
Laterals
Laterals let branches enter at odd angles to the main run and both straight and
reducing laterals are available. 45° straight laterals are the most common and are
available in STD or XS weights.
Reducing laterals and laterals at odd angles usually require special order. Reducing
laterals are ordered in a similar way to ordering reducing tees, except that the branch
angle is also stated.
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Fig 2.13: A lateral
Caps
Caps are used to seal off the ends of pipes.
Fig 2.14: A cap
Socket-welded fittings
Socket-welded fittings allow for easy fabrication and fit-up of piping. Square end
preparation of the pipe is all that is required and fillet welds are used, preferably made
in two passes.
Lower levels of operator skill are required to assemble and weld socket joints than are
required for butt joints. The socket-welding system is preferable to the screwed system
as it is simpler to assemble and avoids the possibility of leakage which sometimes
arises in screwed joints.
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Elbows
Socket-welding elbows are available to make changes in direction of 90° or 45°.
Fig 2.15: A socket-welding elbow
Tees
Tees make 90° socket-welded branches either as straight or reducing tees.
Fig 2.16: A socket-welding tee
Laterals
Laterals are available to make 45° branches.
Fig 2.17: A socket-welding lateral
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Coupling
Full couplings are used to join a pipe to a pipe or to a swage of the same diameter. Half
couplings are also available but are not in common use as Sockolets® are generally
preferred.
Fig 2.18: Couplings
Reducers
Reducers are similar to couplings but are used to join pipes of different diameters.
Fig 2.19: A reducer
Reducer inserts
Reducer inserts are used to connect smaller pipes to larger fittings.
Fig 2.20: Reducer inserts
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Swaged nipple or ‘swage’
Swages are used to join socket-welded fittings of different sizes or to weld a socketwelded fitting to a butt welded fitting of a larger size.
When ordering swages, it is necessary to specify nominal diameter, the weight of the
pipes to be joined and the end preparation.
Fig 2.21: A swaged nipple
It is possible to make custom reducer inserts or tees by boring standard blanks.
Normal specification tolerances call for a 1.6 mm shrinkage gap when assembling
socket weld fittings Figure 2.22). Dimensions of socket weld fittings can be obtained
from standard tables.
Max 2 t
Diametrical
clearance 0.75 mm
c
t
1.5 mm approximately
Not less
than 3 t
c-minimum — 1 ¼ t
But not less than 3 mm
t = nominal pipe wall thickness
Fig 2.22: Section view of swage tolerances
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Specialised weld fittings
Specialised weld fittings are designed for making right-angle branch-type outlets such
as tees, crosses and side outlets by welding. They are available in all common types of
material, eg carbon steel, chrome/moly and stainless steel.
Using specialised fittings eliminates the need for parallel line development. No
templates are used and threading, forming or complicated fitting are not necessary.
They are available to make butt welded, socket-welded and welded/screwed joints.
Specialised fittings come in a range of sizes and are fully approved by most design
codes.
®
Weldolet®
Butt-welded Elbolet®
Sweepolet®
Sockolet®
Thredolet®
Butt-welded Latrolet®
Nipolet®
Socket-welded Elbolet®
Socket-welded Latrolet®
Screwed Elbolet®
Screwed Latrolet®
Fig 2.23: Specialised weld fittings
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Flanges
Flanges are used primarily as a way of connecting valves and fittings to pipes and they
vary widely in size and type. They enable valves to be removed periodically for repair or
replacement. Like pipe and pipe fittings they are made to strict code specifications.
Flanges, like pipes, are referred to by nominal size and flange type, ie weld-neck
flange, slip-on flange, as well as by class and the type of flange face.
Flange types
Flange types need to match the designed pressure and temperature ratings of piping
systems.
Weld neck flanges
Weld neck flanges are distinguished from other types of flanges by their long tapered
hub and gradual transition of thickness in the region of the butt weld joining them to
the pipe. The hub provides an important reinforcement of the flange itself from the
perspectives of strength and resistance to ‘dishing’.
The smooth transition from flange thickness effected by the taper is extremely
beneficial under repeated conditions of bending caused by pipeline expansion or other
variable forces. It produces an endurance strength of weld neck flanged assembles
equivalent to that of a butt welded joint which, if done properly, is the same as that of a
seamless pipe. This type of flange is preferable for very severe service conditions such
as high-pressure, sub-zero or elevated temperatures.
Fig 2.24: A weld neck flange
Slip-on flanges
Slip-on flanges are used extensively because of their lower initial cost. They are easier
to fix than a weld-neck type as the pipe does not require such accurate cutting and the
ease of alignment to an assembly is simplified.
However, the final installed cost is not much less than that of the weld-neck flange and
their strength under internal pressure is approximately two-thirds that of weld-neck
flanges with life under fatigue approximately one-third.
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Fig 2.25: A slip-on flange
Socket-welding flanges
Socket-welding flanges are used fairly extensively in chemical process piping, as
smooth, pocketless bore conditions can be obtained by grinding the internal weld flush.
Their cost is about 10 per cent greater than the slip-on flange. Their static strength is
about equal to welded slip-on flanges but their fatigue strength is 50 per cent greater.
Fig 2.26: A socket-welding flange
Lap joint flanges
Lap joint flanges are used mainly with carbon or low alloy-steel piping systems where
the services necessitate frequent dismantling for cleaning and inspection. They also
simplify erection, as the flange can be swivelled to align bolt holes. They require
lap joint stubs and the combined initial cost of the flange and stub is approximately
one-third higher than a comparable weld-neck flange. Their pressure-holding ability
is no better than slip-on flanges and the fatigue life of the assembly is approximately
one-tenth of a weld-neck flange. They should not be used where severe bending
stress occurs.
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Lap joint
Slip on
Fig 2.27: A lap joint flange
Blind flanges
Blind flanges are used to close off the ends of piping, nozzles or valves. Due to internal
pressure acting to bend blind flanges at their centre, they are the most highly stressed
of the flange types. Where severe water-hammer or temperature is a service factor
consideration should be given to the use of closures made from weld-neck flanges and
caps.
Fig 2.28: A blind flange
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Orifice flanges
Orifice flanges are used to measure the flow rate of liquids and gases within a pipeline,
thus eliminating the need for hot tapping or pipe modification.
The orifice flange consists of two flanges with an additional tapped hole in each so
that monitoring equipment, an orifice plate and jacking bolts can be attached. These
facilitate the separation of flanges when they need to be inspected.
Orifice flanges come in a range of nominal sizes and types, such as weld neck, slip on
and screwed.
A
A
A-A
Fig 2.29: An orifice flange
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Flange facings
There are many facings offered but only a handful are in common use. The main
variables in flange facings are the profile of the flange face; the smoothness of the face;
and whether or not the use of a gasket is employed.
Raised face
Raised face is by far the most common type used, accounting for approximately 80%
of all applications. The face is raised 1.6 mm for Class 150 and Class 300 flanges, and
6.5 mm for other classes.
The raised face is machine finished with either concentric or spiral grooves
approximately 0.4 mm deep which bite into and hold the soft, flat gasket normally
employed with this face type.
6
Fig 2.30: A raised face weld neck
Flat face
The most common use for flat face is for non-steel flanges such as cast iron or plastic.
The gasket used has the same outside diameter as the flange. This reduces the danger
of cracking the flange when tightened.
Fig 2.31: A flat face weld neck
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Ring joint
Although expensive, the ring joint facing is the most efficient facing for high-pressure
and high-temperature service. Both flanges of the pair are alike, with a groove
machined into each face. (Flat bottom grooves are standard.) Oval or octagonal ring
type gaskets are fitted into the groove before tightening.
Fig 2.32: A ring joint weld neck
Lap joint
The lap joint flange in combination with the lap joint stub end provides a joint facing
similar to that of a raised face flange.
Slip on
Lap joint
Fig 2.33: A lap joint slip-on
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Male and female
Male and female facings come in two standard types – one with a large male–female
contact area and the other with a small male–female contact area. The large
male–female contact area is excessive for use with metal gaskets and the small
male–female contact is not suitable for use with screwed fittings of standard weight.
The male face is usually 6.5 mm high (1/4”) and the female face is approximately
4.7 mm (3/16”) deep. Both faces are usually smooth and the outer diameter of the
female face acts to locate and retain the gasket.
Fig 2.34: Male and female butt welds
Tongue and groove
Tongue and groove fittings are designed to match each other and, although similar to
male and female fittings, the grooves do not extend into the flange base. These types
of flanges are self-aligning which is useful when bore alignment is critical. Tongue and
groove fittings are available in all nominal sizes.
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Fig 2.35: A tongue and groove butt weld
Finish
Finish refers to the surface texture of the flange face and may be either ‘serrated’ or
‘smooth’. A serrated finish is produced by machining grooves into the surface. A smooth
finish is usually specially ordered and comes in two qualities – the regular smooth finish
which shows no tool marks to the naked eye or the ‘cold water finish’ which is even
smoother. The cold water finish is normally used without gaskets.
Class rating
Flanges are given a ‘class’ rating which refers to service pressure and temperature.
The class of flange may be: 150, 300, 400, 600, 900, 1500, 2500.
The number of boltholes in a flange varies with the size and class. For example, a
class 150, 80 mm flange has four boltholes, and a class 150, 150 mm flange has eight
boltholes. In a class 300, an 80 mm flange has eight boltholes and a 150 mm has
twelve boltholes.
The diameter of the bolthole also varies with class so that large diameter bolts may be
used for additional strength in the heavier classes.
Dimensions of each class of flange, and the dimensions of the bolts used by these
flanges can be determined from standard tables.
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Gaskets
Gaskets are used to provide leak tight joints between matching surfaces. Gasket
materials vary widely and may include:
●●
non-metals – such as paper and rubber
●●
metals – such as copper, iron or stainless steel
●●
combinations of metals and non-metals.
The choice of gasket materials depends on factors such as service pressure, service
temperature, corrosion, bolt loadings and cost.
Gasket types
Gasket types need to match the designed pressure and temperature ratings of piping
systems and the flange type.
Flat ring gaskets
Flat ring gaskets are the most commonly used. They vary in thickness from
approximately 0.2 mm up to approximately 6 mm (the former being the most common),
and in width from approximately 6 mm upwards.
Narrow gaskets are preferred, as they require lower bolt loadings to obtain an effective
seal. However, they must not be too narrow, in case they become crushed or indented
into the flange.
Serrated gaskets
Serrated gaskets are flat metal gaskets which have concentric grooves machined into
their faces. The reduced surface area provided by the grooves allows an efficient seal
at lower bolting loads. They are commonly used with smooth faced flanges where
gaskets of soft material would be unsuitable.
Fig 2.36: A serrated gasket
Laminated gaskets
Laminated gaskets are made up of a skin with a filler material. There are two basic
types of laminated gasket:
●●
flat jacketed
●●
spiral wound.
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Flat jacketed gaskets
Flat jacketed gaskets can be used at higher temperatures than plain flat gaskets and
they require lower bolt loads than flat metal gaskets.
Fig 2.37: A flat jacketed gasket
Spiral wound gaskets
Depending on the type of metal–filler combinations, spiral-wound gaskets are suitable
for raised face, flat faced and lap joint flanges at pressures up to 7000 kPa (1000 PSI)
and temperatures up to 1000°C.
Fig 2.38: Spiral wound gaskets
Ring joint gaskets
Ring joint gaskets are available with either an oval or octagonal cross-section. They
can be used with all classes of flange, especially the 600 – 2500 lb classes. They are
manufactured from soft iron, low-carbon steel, chromium and molybdenum steel and
stainless steels For relatively low-temperature joints, plastic may be used to prevent
corrosion or to provide electrical insulation.
Fig 2.39: A ring joint gasket
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Insulating gaskets
Gaskets made of non-conductive material together with insulating sleeves around bolts
are used where it is necessary to provide electrical isolation between parts of a line.
A guide to the suitability of gasket materials is provided in Table 2.2.
Maximum
service
temperature °C
Maximum
pressure at
temperature
Synthetic rubber
120
450 kPa (60 PSI)
Synthetic rubber with cloth insert
120
3450 (500)
Teflon
250
2050 (300)
Carbon steel
400
14 200 (2100)
Stainless steel
650
17 250 (2500)
S/S Teflon
250
S/S ceramic
1000
Material
Ring type joint
Spiral wound
above 3450 (500)
Table 2.2: Material gasket vs temperature and pressure
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Valves
The variety of valves available for use in piping systems is extensive. This is due to the
range of functions that valves perform, the diversity of fluids carried, and the varying
conditions under which valves must perform these tasks.
Valves can be examined under the following headings:
●●
basic parts
●●
functions performed by valves
●●
valve types
●●
installation of valves
●●
specification of valves.
Basic parts of a valve
Despite vast differences in valve design, common parts can be identified.
Bonnet
Stem
Disc
Seat
Body
Fig 2.40: Basic parts of a valve
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The body
The body is the main structure of the valve which contains – or to which is attached
– the other parts of the valve. The body must possess sufficient mechanical strength
and sufficient resistance to corrosion, erosion and high temperature to meet service
conditions. The material from which the valve body is made is important in this regard
and common materials in use include carbon steel, low-alloy steel, bronze, brass,
stainless steel and monel.
The disc, seat and port
The disc, seat and port arrangement is the means of controlling the flow of fluids
through the valve. Regardless of shape and arrangement the disc is the moving part
that directly controls the flow. The non-moving part upon which the disc bears is called
the seat, and the port is the maximum internal opening through which the fluids can
pass.
The stem
The stem is used to move the disc. It is usually a screwed rod, although in some cases
fluid under pressure moves the disc. There are two basic stem types.
●●
The rising stem – As the valve is operated, the stem rises, lifting the disc with
it. The hand wheel can either rise with the stem, or the stem can rise through the
hand wheel.
Stem
bushing
Stem
bushing
Stem moves
down through
valve bonnet
Stem moves
up through
stem bushing
and handwheel
Gate withdrawn
from line of flow
Gate seated
to block
line of flow
Fully open
Fully closed
Fig 2.41: The rising stem
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●●
The non-rising stem – The stem remains in the same position whether the
valve is open or closed. The disc moves up the thread on the stem as the valve is
operated. The screw is inside the bonnet and in contact with the fluid carried.
Stem turns with handwheel
but does not move
up or down
Gate threads down
off stem and seats
Gate threads up
onto stem
Fully open
Fully closed
Fig 2.42: The non-rising stem
The bonnet
The bonnet is the top housing of the valve. It provides a bearing in which the stem can
run. It acts as a means of sealing the stem of the valve against leakage (usually by
means of a gland and packing). There are three basic means of attaching the bonnet to
the valve body.
42
●●
The screwed bonnet is generally used on small, low pressure valves. A problem
which can sometimes occur with the screwed bonnet is that the bonnet can
become unscrewed as the valve is operated. This is caused by a tight or ‘sticky’
stem.
●●
The bolted bonnet is the most common type used in refinery applications. It is
suitable for medium/high pressure applications.
●●
The breech lock is a heavier more expensive bonnet, normally used for high
pressure work. It employs a seal weld to guard against leakage.
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The operator
The operator is the method of actuating the valve. Valves may be operated manually:
by the use of hand wheels, levers and chains, by geared hand wheels on larger valves
or by powered operation employing electric, pneumatic or hydraulic actuators. Powered
actuators are normally used when:
●●
rapid opening or closing is required
●●
the valve is operated very frequently
●●
access to the valve is difficult
●●
the operation of the valve requires great effort
●●
valve operation present a safety hazard.
Functions performed by valves
Valves perform the following basic functions.
●●
They shut off supply in a pipeline or they enable a piece of pipeline to be isolated
so that repairs to piping or equipment can be carried out faulty or damaged items
can be replaced, etc. This is a shut-off or stop valve.
●●
They throttle, regulate or restrict the flow passing along a pipeline by partially
closing the area of flow through the valve.
●●
They redirect the flow at a branch line by changing the path along which the flow
occurs.
●●
They protect a system against excessive pressure or sudden increases in
pressure. These are safety valves or relief valves. When the pressure in a line
reaches a pre-set high pressure, the valve opens and allows the pressure to
escape either to atmosphere or to another part of the system. Safety valves are
generally used for steam, air or other gases. Relief valves are usually used for
liquids.
●● They enable one part of a continuous system of piping to operate at a different
pressure from another part. These are pressure-reducing valves (also known as
pressure regulators) and are often used in air piping to reduce the compressor or
main line pressure down to a low value for operation of low-pressure equipment.
●● They prevent flow in one direction along a pipe or they allow flow in one direction
only. This valve is referred to as a non-return, or check or reflux valve.
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Types of valves
The type of valve to be used depends on the function it is to perform and the conditions
under which it is expected to perform.
The following types of valves can be used:
●●
gate valve
●●
globe valve
●●
diaphragm valve
●●
ball valve
●●
taper plug valve
●●
butterfly valve
●●
check (non-return) valve
●●
relief valve.
Gate valve
Because of the disc and seat design, the gate valve is for on–off use, and not for
throttling applications. If gate valves are used for throttling applications, they may
damage the disc and seat through erosion or vibration.
Fig 2.43: A gate valve
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Globe valve
The term ‘globe valve’ is applied loosely to a valve whose body is globeshaped or has
globelike features. Globe valves are generally suitable for throttling applications, with
the design of the valve determining how closely flow can be regulated. The direction of
flow through a globe valve is usually from stem to seat to assist leaktight closure of the
valve.
Fig 2.44: A globe valve
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Types of globe valves include:
Angle globe valve
An angle globe valve changes direction through 90°.
Fig 2.45: An angle globe valve
Needle valve
A needle valve is a small valve used for precise flow control.
Fig 2.46: A needle valve
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Wye valve
Because of its smooth flow pattern, a wye valve is preferable for use with erosive fluids.
Fig 2.47: A wye valve
Diaphragm valve
The diaphragm valve is generally used where particles or fibres are carried, eg
slurries. The diaphragm is capable of sealing against these particles and it gives full,
unrestricted flow in the fully open position. The disc is usually a rubber diaphragm.
Handwheel
Bonnet
Stem
Compressor
Rubberised
diaphragm
Diaphragm
weir seat
Fig 2.48: A diaphragm valve
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Ball valve
A spherical ball is used to block the bore of this valve and cut off the flow. The ball,
which has a hole through it, is rotated 90° by a lever and flow is permitted when the
hole through the ball lies along the pipe axis.
Lever handle
Retainer nut
Body
Cartridge
O-ring (top)
Stem O-ring
Stem
Cartridge
O-ring (bottom)
Seat ring
Ball
Ball retainer
Fig 2.49: A ball valve
Taper plug valve
Similar to a ball valve, a tapered (conically shaped) plug is used to seal the bore of the
valve. A hole through the plug is used to permit flow when this hole is lined up with the
axis of the pipe.
Ball and plug valves are quick and easy to operate and require only a 90° turn of the
lever to open or close the valve. When these valves are closed, they pocket fluid in the
ball or plug, which may create problems when used with corrosive fluids.
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Stem
Grounding
spring
Valve
cap
Adjuster
rocker-arm
adjustment
TFE diaphram
cap seal
Valve
body
TFE sleeve
positive shut-off
plug and body seal
Raised ribs, grooves,
and recesses positively
lock sleeve in body
Tapered
plug
Fig 2.50: A taper plug valve
Butterfly valve
A butterfly valve has a circular disc, which is approximately the size of the pipe bore in
diameter. This disc rotates around its centre, so that when closed, the disc completely
covers and seals the bore of the pipe.
When fully open, the disc thickness lies along the centre of the pipe. The contents of
the pipe then pass down and past both sides of the disc.
The butterfly valve has the advantage of 90° on–off operation and does not pocket
fluids like the ball and plug valve.
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Handle
Stem
Packing
Body
Disc
Seat
Closed
Open
Fig 2.51: A butterfly valve
Check (non-return) valve
Check valves permit flow in one direction only. The valve closes if flow is reversed.
Swing check
Lift check
Fig 2.52: A check valve
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Relief valve
Relief valves are used to prevent build-up of excessive pressure of gas or liquid in lines
or vessels. They usually operate against a pre-set spring loading. Relief valves for gas
are designed to permit a large flow; a small flow which will rapidly decrease pressure is
usually all that is required for liquids.
Fig 2.53: A relief valve
Installation of valves
Valves may be attached to lines or vessels by the following methods.
Screwed attachments – Generally used on small diameter, low pressure lines.
Flanged joints –The body of the valve is flanged to make it compatible with flanges of
the same pressure rating. It offers the advantages of easy installation and removal, and
is suitable for medium/high pressure applications.
Butt weld attachments – The valve ends are supplied with standard weld preparation.
Although difficult to fit and remove, this is the preferred method for extreme service
applications. Weld procedures should be designed so as to minimise distortion of the
valve body.
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Wafer valves – These have no flanges of their own and are sandwiched between the
flanges on the pipe ends. They are located and held in position by the bolts which pass
between the pipe flanges. Because the pipe flanges are held a distance apart equal to
the thickness of the wafer valve, longer bolts than usual will be required. The valve has
flat faces which contact the flanges. Gaskets or O-rings are used to seal against leaks.
The outer diameter of the body is made to suit the pitch circle diameter (PCD) of the
bolts of the flange. The bolts go around the valve body rather than passing through it.
Fig 2.54: A wafer valve
These guidelines should be followed when valves are being installed.
52
●●
The direction of flow through the valve must be correct. Where this is important,
flow direction will be indicated on the valve body (usually by an arrow).
●●
Valves should be placed in horizontal rather than vertical runs to facilitate the
draining of the line when the valves are closed.
●●
Heavy valves should be suitably supported. A minimum of 300 mm between flange
and support should be allowed to facilitate installation and removal.
●●
For aesthetic reasons, it is important to keep the centre-lines of valves at the same
height and in line on the plan view.
●●
There should be no safety hazards for the operator to contend with when
accessing valves.
●●
Lines carrying hazardous materials should have valves placed in such a way that
the operator does not have to reach up to open or close them.
●●
Valve stems should not point downward at any angle below the horizontal. This
prevents sediment from collecting in the gland packing which may damage the
stem.
●●
Valve stems should not be pointed into walkways, etc.
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Specification of valves
Manufacturers use identification codes or model numbers to identify their valve; these
are usually cast or stamped into the valve body. There is no standard system and each
manufacturer uses their own so it is necessary to consult manufacturers’ catalogues to
assist in the identification or ordering of valves. The important factors which determine
the suitability of a particular valve for use are:
●●
pressure rating
●●
valve type (gate, globe, etc)
●●
method of attachment
●●
type of operator
●●
disc and seat material
●●
body material.
These same factors are also used to classify the different valve models.
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Bolts
Bolts are used to assemble the piping system through the flanges. They are graded
for tensile strength which is affected by temperature and pressure ratings of the piping
system.
Flange bolts
Two types of bolts are available for the assembly and tightening of flanges:
1.
the machine bolt, which uses one nut
2.
the stud bolt, which uses two nuts.
Fig 2.55: A machine bolt and a stud bolt
Stud bolts have become the preferred method of bolting flanges. They offer the
following advantages.
●●
They can be removed easily (especially when corroded).
●●
They are not easily confused with other bolts used on site.
●●
They can be made from round stock.
●●
The bolt sizes required for flanged joints are readily available from manufacturers’
tables.
Procedure for application of bolt torque on flanged
joints
Step 1
Component parts must be aligned and clamped together with the hold down.
Step 2
Stud (or bolt) threads in area of nut (or forged ring) engagement should be lubricated.
The face of nuts (or bolt heads) should also be lubricated using a suitable lubricant.
Step 3
All bolts should be installed so that torqueing requirements can be followed.
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Step 4
All bolts should be numbered so that torqueing requirements can be followed.
Step 5
Torque should be applied in 20% (1/5) steps of required final torque, with all bolts
loaded at each step before the next step is undertaken.
Step 6
Bolts should be tightened in sequential order: 0°–180°, 90°–225° and
135°–315° at each step until final torque is reached. (See Figures 2.56 – 2.60.)
Step 7
Rotational tightening should be used until all bolts are stable at final torque level; two
complete times around are usually required.
Bolt torque procedure
1
0°
8
5
315 °
4
45 °
270 °
6
90 °
225 °
135 °
180 °
3
7
2
Sequential order
Rotational order
1–2
1
3–4
5
5–6
3
7–8
7
2
6
4
8
Fig 2.56: Eight bolts per flange
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Bolt torque procedure
1
12
8
4
10
0°
330 °
300 °
Bolt torque procedure
16
5
8
30 °
60 °
270 °
9
3
90 °
240 °
210 °
6
120 °
180 °
2
12
7
4
14
11
0°
9
22½ ° 5
45 °
292½ °
67½ °
270 °
90 °
247½ °
6
150 °
337½ °
315 °
1
112½ °
225 °
135 °
202½ °
157½ °
180 °
10
15
2
13
3
11
7
Sequential order
Rotational order
Sequential order
Rotational order
1–2
1
1–2
1
2
3–4
5
3–4
9
10
5–6
9
5–6
5
6
7–8
3
7–8
13
14
9–10
7
9–10
3
4
11–12
11
11–12
11
12
2
13–14
7
8
6
15–16
15
16
10
4
8
12
Fig 2.57: 12 bolts per flange
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Fig 2.58: 16 bolts per flange
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Bolt torque procedure
Bolt torque procedure
20
8
1
13
342 ° 0 ° 18 °
324 °
36 °
306 °
16
4
12
3
90 °
252 °
18
9
72 °
270 °
108 °
234 °
126 °
7
216 °
144 °
198 °180 ° 162 °
19
6
11
14
2
Sequential order
8
17
54 °
288 °
10
5
15
20
24
1
9
17
345 ° 0 ° 15 °
330 °
30 °
315 °
45 °
300 °
5
60 °
13
12
285 °
75 °
21
4
270 °
90 °
3
255 °
22
14
105 °
240 °
6
Rotational order
16
120 °
225 °
135 °
150 °
210 °
7
195 ° 180 ° 165 °
18
10
Sequential order
2
23
11
19
15
Rotational order
1–2
1
2
1–2
13–14
1
2
3–4
13
14
3–4
15–16
9
10
5–6
5
6
5–6
17–18
17
18
7–8
17
18
7–8
19–20
5
6
9–10
9
10
9–10
21–22
13
14
11–12
3
4
11–12
23–24
21
22
13–14
15
16
3
4
15–16
7
8
11
12
17–18
19
20
19
20
19–20
11
12
7
8
15
16
23
24
Fig 2.59: 20 bolts per flange
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Fig 2.60: 24 bolts per flange
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Brackets and hangers (support)
Piping systems may be subjected to a variety of stresses, which means that the
pipework has to be supported. The lifespan of the pipe will be extended if appropriate
supports are used to accommodate expansion and contraction due to environmental
conditions.
Stresses affecting pipe support
The forces acting on pipework are:
●●
the mass (weight) of the pipework and fluids carried by it
●●
thermal expansion and contraction
●●
vibration
●●
settlement stresses.
The mass (weight) of the pipework
Piping systems may have considerable mass that needs to be supported; this factor is
a major consideration in the design of pipework. For example, a reduction of mass is a
significant reason for the widespread use of buttwelded piping systems.
Pipework which is not suitably supported will sag, causing pockets of liquid which
cannot drain from the pipe. Small-diameter pipes sag more easily than those of a larger
diameter, and therefore require more support.
Because of the high cost of pipe support, it is sometimes cheaper to simply use a larger
diameter pipe, than to use a small-diameter pipe with support.
Thermal expansion and contraction
Changes in the temperature in piping due to variations in the ambient temperature
or variations in the temperature of the fluids carried cause changes in the length of
pipework. Changes in length depend on the variation in the temperature and the
coefficient of expansion of the piping material.
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The expansion of carbon steel pipe can be determined from Table 2.3.
400
Temperature 0o C
300
200
100
75
50
25
0
3
6
9 12 15 18 21 24 27 30 33 36 39 42 45
Expansion – mm per 10 m
Table 2.3: Temperate vs expansion
Piping systems and pipe supports must be designed with thermal expansion in mind.
Piping systems which are too rigid may place excessive expansion and/or contraction
forces on nozzles, flanges, couplings, etc.
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Flexibility
Expansion loops built into pipework are used to enable movement. An expansion loop
is usually an offset-in piping made perpendicular to the pipe run by the use of standard
materials – the greater the offset, the greater the amount of movement which can be
absorbed.
Double offset
expansion bend
Expansion
square bend
Expansion
‘U’ bend
The greater the offset, the
greater the amount of movement
which can be absorbed.
Fig 2.61: Expansion loops
Flexibility can be built into piping systems by other design methods
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Limited flexibility
Greater flexibility
Fig 2.62: Flexibility options
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Cold springing
Cold springing involves offsetting branches during fabrication to minimise stresses
placed on the piping when expansion occurs. The branch is pre-stressed to account for
half the movement which would occur with thermal expansion.
Hot
position
Cold
position
Expansion places high
stress on branch pipe.
E
Expansion
Cold
position
By cold springing joint
excessive stress on branch
pipe is minimised.
Hot
position
E
2
Fig 2.63: Cold springing
Vibration
Vibration along with other stresses can significantly increase fatigue failure in piping
systems. Where pipework and equipment are subject to load and vibration, the load
carried and the vibration should be minimised.
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Gravitational load due to
improperly supported pipe,
combined with vibration
from pump, leads to fatigue
failure of cast iron flange.
The suitably supported pipe
reduces gravitational load
on the cast iron flange,
thereby reducing likelihood
of fatigue failure.
If the problem is considered
significant enough to
warrant it, a flexible
coupling may also be used to
minimise the effect of
vibration.
Flexible coupling
Fig 2.64: Vibration
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Settlement stresses
The positional relationship of equipment placed on separate foundations may
change as settlement of the foundations occurs. This may place excessive stress on
interconnecting pipework.
The problem can be overcome by allowing for this in the pipework.
Settlement of foundations
in direction shown may
cause excessive stress on
connecting pipe.
The offset
allows
flexibility of the
connecting pipe thereby
minimising stress due to
foundation settlement.
Fig 2.65: Settlement stresses
Types of pipe support
Pipework can be supported by various mechanisms.
Supports
Supports are usually made from steel or concrete and are designed to support the
weight of the pipework, usually from below.
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Fig 2.66: Pipe supports
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Hangers
Hangers are used to support pipework from above.
Upper supports
Midsections
Pipe attachments
Fig 2.67: Pipe hangers
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Guides
Guides enable movement along the pipeline but prevent movement in other directions.
Teflon pad
Stainless steel
Fig 2.68: Pipe guides
Pipe-racks
Pipe racks are used to support groups of pipes and are commonly seen only outside,
as piping within buildings is usually supported from structural steelwork.
A pipe rack consists of vertical members (stanchions) and a supporting horizontal
platform on which the pipework rests. Pipe racks may be single or multi-decked
depending on the size, the number of pipes to be carried, and the available space for
the pipe rack. Pipe racks commonly serve secondary functions and generally support
lighting, cable trays or utility stations.
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Fig 2.69: Order of pipes
Design guidelines for pipe racks
68
●●
Pipework must be placed in such a way that it provides ease of access to
equipment for operation and maintenance.
●●
Pipework must be placed so that it does not constitute a safety hazard.
●●
Pipework should be placed so as to comply with recommended minimum
clearances:
○○
above roadways – 6 m
○○
above walkways – 2 m
○○
operating space around equipment – 750 mm.
●●
Large diameter pipes may be located 300–450 mm above or below ground
because of their weight. Other piping should be suitably supported above the
ground on pipe racks or supports.
●●
Piping should be placed to the side of equipment rather than above it.
●●
Large liquid-filled lines should be placed close to the stanchions on a pipe rack in
order to avoid excessive stress on bents.
●●
Hotlines that require expansion loops should be grouped together to the side of
pipe racks with the largest lines outermost.
ENG2068
© WestOne Services 2013
Fig 2.70: Pipes with expansion loops
●●
Lines on pipe racks should be spaced with the outer edges of flanges a minimum
of 25 mm apart, with the flanges offset a minimum distance of 300 mm.
25mm
300 minimum
Fig 2.71: Minimum offset of flanges within the pipe rack
●●
On pipe racks, a change in the horizontal direction of pipes should be
accompanied by a change in elevation to prevent blocking of other lines on the
pipe rack.
●●
When designing pipe racks additional space (20–25%) must be allowed for to
provide for future requirements.
●●
The spacing of platforms depends on pipe sizes. However, it is customary to locate
them approximately 8 m apart.
●●
Pipe racks should be single deck if space permits. If multi-deck racks are used,
sufficient space should be left between decks to take off branch lines.
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Fig 2.72: Multi-deck pipe rack
●●
A minimum distance beneath pipe racks should be maintained so that they can be
accessed easily if work needs to be carried out at a later date.
●●
Elevations should be set so that lines will drain.
Positioning of pipe supports and hangers
Support of pipework is expensive and piping support specialists are usually employed
for large projects.
Sections of piping should be supported, so that each section is in equilibrium and
removing adjacent sections of piping or valves that need to be replaced will not upset
the balance of the system as a whole.
The weight of the piping should be shared equally among the pipe supports. Heavy
fittings and valves will affect the centre of gravity (balance) of the pipework and
allowances may need to be made for their removal.
Additional supports can reduce balance or sagging problems but these will also
increase costs. The best solution is to use fewer, well-placed supports.
The diagrams that follow show the basic principles that may be applied to support
pipework.
Central support is OK for short or
thick sections of pipe, but for long
or small diameter pipes, ends sag
downwards causing problems of
removal or installation.
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Pipe sags in middle, preventing
complete draining.
Pipe is balanced and level, but
necessitates the additional
expense of three supports.
Ends tend to sag and middle
tends to rise due to uneven
distribution of weight.
Placement of supports as shown
to keep each half of the pipe in
equilibrium without sagging and
without the need for additional
hanger or support.
1
2
3
4
A cantilevered end will increase
the load on support #4 and
reduce the load on support #3.
Position supports close to heavy
valves where possible.
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Tendency to sag
around support.
1
Locate supports at,
or as close to, riser
as possible.
Use additional
support.
2
3
4
5
The pipeline is supported so that any of the flanged sections may be
unbolted and removed without upsetting the balance of the line. Note
that the support for section 5 is offset to allow for the weight of the valve.
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Identification of piping
To eliminate hazards associated with piping that carries hazardous materials,
Standards Australia International (SAI) has released AS 1345-1995 Identification of the
contents of pipes, conduits and ducts.
The code is designed to identify piping, ducts and conduits in general, and in ships
and associated installations for safety purposes. The code does not apply to pipelines
buried in the ground.
The code cannot be expected to cover every particular industrial requirement and
discretion should be used in its application.
Colour codes
The code uses ground colours to indicate the types of fluids carried by the pipelines. It
also uses safety colours and lettering to provide additional information.
Ground colours
Colour
Type of fluid
green
water
silver
steam
brown
oil
violet
acids and alkalis
light blue
air
yellow ochre
gases (except air)
light orange
electricity
black
other fluids
Table 2.4: Ground colours
Safety colours
Colour
Type of fluid
red
fire-fighting materials (water, foam, etc)
safety yellow (with black stripes)
dangerous materials
safety yellow (with black trefoil)
ionising radiation
auxiliary blue
fresh water (potable)
Table 2.5: Safety colours
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Application of colour codes
Colours are applied directly to the pipe or, in the case of small pipes, over an area
immediately behind the pipe. Or, coloured tags can be used, provided that they are
attached securely to the pipe and are clearly visible.
The ground colour is applied over the full length of the pipeline or over a minimum
length of 400 mm, whichever is available.
When used in conjunction with a safety colour, the ground colour is applied for a
minimum length of 150 mm on each side of the safety colour.
The safety colour is applied for a minimum length of 75 mm where it is clearly visible.
The location of identification markings is at intervals of not more than 8 m and
preferably adjacent to branches, junctions, valves, etc.
AS 1345-1995 Identification of the contents of pipes, conduits and ducts should be
applied. Requirements laid down in other standards should also be kept in mind. For
example:
74
●●
AS 2885.4-2010 Pipelines - Gas and liquid petroleum - Submarine pipeline
systems
●●
AS/NZS 1596:2008 The storage and handling of LP Gas
●●
AS 4041-2006 Pressure piping.
ENG2068
© WestOne Services 2013
Chapter 3 – Drawing
Types of drawings
The main purpose of a technical drawing is to communicate fabrication requirements
clearly and simply.
To design process piping, five types of drawings are developed in sequence. These
drawings are developed from the schematics and specifications for process piping
prepared by the process engineer
In order of development, the sequence is as follows:
1.
general arrangement (GA)
2.
process flow diagram (PFD)
3.
piping and instrumentation diagram (P&ID)
4.
plot plan layout
5.
orthographic and isometric drawings.
Pipe fabricators are required to work from drawings that will vary considerably.
Pipework drawings in their presentation and adherence to relevant codes do not follow
as strictly the standards laid down for other engineering drawings. The standards most
applicable to pipework drawings produced in Australia are:
●●
AS 1100.101-1992 Technical drawing - General principles
●●
AS 1101.1-2007 Graphic symbols for general engineering - Hydraulic and
pneumatic systems.
General arrangement
The piping plan or general arrangement (GA) drawing shows all major equipment to
scale, its north/south and east/west orientation and all piping leading to and from the
equipment. All instrumentation, access ladders and platforms are shown.
The GA will usually show a plan view (top) with elevations (side) and section elevations,
as well as all pipe dimensions and piping details including line numbers, size and
specifications with the direction of flow noted for all lines, so that the draftsperson will
have all necessary information to create the final fabrication drawings or isometrics.
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1
F
E
D
Issue
Date
1
A 14-8-13
RL 000
RL 270
RL 550
RL 707
RL 850
RL 1270
Zone
C RL 1400 BOP
B
A
201
300
ENG2068
300
76
© WestOne Services 2013
First issue
C
1000
2
Amendments
Change
500
300
2
700
785
1900
700
CC TB
3
ECN BY CKD
3
Finish
STD WT Pipe
Class 150
FLG’s
Material
Third angle
A
Record of Issue
Drawn CC
Traced
TB
Checked
Approved
Issued 14-8-13
563
Line 3 (50NB)
5
Fig 3.1: General arrangement
Drawing practice
AS 1100
Angular
Linear
Unless noted otherwise
tolerances are:
Line 3 (80NB)
Line 1 (80NB/50NB)
Line 1 (80NB/50NB)
Line 1 (80NB)
4
A3
6
Size
NTS
N
7
Drawing exercise 24
DWG No
7
8
D
C
B
A
8
1
SHT
F
E
Drawing exercise
Complete 3 isometric drawings &
3 material lists for each line
Piping GA
Scale
Title
6
Dimensioning
Dimensioning of GA drawings follows conventional drawing practice closely
however, elevation (height) dimensioning needs special consideration.
Before any building or erecting begins in the field, the site is made as flat as possible
and, after levelling, is termed ‘finished grade’. The ‘highest point of finished grade’
becomes the datum from which all plant elevations are taken. This horizontal plane is
given a ‘false’ or nominal elevation, usually 100.
The nominal elevation of 100 ensures that foundations, basements, buried tanks, etc,
will have positive elevations. ‘Minus’ elevations which may cause error and nuisance
are avoided.
Horizontal distances may be expressed as distances N, S, E or W to match
distances on the plot plan. Dimensions may emanate from structural steelwork to
aid in the location of the pipework within the plant. Dimensioning practices will be
discussed in greater detail in this chapter.
Process flow diagram (PFD)
A process flow diagram (PFD) is an unscaled drawing or schematic which describes
the process of transferring material by piping.
It will:
●●
state, for example, the materials to be conveyed by the piping
●●
specify the rates of flow
●●
list the pumps required
●●
provide information such as pressure or temperature.
At this point the pipe sizes, types of valves, etc, have not been determined. The PFD
and specifications are then transferred to a piping and instrumentation (P&ID) diagram,
plot plan or isometric drawing.
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1
Sour gas
Absorber
Makeup water
1
2
3
3
Lean amine
Rich amine
Bottom
tray
Top tray
2
Revision note
File name
PFD
CW
6
FSCM NO
Vapor
Pump
regenerator
9/9/2013
Contract No
Re
Issued
Approved
Check
Drawn
Size
6
Reflux
Pump
Bottom
tray
Top tray
Condenser
Lean amine
Rich amine
5
Rev No
Fig 3.2: Process flow diagram
CW
Sweet gas
4
7
DWG No
8
Process Flow Diagram
NTS
Scale
Condensate
8
Signature Checked
Steam
Gas
Date
PFD1
Sheet
7
F
E
D
C
B
A
Piping and instrumentation diagram (P&ID)
© WestOne Services 2013
Re
Issued
Approved
Check
6
9/9/2013
Drawn
Line A-256-1ʺ
3
2
Line B-256-3ʺ
Fig 3.3: Piping and instrumentation diagram
7
DWG No
P & ID
PID1
Sheet
PID
File name
Size
25
A-8975
Contract No
1
1
Note 15
2
3
34-27
4
5
Rev No
RO
AD
Revision note
6
FSCM NO
LGM
56
7
Date
Line C-256-2ʺ
Scale
NTS
8
F
E
D
C
8
Signature Checked
B
A
The P&ID is similar to, but more detailed than, a PFD. It is a single-line schematic
drawing that includes all major equipment items, instruments and controls, major valves
and line sizes, It contains all the data necessary for the various design groups involved
in the project to proceed to the next step in the design of the plant.
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Plot plan
The draughtsperson produces a site plan which shows the whole site, including
boundaries, roads, buildings, plant areas, etc. This allows the piping engineer to
arrange equipment to optimise process requirements and design.
When the site plan has been created and the GA drawings approved, they are then
developed into ‘plot plans’ by the addition of dimensions and coordinates to locate all
major items of equipment and structures.
Dimensions and coordinates emanate from the plant datum point. Equipment
coordinates are given to the centre-lines and, depending on the company, coordinates
for pumps are given to the centre-lines of the pump discharge port.
Pipeway
Meters
Instrument
air plant
Drover loop
E 130.220
Process unit plot limit
T 120 A
E 140.000
T 20 A
E 148.000
E 36
N 272.000
E 157.750
N 206.550
S 80
Pipeway
E 170B
E 159.000
E 60 A
E 180.500
S 120
N 122.000
Roadway N 110.000
N 195.550
E 170A
W 20
E 200.500
E 219.000
E 60 B
E 227.650
E 240.000
T 120 B
Control
room
Motor
control room
E 250.000
E 260.000
E 270.000
Pipeway
V 220
E 250
Pipeway
W 21
E 270
Hydro
unit
250 KVA
generator
T 120 B
Piping skid
T 20 B
E 345
E 300.000
V 250
Fig 3.4: Plot plan
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Orthographic and isometric drawings
Orthographic and isometric drawings are representations of an object which are
presented in alternative views so that they can be easily understood.
T
vieop
w
Top view
Fro
vie nt
w
Front view
Pictorial view
e
Sidw
vie
Side view
Orthographic view
Isometric view
Fig 3.5: Pictorial, orthographic and isometric representations of a box
These drawings are used extensively in the development of process pipe systems.
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Types of projection
An essential factor in piping fabrication is the ability of the tradesperson to read
technical drawings.
The most common types of projection used in piping drawings are as follows.
Note
1. All pipe schedule 80
2. All flanges class 300
3. Stud bolts used throughout
Orthographic projection.
900
1000
Ø 200 NB
82
ENG2068
1300
L 20-1
900
900
900
L 20-2
Ø 50 NB
200
900
1200
L 20-3
EL 1500
EL 2290 B.O.P
N
Sockolet
®
1.
© WestOne Services 2013
5
00
1 16
0-B
L22
1
l
4
rizo 5 o
nta
ho
0
50
© WestOne Services 2013
2
9
9
10
3
17
7
18
16
0
50
16
4
50
F.F
8
.W
11
6
0
13
14
12
5
0
50
-B2
20
L2
1
-C
20
L2
0
70
15
N
0
90
0
55
-B3
20
L2
Signature
Scale NTS
Spool drawing
W600SCO
“
“
# 600LB
XS
“
“
“
“
SCH80
“
“
“
“
“
“
“
Spec
Date 9 /11/2012
1
1
150 Lap-Joint
90 RF WN
150 RF WN
Valves
150 Check
150 Diaphragm
Flanges
Fittings
150 45o Weld ELL
150 90o Weld ELL
150 EQ B.W. Tee
150 - 90 Conc. Red.
150 Stub end
Pipe
150 NB x 330
150 NB x 515
150 NB x 372
150 NB x 420
90 NB x 560
150 N.B. x
150 N.B. x
150 N.B. x 900
Description
Drawing No 6.36
17
18
1
1
3
1
13
14
15
16
2
1
1
1
1
1
1
1
1
1
1
1
Qty
9
10
11
12
1
2
3
4
5
6
7
8
Item
Materials list
2.
Isometric projection.
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Orthographic projection
The views in orthographic projection are drawn as they would appear when the object
is viewed perpendicular to its surface. Visible outlines are drawn as continuous, ‘full
dark’ lines. Hidden detail is drawn as dashed ‘half dark’ lines. Usually more than one
view is required to show the object in sufficient detail to avoid any misunderstandings.
End view
Side view
Pictorial view
Side view
End view
Orthographic view
Fig 3.6: Two-line orthographic view
In Figure 3.6, a simple shaft is shown in pictorial view and two views are shown in
orthographic projection. The two views are necessary in this case to completely
delineate the object. Perspective is not taken into account in orthographic views.
There are two types of orthographic projection:
84
●●
first-angle projection
●●
third-angle projection.
ENG2068
© WestOne Services 2013
Third-angle projection is the preferred type while first-angle projection is used rarely in
Australia. However, it is necessary to distinguish between the two types of projection to
avoid confusion and enhance pipe fabricators’ understanding when reading drawings.
First-angle and third-angle orthographic projections are very similar in that the views of
the object do not change. The difference is in the positioning of the views. In first-angle
projection, the projected view is placed behind the object relative to the viewer. In
third-angle projection, the projected view is placed between the viewer and the object.
Fig 3.7: Pictorial view of a tapered pin
Fig 3.8: Projected end view of the pin (first-angle projection)
Fig 3.9: Projected end view of the pin (third-angle projection)
Third angle projection is used for all engineering drawings drawn in orthographic
projection.
This means that:
a)
a top view is placed above the viewed object (Figure 3.10 View ‘c’)
b)
a bottom view is placed below the viewed object (Figure 3.10 View ‘d’)
c)
a view from the left is placed to the left of the object (Figure 3.10 View ‘b’)
d)
a view from the right is placed to the right of the object (Figure 3.10 View ‘e’).
© WestOne Services 2013
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c
e
a
b
d
View ‘c’
c
b
e
d
View ‘b’
View ‘a’
view ‘e’
View ‘d’
Fig 3.10: Comparison of orthographic and isometric views
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Isometric projection
Isometric projection is a method which enables a three-dimensional picture of an object
in one view to be drawn.
Isometric drawings are made around three principal axes at 120° to each other so
that each of the three faces is inclined equally towards the viewer. This means that
the effect of perspective is equal on all sides, thus eliminating the need for faces to be
drawn at different scales so that they appear in proportion.
1200
1200
1200
Fig 3.11: Isometric projection
The isometric axis may be rotated so that different faces of the object may be viewed
simultaneously.
To
p
de
Sid
d
En
Si
d
e
e
d
Bo
tt
om
Si
En
En
d
m
to
t
Bo
Fig 3.12: Isometric axis
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Spool drawings
Isometric views showing details and dimensions of all lines are produced from the GAs.
These are called isometric spool drawings or simply spool drawings.
Spools
A spool is an assembly of fittings, flanges and pipes that are to be prefabricated. It
does not include bolts, gaskets, valves or instruments. Straight mill-run lengths of
pipe over 6 m are usually not included in a spool, as such lengths may be welded into
the system on erection. (On the ISO drawing, this is indicated by noting the length
and stating ‘BY FIELD’.)
A completed spool drawing will show:
●●
title block information
●●
the piping schedule
●●
the orientation symbol
●●
a view of the pipe spool
●●
dimensions
●●
adjoining pipe spools
●●
the direction of flow of the conveyed fluid or gas.
Each pipe spool drawing may also list the materials required for fabrication of the spool.
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Fig 3.13: Pipe spool drawing
© WestOne Services 2013
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F
E
D
C
B
A
7
7
53
2
Issue
1
Date
A 27-6-13
Zone
First issue
53
1
2
Amendments
Change
Note
1. All pipe 80NB schedule 40
2. All flanges class 150
53
1
3
2
3
5
8
250 BOP
7
4
Drawing practice
AS 1100
Angular
Linear
Unless noted otherwise
tolerances are:
10
CC TB
11
ECN BY CKD
0
72
0
72
3
350 BOP
Finish
Material
Third angle
0
54
6
4
0
450 BOP
1
N
12
A
Record of Issue
0
54
Drawn CC
Traced
TB
Checked
Approved
Issued 27-6-13
54
9
5
6
Size
A3
NTS
6
7
Fittings
Pipe
Description
DWG No
7
80NB Sched 40 pipe spools
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Item Qty
Scale
Title
550 BOP
8
8
1
SHT
Spec
F
E
D
C
B
A
A pipe run in isometric is schematic in that pipes are shown by a single, bold line drawn
along the pipe’s centre-line axis. Piping components are represented on the drawing by
simple, stylised symbols which are widely accepted and more or less self-explanatory.
The drawings are not to scale, although any details relevant to fabrication and erection
are shown.
Isometric spool drawings show the pipe spool as a pictorial view. This enables the
fabricator to envisage what the finished spool will look like.
The isometric spool drawings are sent to the shop fabricator. The drawings will usually
show the complete line from one piece of equipment to another and give all the
necessary information required for the fabrication and erection of the piping.
The size of the prefabricated spool is limited by the shop fabricator’s means of transport
but a spool is usually contained within a space of dimensions 12 m × 3 m × 2.4 m.
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The orientation symbol
N
N
Orthographic
Isometric
Fig 3.14: Orientation symbols
The orientation symbol or ‘north arrow’ appears on all piping drawings. The
orientation symbol is of the utmost importance as it shows:
●●
the direction of the piping run through the plant
●●
the position of pipes relative to others
●●
the relationship between pipes and other items of equipment.
The symbol is normally placed in the top right-hand corner of the drawing. On an
orthographic drawing, north is usually orientated towards the top of the page.
On an isometric drawing, north is usually drawn up and to the right. South is opposite
from north and points down and to the left. West is 90° from north however, in the
isometric, it becomes the opposite 120° line – in this case, running up and to the left.
East will be opposite to west and will run down and to the right. Pipelines running
north/south or east/west will run parallel to the ground unless otherwise noted.
Up
N
W
Point of intersection
S
Down
E
Fig 3.15: Point of intersection
Bisecting the north and west and the south and east reference lines is the up
and down reference line. The point of intersection (PI) is the point from which all
directions start.
Any time the pipe has a turn – north, south, east, west, up and/or down – the pipe
fabricator must imagine being at the PI to determine which way the pipe turns.
© WestOne Services 2013
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Parallel line
Parallel line drawings are used to develop a two-dimensional template of a
three-dimensional shape.
End view
0
7
8 9
2
3
4
5
6
7
8
11
5
3
2
9 10 11 12
12
10
6
4
1
11
Side view
10
12
0
1
9
0
1 2
3
4
5
6
7
8
Parallel line
Isometric
Fig 3.16: Cylindrical development
Parallel line development is a method which can be applied to any object whose sides
are parallel to the axis; it is ideally suited to piping fabrication.
Parallel line development process
The parallel line method of development is used to obtain the ‘true shape’ of the object
in a rolled-out form (also called the stretch out). This method of pattern development
uses vertical parallel lines (also called generator lines) to obtain the true lengths. The
true shape is also determined by intersection lines that form in conjunction with the
vertical lines.
Determining the fabrication method
There are two choices when developing the parallel line method and that is either
the construction of a pipe from plate or a template that wraps around the pipe. Both
methods create a stretch out, by either the mean diameter (also known as the ‘neutral
axis’ – an imaginary centre-line through the plate thickness) or outside diameters when
calculating this length.
The plate method requires the mean diameter in its calculation and the pipe
wraparound uses the outside diameter. The correct use of the diameters is paramount
as the stretch out lengths will differ for both.
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Construction of a pipe from plate
The pattern is drawn on, or transferred to, the plate using a centre punch, rolled into the
cylindrical shape and then cut to the pattern.
During rolling (or pressing) operations, the inside of the bend will be compressed, and
the outside of the bend will be stretched around the neutral axis.
The neutral axis is the only part of the plate whose dimension is left unchanged by the
forming operation. For this reason, it is necessary to base all calculations on the neutral
axis when the metal is rolled into a circle.
t
Neutral
axis
ter
iame
This side gets
compressed during
rolling.
nd
Mea
N
A
ID = MD + t
This side is stretched
during rolling.
OD = MD + t
Fig 3.17: Diameter of pipe
Sleeve templates
When working with piping, the most practical method of development is to make a
template which is then used to mark out the pipe.
Fig 3.18: Sleeve template
Calculations for the template can be based on the outside diameter of the pipe.
© WestOne Services 2013
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Drawing steps
The following example shows step by step the method of development of one half of
a simple pipe joint (pipe A). These basic principles can be applied to more complex
development problems.
Step 1
Select the view which
best shows the pipe to
be developed and draw
a ‘layout’ of the pipe
to accurate size and
shape.
Step 2
Divide the pipe
circumference into
an equal number of
spaces (12 spaces
is suitable for most
applications, more
may be required for
large diameter pipes,
or where accuracy is
important). Transfer
these ‘ordinates’ to the
pipe wall.
Step 3
Number the ordinates
in logical sequence
consecutively around
the pipe.
12
0
11
10
1
8
5
9
2
4 3
6
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Note: Although any
numbers will suffice,
it is customary to
start the numbering
sequence with zero.
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Step 4
Determine the
circumference of
the pipe using this
calculation
D×π=C
ie the diameter (D)
is measured and
multiplied by Pi (π). The
circumference is now
the stretch out.
12
0
11
5 8 9 10 1
2
4 3
6
0 1 2 3 4 5
7
12
0
11
5 8 9 10 1
2
4 3
6
7
0 1 2 3 4 5
6 7 8
6 7 8
9 10 11 12
9 10 11 12
6
5, 7
4, 8
3, 9
10, 2
11, 1
12, 0
12
0
11
5 8 9 10 1
2
4 3
6
7
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0 1 2 3 4 5
6 7 8
9 10 11 12
Divide the stretch out
into 12 or 24 equal
parts. There is an
option to divide the
pattern into 24 parts
which will create a
smoother curve that
eliminates gaps;
however, 12 is usually
sufficient.
Step 5
Produce the points on
the baseline upward,
perpendicular to the
baseline. (These
represent the ordinates
on the pipe.)
Step 6
The height of each
ordinate is the distance
from the base of the
pipe to the line of
intersection. Transfer
the ordinate heights
horizontally across to
the development.
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6
5, 7
4, 8
3, 9
2, 10
1, 11
0, 12
12
0
11
5 8 9 10 1
2
4 3
6
7
0 1 2 3 4 5
6 7 8
9 10 11 12
Locate and number
each coordinate.
6
5, 7
4, 8
3, 9
2, 10
1, 11
0, 12
12
0
11
10
1
8
5
9
2
4 3
6
7
Step 7
As each ordinate
height from the pipe
layout meets its
corresponding ordinate
on the development,
it will form a series
of coordinates: eg
1,1:2,2:3,3
0 1 2 3 4 5
6 7 8
Step 8
Join the coordinates to
produce the required
development.
9 10 11 12
Development of custom branch connections
The parallel line method of fabrication is used to create custom branch connections
which may be required when a standard fitting is not suitable or available.
There are two basic types of branch connection.
●●
Set-in branches – where the branch line is set-into the wall of the main piping run.
The hole in the main pipe is cut to the outside diameter of the branch line.
Fig 3.19: A set-in branch
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●●
Set-on branches – where the branch line sits on the wall of the main piping run,
the hole in the main pipe is cut to the inside diameter of the branch.
Fig 3.20: A set-on branch
The easiest and most practical way of preparing the joint for welding is to cut pipes
with the torch held perpendicular to the surface of the pipe and grind the weld
preparation afterwards.
Acceptable methods of weld preparation are specified in:
●●
AS 4458-1997 Pressure equipment – Manufacture
●●
AS 4041-2006 Pressure piping.
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Piping symbols
Standard symbols are used to represent fittings and equipment on piping drawings.
These symbols are used to show:
●●
pipe
●●
piping materials
●●
direction of the piping run
●●
changes of direction of the piping
●●
methods of joining the pipe.
To be able to understand and interpret spool drawings, pipe fabricators will have to be
familiar with these symbols.
The draughtsperson may use a certain amount of ‘artistic licence’ to make drawings
cheaper to produce or clearer and easier to read. This means that there may be
variations in the presentation of the symbols.
An example of this may be seen in the representations of a weld-neck flange shown in
Figures 3.21 and 3.22.
Fig 3.21: Representations of a flange depicted with different line thicknesses
Fig 3.22: Representations which show a flange more graphically for clarity
Drawings may also be produced from copies of drawings made overseas where
conventions vary slightly from Australian standard drawing practice.
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Symbols
General
Symbol
Pipe – general symbol
Pipe – concealed at section
Pipe – in front of or above section
Crossing pipe – not connected
Crossing pipe – connected
Tee – stub in
Flexible hose
Direction of flow
Direction of fall – both types acceptable
Butt weld
Socket weld
Screwed joint
Site weld
Reinforcement – saddle
Reinforcement – wraparound, saddle
Expansion joint
Trap
End cap
Non-fixed support
Anchor point
Anchor block – at tee joint
Joint – general symbol
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Pipe equipment
Symbol
Apparatus – general symbol: it is preferred that the
circular symbol be used for items in which there are
rotating parts. For other apparatus, the rectangular
symbol is used.
Pump – Use Ø 10 circle
Steam trap
Strainer – general symbol
Strainer – Y type
Valves
Symbol
Valve – general symbol – also for shut-off and
regulating valve – two-way
Valve – general symbol – also for shut-off and
regulating valve – angle
Shut-off and regulating valve – three-way
Reducing valve
Diaphragm valve
Safety valve
Gate valve
Globe valve
Butterfly valve
Check, non-return, reflux, one way valve
Ball valve
Needle valve
Relief valve
Plug valve
Sprinkler head – on pipe
Sprinkler head – upright
Sprinkler head – pendant
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Control and regulating
Symbol
Hand-operated – general symbol
Spring
Weight
Float
Piston
Diaphragm
Electric motor
M
Solenoid
Fitting
Double line
Butt welded
Socket-welded
90° elbow
Tee
45° elbow
Lateral
Eccentric reducer
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Fitting
Double line
Butt welded
Socket-welded
End view
Side view
End view
Concentric reducer
Cap
Specialised Fitting
Weldolet
Latrolet
Sweepolet
Nipolet
Flange
Symbol
Mitres
Weld neck
M
Slip-on
M
M
M
M
M
Blind
Lap joint
Orifice
Reducing
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Symbol guide
As a guide to the application of these symbols, consider the following information.
•
The general piping symbol is always shown as the darkest line on the drawing. For
example, a section of piping with a reducer or other fitting would be shown with the
piping drawn darkest and the fitting represented by a lighter line.
•
The symbol for a butt weld is shown by a dot at the location of the weld.
•
A butt weld made on site would be represented by a cross over the butt weld.
Sometimes the letters FFW will accompany the site weld symbol. This stands
for ‘field fit and weld’ which means that the joint is fitted and welded on site. To
accommodate this FFW, approximately 150 mm of extra pipe is allowed. This 150
mm allowance is known as ‘green’.
•
All piping drawings indicate the direction of flow with an arrow.
•
Where pipes cross but are not connected, the pipe in the foreground is represented
by a continuous line and the pipe in the background is broken where the lines cross.
•
A butt welded 90° elbow can be drawn two different ways.:
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•
While most fittings are represented by a single line, reducing fittings are drawn to
shape and approximate scale.
Butt-weld elbow
Butt-weld reducing elbow
•
Where elbow symbols are used, they always represent a long radius elbow unless
otherwise noted.
•
Tee connections may be made by the use of a standard fitting (tee) or by fabrication
(known as a ‘stub-in’).
Joint
Tee
Symbol
Stub-in
Symbols used to indicate change of direction
Symbols are used to show changes in direction of the piping run. This is one of the
more difficult aspects of pipework drawing to understand. It helps to keep in mind the
way the joint would appear in third-angle projection.
Pipe riser from bend
This symbol shows a pipe which changes direction from horizontal to vertical going
upwards towards the observer.
‘A’
Fig 3.23: Pipe riser from bend
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If the pipe terminates and is left open, it is normally shaded to indicate this.
Or
Pipe dropper from bend
This is the opposite of the previous example. In this case, the vertical pipe runs away
from the observer.
’A‘
Fig 3.24: A pipe dropper from bend.
Combinations
The following symbols are used in combination to show a pipe that changes from
horizontal to vertical and back to horizontal.
Fig 3.25: Symbols used in combination
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Pipes which change direction at a riser or dropper can be represented by following the
same principle.
N
Lower pipe runs
North/South
Upper pipe runs
North/South
Fig 3.26: Symbols used in combination
Pipe riser from tee
A
Fig 3.27: A pipe riser from tee
Pipe dropper from tee
A
Fig 3.28: A pipe dropper from tee
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Dimensioning and line types
The dimensioning of piping drawings is in principle the same as for any other
engineering drawing. For example, leader lines, dimension lines, arrowheads, line work
and so on are all used in a similar way.
Pipe fabricators need to be aware of the following points and differences when reading
pipe drawings.
General dimensional practice
●●
Horizontal dimensions are given to vertical leader lines.
●●
Principal dimensions are given to changes of direction.
●●
Secondary dimensions are given to items of equipment such as reducers.
●●
To aid erection a pair of dimensions locating the pipework to plant or equipment
is usually given.
●●
Although isometric drawings are not drawn to scale, valves and fittings are
drawn reasonably proportional, especially where a fitting to fitting arrangement
locates a valve. For example, in Figure 3.29, the valve is clearly at the elbow –
not the tee.
Fig 3.29: Isometric spool
●●
Vessels and other equipment items are dimensioned to their centre-lines and
the faces of flanges or nozzles.
●●
The centre-line elevation of horizontal nozzles, and the face elevation of vertical
nozzles are given for vessels and equipment.
●●
Reducers not located by a fitting-to-fitting arrangement are dimensioned to their
large end.
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Single- and double-line comparison
When orthographic projection is used, pipelines may be drawn as either single-line or
double-line drawings. Double-line representation shows the two edges of the pipework
and is usually used for pipes over Ø 350.
Double-line drawings show a more graphic representation of the pipework; however,
these are more difficult and more expensive to produce.
Fig 3.30: Double-line pipe
Single-line orthographic drawings represent the pipe by its centre-line only, which is
drawn as a continuous heavy line (usually the darkest line on the drawing). The size of
the pipe is shown by drawing a representation of the pipe end to scale, either at the end
of the line or some other convenient place.
Pipesize
drawn to scale
Fig 3.31: Single-line pipe
On single-line diagrams, all fittings – except reducing fittings – are drawn single-lined.
Single-line drawings are generally used for pipework under Ø 350.
Single-line drawings with their use of stylised symbols are easier and quicker,
and therefore cheaper to produce. Single-line drawings are easy to read, and this
advantage, coupled with their lower cost, makes them the preferred type.
Fig 3.32: Comparison of double-line drawing and single-line drawing
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Running dimensions
Dimensions on piping drawings are not from a common reference point like they are in
structural drawings; they are placed consecutively as running dimensions.
Structural practice
Piping practice
Fig 3.33: Structural and piping practice
Item number identification
On all spool drawings, the line identification number is placed on the pipe. The
adjoining spool piece is shown as a dashed line, and its identification number is given.
The line identification number should be placed above the line representing the pipe,
and elevations should be placed below it.
C2
00 -
L3
C2
0
atio 0 - L2
n 22
1.65
0
Elev
Fig 3.34: Pipe identification
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Use of levels and grids
When a plant is designed, a system of levels is used to refer to elevations, and grids
are used to make reference to horizontal dimensions.
Levels are taken from the lowest part of the plant (datum), which is given a positive
elevation, eg 30 m. This positive elevation enables sumps or other below-ground
equipment to be dimensioned without the need for minus elevations.
EL 38.000
EL 37.750
EL 35.000
EL 32.000
datum
EL 30.000
EL 29.000
Fig 3.35: Elevations
Grids are normally taken from the south-west corner of the plant. Distances north and
east of this point are referenced. For example, the tower on the plot in Figure 3.36 is
situated at N44.000, E20.000.
60―
Roadway
N 44.000
E 150.000
50―
N 56.000
N 52.000
E 20.000
40―
30―
20―
―
―
―
E 100.000
90
―
80
―
70
―
60
―
50
―
40
―
30
―
20
―
―
10
E 30.000
N
―
10―
100 120 130 140
Fig 3.36: A grid
It is common practice to dimension pipework with reference to levels and grids, and
also to give dimensions from structural steelwork within the plant.
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Flanged joints
Dimensions are given to the faces of flanges. Most flanges have gaskets and the
thickness of the gasket is indicated with ‘hash’ marks which show where the gasket is
included in the valve dimension.
The total dimension between the flange faces, including the gasket, should be given.
Fig 3.37: Flange dimensions
Valves
150
V136
Standard valves (especially butt- or socket-welded valves) are usually dimensioned to
their centres. The valve stem is shown in its proper orientation, and the valve number is
usually shown along the valve centre-line.
Fig 3.38: Valve dimensions
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Offsets
An offset is a line running in a direction other than along the axes, ie other than up,
down, north, south, east or west. It is sometimes difficult to determine the direction
of an offset and a 45° offset in a horizontal direction may appear the same as a 45°
offset in a vertical direction. If clarification is needed, a simple grid and note are usually
provided.
In this example, the pipe is drawn the same in both cases. It is the grid which
determines the direction of the piping run.
W
Up
N
S
E
Down
al
o
45
l
ta
ic
ert
V
o
45
n
rizo
Ho
Fig 3.39: A simple offset
Offsets and angles are not always what they appear to be when drawn in isometric
projection.
W
C
Up
N
S
E
Down
B
A
Fig 3.40: A simple offset with a change of direction
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Angle ‘A’ is actually a right angle. Angle ‘B’ is drawn at 90° and shows a pipe changing
direction from the vertical to run to north-east. Angle ‘C’ represents a horizontal offset
from north.
The basic symbols used to show pipe and changes of direction are used to show
offsets. When interpreting symbols depicting offsets, it is important to keep in mind the
view as it would appear in third-angle projection.
The following figure shows a 45° elbow as it would appear in orthographic projection
and as it would appear when represented symbolically.
45o Elbow – Orthographic
45o Elbow – Isometric
Fig 3.41: 45° elbow – Orthographic and isometric
Laterals or branch lines are shown in the same manner.
Fig 3.42: Laterals or branch lines
When an ellipse appears as it does in the examples above, it is always an indicator of
an offset or a branch other than 90°.
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Compound offsets
Whereas an offset changes its orientation in two directions, eg up and to the west, or
to the south and east, a compound offset changes its orientation in three directions at
once.
In Figure 3.43, the pipe runs upward to the west and to the north from the point of
intersection.
nsion
Dime
N
P.I.
Fig 3.43: A compound offset
A compound offset is indicated by the ‘box’ shown in Figure 3.43. Lines (both the pipe
and the box) are broken to indicate which is in the foreground, and the offset length is
always dimensioned with a dimension line running parallel to the offset.
Offset boxes should not be drawn as squares even when offset dimensions are the
same in two or more directions. It is necessary to draw offset boxes as rectangles or
the projection will appear incorrect with offsets running along the major axes.
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Chapter 4 – Fabrication methods
Pipe fabrication
Pipe fabrication involves assembling pieces such as elbows, tees and flanges into
sections which, along with the pipe and all other equipment, can be accurately fitted
together into the plant.
Because of the cost and importance of such lines, pipe fabricators must assemble
and weld pipes together with a high degree of precision. This requires careful thought
and planning, accurate layout of work and control of welding operations as well as the
competent use of jigs, templates and other precision tools.
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Preparing for fabrication
In preparation for fabricating, fabricators are required to calculate all the necessary
pipes and fittings according to the drawing specifications. The pipe fabricator will need
to take into consideration welding and tack welding processes along with any distortion
that may arise from welding. The tools required for the fitting-up of pipes and flanges,
such as pipe supports and clamps will also need some thought.
Extracting information from drawings
After careful scrutiny of the drawing, it is the fabricator’s job to check their interpretation
of the drawing by quickly constructing a simple wire model of the pipe spool.
The project design model may also be consulted (if available), especially for complex
pipe spools. Construction of a wire model will help the fabricator with interpretation as
well as with determining the best sequence of fabrication.
Before fabrication starts, workshop sketches or isometric spool drawings are prepared
from either general arrangements (GAs) or isometrics. These drawings contain all the
information the fabricator needs to be able to fabricate pipes. The fabricator will also
be supplied with accurate material take-off lists and a copy of the client’s fabrication
specifications.
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Fig 4.1: Isometric spool drawing
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0
50
1 16
0-B
L22
1
4
rizo 5 o
nta
l
ho
50
0
2
9
9
10
3
17
7
18
16
50
0
16
4
F.F
8
.W
11
6
0
50
13
14
12
5
0
50
-B2
20
L2
1
-C
20
L2
0
70
15
N
0
90
5
50
20
L2
-B3
Date 9 /11/2012
Signature
Spool drawing
W600SCO
“
“
# 600LB
XS
“
“
“
“
SCH80
“
“
“
“
“
“
“
Spec
Scale NTS
1
1
150 Lap-Joint
90 RF WN
150 RF WN
Valves
150 Check
150 Diaphragm
Flanges
150 Stub end
150 - 90 Conc. Red.
Fittings
150 45o Weld ELL
150 90o Weld ELL
150 EQ B.W. Tee
Pipe
150 NB x 330
150 NB x 515
150 NB x 372
150 NB x 420
90 NB x 560
150 N.B. x
150 N.B. x
150 N.B. x 900
Description
Drawing No 6.36
17
18
1
1
3
1
13
14
15
16
2
1
1
1
1
1
1
1
1
1
1
1
Qty
9
10
11
12
1
2
3
4
5
6
7
8
Item
Materials list
Calculations
To fabricate a spool system, the fabricator must be able to calculate the cutting length
of pipes and take into account the sizes of fittings, flanges and weld preparation. The
allowance for fittings and flanges can be gained from standard tables however the weld
preparation may range from 2 mm to 3 mm.
Y(2)
Y(1)
C(1)
C(2)
0
Fig 4.2: Weld neck flange
Y(1)
C(2) Y(2)
C(1)
0
Fig 4.3: Slip on flange
Allowance for welding gap and weld shrinkage can be calculated in various ways and
the weld gap required may vary. As a general rule the weld will shrink approximately
half the root gap, so this needs to be considered when working out calculations.
The fabricator may also want to confirm the weld shrinkage by completing a weld test
and making adjustments as necessary. All the gaps noted in this text are 3 mm.
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400
A
500
B
500
400
A
B
Fig 4.4: Double-line and single-line orthographic view with dimensions
To calculate pipes A and B, extract information such as the nominal size (NS) and
schedule (SCH) from the drawing.
●●
NS = 100 – the average diameter of the pipe
●●
SCH = 40 – the thickness of the pipe
●●
Class 150
Now we need to identify the lengths of each pipe, remember that the dimension lines
work from the centres of the pipe.
●●
Pipe A = 400 – the length of the pipe from the centres
●●
Pipe B = 500 – the length of the pipe from the centres
The lengths of the fittings now need to be worked out. (Fittings can measure from the
centre to the face, or face to face; they are all obtained from charts.)
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400
500
A
76
B
105 105
152
Fig 4.5: Double-line orthographic view with dimensions
●●
Raised face weld neck (RFWN) = 76. This information is on the data charts under
flanges to American standards column Y1. Different class options should be noted.
●●
Equal tee = 105. This can be found on the data charts in the carbon steel butt
welding fittings column marked ‘C’.
●●
90° long radius elbow 90ELB = 152. This can be found on the data charts in the
carbon steel butt welding fittings column marked ‘A’.
●●
The weld preparation gap = 3.
●●
The weld shrinkage =1.5.
Once this information has been determined, it can be applied to a simple equation,
such as:
Pipe A = 400 – 152 – 105 – 3 – 3 + 1.5 + 1.5 = 140
Pipe B = 500 – 105 – 76 – 3 – 3 + 1.5 + 1.5 = 316
Piping schedule
The piping schedule is simply a materials list similar to that found on other engineering
drawings. The schedule gives details of all the pipes, valves and fittings used to
fabricate the pipe spool and is usually divided into sections for different materials such
as tubes, fittings, valves, flanges, bolts.
It contains all the materials needed to fabricate the pipe spool shown on the drawing,
with each item clearly numbered. Standard abbreviations are always used in the
piping schedule.
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Material list
Description of item
Description of item
Nom
size
Sch
Type or Std
Qty
Nom
size
Sch
Type or Std
Qty
Flanges
Flttings
Tubes
Mlsc
Jolnts
Bolts
Valves
Fig 4.6: A piping schedule
Tools
A pipe fabricator relies on a selection of quality tools to construct and align piping
systems.
These tools usually consist of a large plate square, a pipe square, level(s), a
combination square, a protractor set, flange pins, wraparound tapes and a pipe
alignment device. The only tools that pipe fabricators may not be familiar with are the
wraparound tapes, flange pins and pipe alignment devices, which are specialised to the
pipe fabrication trade.
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The wraparound
The wraparound – sometimes referred to as a ‘runaround’ – is a flat strip of flexible
material about 1.5–3 mm thick, 75–100 mm wide and 450 mm or more long. It is
made of any composition gasket material or leather belting. The edges must be
perfectly straight. The length may vary, but the wraparound should be long enough
to go around the pipe one-and-a-half times, so that it may be lined up to make it
possible to obtain a straight line around the pipe.
When laying out a straight line around a pipe, the wraparound should be placed on
the pipe at the location of the centre-line, and the edges should be lined up. A chalk
line should be drawn around the pipe with a piece of engineer’s chalk and using the
edge of the wraparound as a guide.
Fig 4.7: Using a wraparound
Depending on the sizes of the pipes and fittings, lifting tackle may be necessary and
chain blocks, turfers and cranes are often required. Three legged adjustable pipe
stands, adjustable trestles and adjustable pipe rollers are essential for successful pipe
fabrication.
Ratchet line up clamp
Pipe claw
Figure 4.8: Typical pipe joint alignment devices
Carelessness must be avoided when tools are being used as this will impair their
accuracy. Levels and squares should be checked periodically, because a level that
does not read correctly or a square that is ‘out of square’ can result in serious errors.
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Fabrication process
The fabrication process requires tradespersons to assemble pipes and pipe fittings
according to the spool drawing. Pipe fabricators need to take into consideration the size
of the assembly, as transport may become an issue. Sub-assemblies are an effective
way of transporting large projects.
Assembly methods
Before fabrication starts, the fabrication specifications, the weld procedure for
fabrication tolerances, the dos and don’ts and weld preparations must be consulted.
When the fabrication sequence and sub-assemblies have been identified, the
sub-assemblies are broken into pipe runs and given numbers for easy identification.
Cutting sizes are then calculated and the fabrication specification is checked to
determine the shortest run of straight pipe that can have a welded joint. The fittings
must be checked for size before the calculation of run lengths. Catalogues give nominal
sizes, and actual sizes may vary.
Assembly of sub-assembly
Appropriate equipment such as marking out tables, adjustable pipe stands, levels, etc
is used to set up and tack individual pipe components. Weld preparation root gap is
determined from the welding procedure and by consulting the welding operator. The
welding procedure will in most cases allow slight leeway to accommodate the specific
requirements of the welding operator.
Usually a piece of wire or a welding electrode of the correct diameter bent to a ‘V’
shape will give the required gap. Depending on the diameter of the pipe, four tack
welds, 25 mm long and 90° apart are usually adequate. On large tubulars, it may be
necessary to have tacks 150 mm long with multiple passes.
As fabrication of sub-assemblies continues, the welding operator can be welding the
rolling butts and flanges of the sub-assemblies.
As work progresses, dimensions should be continually checked and shrinkage
dimensions of welds checked and adjustments made, if appropriate. Distortion of
sub-assemblies should also be monitored and corrected before incorporation into final
assembly.
If distortion occurs, the fabrication specification is checked to determine whether
deviation is within acceptable limits. If not, it is rectified by applying spot heating (if
permissible) or other means such as mechanical pressing.
Welded sub-assemblies should be set up to comply with the configuration and
dimensions on the fabrication drawing. Once tacked, the assembly is ready for welding.
It is essential that the assembly is well supported and that all necessary precautions
are taken to reduce distortion.
Two or more sub-assemblies can often be tacked up and welded before incorporation
into the final spool assembly.
After welding, the assembly should be checked for distortion and dimensional accuracy
and rectified if not within acceptable limits.
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Cutting the pipe
The process by which pipe is cut is determined by its ferrous or non-ferrous nature.
There are several types of cutting machines available, both hand and mechanical.
Tools such as pipe cutters, joint profile machines, oxy and plasma cutting tools are all
appropriate for cutting pipe.
To ensure accuracy of cut, a scribed line should be centre punched every 10 mm.
Dividing the pipe surface into four equal parts
The pipe fabricator is often required to divide the pipe surface into four equal parts this
will aid in the assembly process.
The four equal parts now become centre-lines from which to take measurements, and
in which to locate fittings.
The fabricator is required to follow these four steps to achieve this.
1.
Wrap a strip of paper around the pipe.
2.
Double the paper as shown in Figure 4.9 and double it again. This will divide the
paper into four parts. The distance between an end and a crease, and between
each crease, is equal to a quarter of the circumference.
3.
Place the paper around the pipe.
4.
Mark the pipe with engineer’s chalk at each crease and where the two ends meet.
Fig 4.9: Dividing pipe surface into four equal parts
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Bevelling
After cutting, weld preparation bevels should be prepared to weld procedure
specification.
If an oxy-cutting process is used, the pipe edge should be heated slightly to help
produce a smooth cut face.
Slag from the oxy cutting must be removed before bevelling starts.
Excellent results can be produced manually with oxy cutting equipment if the bevel is
made from the root face of the preparation, cutting back to the outer surface. With this
technique, the distance from the top of the flame’s inner cone is slightly increased to
ensure that the root face is not damaged by excessive heat.
When oxy cutting is finished, the slag, oxide and burrs from both the bore and the
external surface of the pipe should be removed. The preparation may be smoothed by
grinding of filing.
It is critical that weld preparations comply completely with the weld procedure
specification, because incorrect weld preparation is often a reason for rejection of
prepared butt joints by inspectors and welding operators.
The following problems are common reasons for rejection:
1.
not enough or too much, root face
2.
not enough or too much, gap
3.
misalignment
4.
bevel not adequately prepared, ie inadequate bevel and not enough metal removed
with round bevel surface (see Figure 4.10).
Rounded face bevel
restricts access to root.
Fig 4.10: Unsuitable weld preparation
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Lining up the pipe
Correct alignment of the pipe and pipe fittings is one of the most important tasks
performed by the pipe fabricator. The methods of ensuring correct alignment will vary
depending on available equipment and there is no one ‘best system’.
The procedures suggested here are common and will enable pipe to be quickly and
accurately aligned using manual tools.
Setting of flanges
There are no hard and fast rules as to when to set flanges on the assembly; they
may be placed on sub-assemblies to facilitate setting up and welding. However, it is
generally deemed best practice to set up flanges once the pipe assembly has been
completed, as this approach allows for any minor inaccuracies to be rectified as flanges
are placed.
Flanges are more likely to remain accurate and in correct alignment, as their final
position after welding is not going to be influenced by the expansion and contraction
stresses (distortion) of other welds in the assembly which may have to be welded after
the flanges have been placed.
Once the flanges have been placed, it is important to make sure that the assembly
is level and accurately set. This can be done using appropriate tools such as spirit
levels, plumb lines and squares. The pipe should also be checked to see that it is
dimensionally correct to accept the flange.
The flange should be positioned using a level, ensuring that the boltholes straddle the
centre-line (unless otherwise stated). Flanges must be positioned equally around the
pipe diameter. This can be made easier using small wedges which have been created
by tapering the end of welding rod stubs.
Four 25 mm long tacks are usually adequate, but it depends on the diameter of the
flange.
After the flanges have been tacked, it is important to check dimensions and hole
positions. The flange is then ready for welding.
Fitting up the pipes
The two pipes to be welded must be properly and accurately aligned before they are
welded. There must be no misalignment of the internal bore or the external surface
of the pipe and the pipes and pipe fittings must be aligned so that the finished piping
system will be in the correct location and orientation. Considerable skill is required to fit
up two pipes in preparation for welding and this is an essential and fundamental part of
the pipe fabricator’s responsibility.
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Tacking the pipe
There are several ways in which pipe joints can be tack welded.
Bridge tacks
A rod or bar of base metal composition is used to bridge the root gap by tack welding
to the groove sides. The bridge rod and tacks are not incorporated into the final joint,
thus ensuring an accurate joint for the welding operator and eliminating the chances of
a defective tack being incorporated into the final weld. Bridge tacks are normally placed
by the pipe fabricator.
Fig 4.11: Bridge tacks
Integral tacks
Integral tacks must be placed with care as they form part of the root run. For this
reason, tacking is not normally done with stainless steel or alloy materials until
pre-purging and purging have been completed.
Both ends of the tack should be carefully ground to a feathered edge to allow the tie-in
of the remainder of the root bead. Integral tacks must be done by a coded welder.
Fig 4.12: Integral tacks
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It is highly desirable that tack welds be removed as welding progresses.
Green or run off
The complete assembly shown on a spool drawing is seldom completely welded in the
workshop due to allowances being made for site variation.
Depending on the complexity of the pipe spool, it is often necessary to leave extra
material length on the pipe to allow for site variations. This extra length is often called
‘green’ or ‘run off’.
Usually 150 mm of ‘green’ is left when the drawing indicates a fit and field weld (FFW).
In addition, selected flanges should only be tacked where possible to accommodate
site variations and any inaccuracies of the fabricated spool.
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Welding process
Several considerations need to be looked at when pipes are being welded together.
These include the grade of material, the welding process and the thickness of the
material. These factors determine the consumables, type of welding machine and the
design of weld preparation according to standards.
Preparing for welding
Contaminants such as grease, oil, scale or rust will have harmful effects on the quality
of the weld. All traces of the oxide produced by oxygen/fuel cutting must be removed by
filing, grinding or wire brushing.
The pipe fabricator/welder must also make sure that any other contaminants are
removed before starting to weld. This can usually be accomplished by vigorous
application of a wire brush. Stainless steels and other exotic alloys must be degreased
with a suitable solvent immediately before welding. After cleaning, the piping should be
handled with clean hands or clean gloves to ensure that the base metal and filler metal
remain clean.
Butt joints
In butt joint preparation, two important factors emerge:
●●
the shape of the groove, which relates to wall thickness
●●
the pipe roundness, which affects accuracy. (If the pipe is out of round, the weld
joint may be misaligned.)
A small root face is recommended for good root penetration. Where a feathered edge is
used, there is a tendency to melt away unevenly during welding. This makes it difficult
to control the weld pool and can result in weld defects such as uneven penetration.
A U joint is preferred for heavy wall pipe.
Butt welds are usually single-Vee preparations with the dimensions shown, unless the
piping system is of a large enough diameter that access is permitted.
30 ° + 7½
–0
1.5 - 3 mm
1.5 mm
Fig 4.13: Single-Vee butt
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For detailed information on butt weld preparation, refer to:
●●
AS/NZS 3992:1998/Amdt 1:2000 Pressure equipment – Welding and brazing
qualification
●●
AS 4458-1997 Pressure equipment – Manufacture.
Branch joints
It should be noted that difficulties arise when setting up set-in branches. These joints
should be only used where design conditions do not permit set-on type joints. Typical
examples of the use of set-in joints are branch joints in pressure vessels, high operating
pressures and corrosive media. The applicable codes mentioned previously contain
recommendations.
x
x
Y
w
Set-on unequal branch
45 °
min
s
g
Section at X
Set-on equal branch
45 °
min
g
g
3 mm
Ledge
Section at Y
Section at W
Fig 4.14: Set-on branches
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When the hole in the header is cut by oxygen fuel gas, the ledge illustrated should be
obtained. This can be removed by grinding if required. Alternatively, if the hole in the
header is prepared by machining, this ledge will not be obtained (see section at W).
x
x
Y2
Y1
w
s
60 °
min
45 °
min
45 °
min
45 °
s min
g
g
g
s
g
s = 1.5 mm ± 0.8 mm
g = 2.5 mm ± 0.8 mm
Fig 4.15: Set-in branches
Flanges
The clearance between the base of the flange and the outside diameter of the pipe
should not typically exceed 3 mm at any one point, and the sum of the clearance
diametrically opposite should not be more than 5 mm.
The section of flange type and joint to be used will depend on the service requirements.
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Weld neck flange
1
See recommended weld
preparation.
2
Where access permits joint
may be background and
back welded.
Fillet welded flange
F
2
F1
1
F1 = 1.5t
2
F2 - t min
t
t
F2
F1
t
Hubbed flange
1
2
F1 - 1.5t but should not
exceed 16 mm.
F2 = t min
t
Fig 4.16: Weld specifications for flanges
Distortion
Distortion is easily controlled in pipe butt joints by ensuring that the heat input is
equalised all around the joint. Fit-up is most important as an uneven root gap means
that, where the gap is wider, more weld metal is required and the uneven shrinkage
forces can cause distortion. Tacks must also be strong enough to hold the root gap
even.
Welders can sometimes be tempted – especially when settled into a comfortable
position – to carry on with the next pass before completing the previous pass all around
the joint. The unequal heat input obtained causes unequal shrinkage which results in
angular distortion.
Where two or more welders are welding the same joint, it is important that the welding
procedure is balanced so that the heat input is even all around the joint.
When pipe branch joints are being welded, it is advisable to tack weld a stay or stays to
maintain the correct alignment.
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Fig 4.17: A temporary stay to maintain alignment
Where a number of branch joints are in close proximity to each other as in the branches
from a header pipe, the problem of the header pipe becoming distorted needs to be
avoided.
One way of overcoming this problem is to attach a suitable strong back to the header
pipe on the side opposite the branch welds.
Fig 4.18: Minimising distortion in a header pipe
Further information on welding can be found in the technical notes available for
purchase from Welding Technology Institute of Australia.
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MRC Data Chart reproduced with the permission of MRC Global Australia.
134
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Appendix 1 – MRC Data Chart
Data Chart
Pipe | Fittings | Flanges
Face Side of Chart
Reverse Side of Chart
MRC Data Chart reproduced with the permission of MRC Global Australia.
© WestOne Services 2013
ENG2068
135
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DisClaimer:
The information contained in this data chart is provided in good faith, and every reasonable effort is made to ensure that it is correct and up to date. However MRC does not warrant the accuracy
and completeness of the information within this data chart. Accordingly, this information is provided 'as is' without warranty of any kind. Any person relying on any of the information contained in this
handbook or making any use of the information contained herein, shall do so at its own risk.
To the fullest extent permitted by the applicable law, MRC hereby disclaims any liability and in no event shall MRC be liable for any damage including, without limitation, direct, indirect or consequential
damages including loss of revenue, loss of profit, loss of opportunity or other loss arising from the use of or the inability to use the information contained in this handbook including damages arising from
inaccuracies, omissions or errors.
MRC Data Chart reproduced with the permission of MRC Global Australia.
136
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sTeel PiPes TO ameriCaN sTaNDarD asme B36.10
Dimensions (mm)
Weight (kg/m)
Nominal size
Nominal Wall Thickness & Weight for
Welded & seamless steel Pipe asme B36.10
Outside
Diameter
DN
NPs
mm
sTD
eXTra
sTrONG
XX
sTrONG
sCHeD.
10
sCHeD.
20
sCHeD.
30
6
1/8
10.3
–
–
–
–
–
–
–
–
1/4
13.7
–
–
–
–
–
–
–
–
–
10
3/8
17.1
–
–
–
–
–
–
–
–
–
15
1/2
21.3
–
–
–
–
–
–
3/4
26.7
–
–
–
–
–
–
–
25
1
33.4
–
–
–
–
–
–
32
1 - 1/4
42.2
–
–
–
–
–
–
40
1 - 1/2
48.3
–
–
–
–
–
–
50
2
60.3
–
–
–
–
–
–
65
2 - 1/2
73.0
–
–
–
–
–
–
80
3
88.9
7.47
2.55
7.82
3.64
9.09
5.45
9.7
7.77
10.15
9.56
11.07
13.44
14.02
20.39
15.24
27.67
–
20
2.41
0.47
3.02
0.80
3.20
1.10
3.73
1.62
3.91
2.20
4.55
3.24
4.85
4.47
5.08
5.41
5.54
7.48
7.01
11.41
7.62
15.27
8.08
18.63
8.56
22.32
9.53
30.97
10.97
42.56
12.7
64.64
12.7
81.55
12.7
97.46
12.7
107.10
12.7
123.30
12.7
139.15
12.7
155.12
12.7
171.09
12.7
187.06
12.7
202.72
12.7
218.69
12.7
234.67
12.7
250.64
12.7
266.61
12.7
282.27
12.7
330.19
–
8
1.73
0.37
2.24
0.63
2.31
0.84
2.77
1.27
2.87
1.69
3.38
2.50
3.56
3.39
3.68
4.05
3.91
5.44
5.16
8.63
5.49
11.29
5.74
13.57
6.02
16.07
6.55
21.77
7.11
28.26
8.18
42.55
9.27
60.31
9.53
73.88
9.53
81.33
9.53
93.27
9.53
105.16
9.53
117.15
9.53
129.13
9.53
141.12
9.53
152.87
9.53
164.85
9.53
176.84
9.53
188.82
9.53
200.31
9.53
212.56
9.53
248.52
–
–
–
–
–
–
4.78
1.95
5.56
2.90
6.35
4.24
6.35
5.61
7.14
7.25
8.74
11.11
9.53
14.92
11.13
21.35
101.6
4
114.3
125
5
141.3
150
6
168.3
200
8
219.1
250
10
273.1
300
12
323.9
350
14
355.6
400
16
406.4
450
18
457
500
20
508
550
22
559
600
24
610
650
26
660
700
28
711
750
30
762
800
32
813
850
34
864
900
36
914
1050
42
1067
sCHeD.
60
–
–
–
–
–
–
sCHeD. sCHeD. sCHeD.
100
120
140
sCHeD.
160
–
–
–
–
–
–
–
–
17.12
41.03
19.05
57.43
21.95
79.22
22.23
107.92
25.4
155.15
25.4
186.97
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
6.35
54.59
6.35
62.64
6.35
70.57
6.35
78.55
6.35
86.54
6.35
94.53
7.92
127.36
7.92
137.32
7.92
147.28
7.92
157.24
7.92
167.20
7.92
176.96
6.35
33.31
6.35
41.77
6.35
49.73
7.92
67.90
7.92
77.83
7.92
87.71
Std.W.T.
117.15
Std.W.T.
129.13
Std.W.T.
141.12
XS
202.72
XS
218.69
XS
234.67
XS
250.64
XS
266.61
XS
282.27
7.04
36.81
7.8
51.03
8.38
65.20
Std.W.T.
81.33
Std.W.T.
93.27
11.13
122.38
XS
155.12
XS
171.09
14.27
209.64
10.31
79.73
11.13
94.55
XS
123.30
14.27
155.80
15.09
183.42
17.48
255.41
10.31
53.08
XS
81.55
14.27
108.96
15.09
126.70
16.66
160.12
19.05
205.74
20.62
247.83
22.23
294.25
24.61
355.26
15.09
96.01
17.48
132.08
19.05
158.10
21.44
203.53
23.83
254.55
26.19
311.17
28.58
373.83
30.96
442.08
15.09
75.92
18.26
114.75
21.44
159.91
23.83
194.96
26.19
245.56
29.36
309.62
32.54
381.53
34.93
451.42
38.89
547.71
11.13
28.32
12.7
40.28
14.27
54.20
18.26
90.44
21.44
133.06
XXS
186.97
27.79
224.65
30.96
286.64
34.93
363.56
38.1
441.49
41.28
527.05
46.02
640.03
20.62
100.92
XXS
155.15
28.58
208.14
31.75
253.56
36.53
333.19
39.67
408.26
44.45
508.11
47.63
600.63
52.37
720.15
13.49
33.54
15.88
49.11
18.26
67.56
23.01
111.27
28.58
172.33
33.32
238.76
35.71
281.70
40.49
365.35
45.24
459.37
50.01
564.81
53.98
672.26
59.54
808.22
–
–
–
–
–
–
–
–
15.88
271.21
15.88
292.18
15.88
312.15
15.88
332.12
15.88
351.7
–
–
–
–
–
–
–
–
–
–
–
–
–
–
17.48
342.91
17.48
364.90
19.05
420.42
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
sCHeD.
80
SAME AS EXTRA STRONG W.T. (X.S.)
3 - 1/2
SAME AS STANDARD W.T. (Std. W.T.)
90
100
sCHeD.
40
–
–
Formula to attain approximate mass in kilograms per metre (kg/m) for steel round Pipe and Tubing
m = (D – t) t x 0.02466
Where: m = mass to the nearest 0.01 kg/m
eXamPle:
D = Outside Diameter in millimetres
(To nearest 0.1mm for OD up to 406.4mm)
(To nearest 1.0mm for OD 457mm and above)
t = Wall Thickness to nearest 0.01mm
Nominal Size
DN300 NPS12
OD = 323.9mm
W.T. = 9.53mm
Step 1. 323.9 – 9.53 = 314.37
Step 2. 314.37 x 9.53 = 2995.9461
Step 3. 2995.9461 x 0.024 66
= 73.88kg/m
1
1
1
Steel Pipes to ASME B36.10
Stainless Steel Pipes to ASME B36.19
2
MRC Data Chart reproduced with the permission of MRC Global Australia.
© WestOne Services 2013
ENG2068
137
2
2
sTaiNless sTeel PiPes TO ameriCaN
sTaNDarD asme B36.19
Nominal
size DN
Outside
Diameter
(mm)
6
8
10
Nominal Wall Thickness & inside Diameter (mm)
schedule 5s
schedule 10s
Wall
Thickness
inside
Diameter
Wall
Thickness
10.29
–
–
1.24
13.72
–
–
1.65
17.15
–
–
1.65
15
21.34
1.65
18.04
20
26.67
1.65
23.37
25
33.40
1.65
30.10
32
42.16
1.65
38.86
40
48.26
1.65
50
60.33
65
73.03
80
88.90
100
inside
Diameter
schedule 40s
schedule 80s
Wall
Thickness
inside
Diameter
Wall
Thickness
inside
Diameter
7.81
1.73
10.42
2.24
6.83
2.41
5.47
9.24
3.02
13.85
2.31
7.68
12.53
3.20
10.75
2.11
17.12
2.77
15.80
3.73
13.88
2.11
22.45
2.87
20.93
3.91
18.85
2.77
27.86
3.38
26.64
4.55
24.30
2.77
36.62
3.56
35.04
4.85
32.46
44.96
2.77
42.72
3.68
40.90
5.08
38.10
1.65
57.03
2.77
54.79
3.91
52.51
5.54
49.25
2.11
68.81
3.05
66.93
5.16
62.71
7.01
59.01
2.11
84.68
3.05
82.80
5.49
77.92
7.62
73.66
114.30
2.11
110.08
3.05
108.20
6.02
102.26
8.56
97.18
125
141.30
2.77
135.76
3.40
134.50
6.55
128.19
9.52
122.25
150
168.28
2.77
162.74
3.40
161.47
7.11
154.05
10.97
146.33
200
219.08
2.77
213.54
3.76
211.56
8.18
202.72
12.70
193.68
250
273.05
3.40
266.24
4.19
264.67
9.27
254.51
12.70
247.65
300
323.85
3.96
315.93
4.57
314.71
9.52
304.08
12.70
298.45
350
355.60
3.96
347.68
4.78
346.05
-
-
-
-
400
406.40
4.19
398.02
4.78
396.85
-
-
-
-
450
457.20
4.19
448.82
4.78
447.65
-
-
-
-
500
508.00
4.78
498.45
5.54
496.93
-
-
-
-
600
609.60
5.54
598.53
6.35
596.90
-
-
-
-
750
762.00
6.35
749.30
7.92
746.16
-
-
-
-
MRC Data Chart reproduced with the permission of MRC Global Australia.
138
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© WestOne Services 2013
CarBON sTeel BUTTWelDiNG FiTTiNGs TO
asme B16.9, B16.28 & Bs.1640
B16.9
LONG RADIUS WELDING ELBOWS, RETURN BENDS & CAPS
B
B16.28
SHORT RADIUS WELDING ELBOWS & RETURN BENDS
K
A
E
V
D
B
A
A
90°
15
20
25
32
40
50
65
80
90
100
125
150
200
250
300
350
400
450
500
600
750
900
21.3
26.7
33.4
42.2
48.3
60.3
73.0
88.9
101.6
114.3
141.3
168.3
219.1
273.1
323.9
355.6
406.4
457
508
610
762
914
sch.
20
sch.
30
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6.35 7.04
—
6.35 7.80
—
6.35 8.38
6.35 7.92 9.53
6.35 7.92 9.53
6.35 7.92 11.13
6.35 9.53 12.70
6.35 9.53 14.27
7.92 12.70 15.88
7.92 12.70 15.88
Nominal size
DN
small end
25
32
40
50
65
80
90
20
15
25
20
15
32
25
20
15
40
32
25
20
15
50
40
32
25
20
65
50
40
32
25
80
65
50
40
32
25
90
80
65
50
40
std.
Wt.
2.77
2.87
3.38
3.56
3.68
3.91
5.16
5.49
5.74
6.02
6.55
7.11
8.18
9.27
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
sch.
40
10.31
11.13
12.7
14.27
15.09
17.48
—
19.05
sch.
60
X stg.
—
—
—
—
—
—
—
—
—
—
—
—
10.31
12.70
14.27
15.09
16.66
19.05
20.62
24.61
—
—
3.73
3.91
4.55
4.85
5.08
5.54
7.01
7.62
8.08
8.56
9.53
10.97
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
sch.
80
15.09
17.48
19.05
21.44
23.83
26.19
30.96
—
—
sch.
100
sch.
120
sch.
140
sch.
160
—
—
—
—
—
—
—
—
—
—
—
—
15.09
18.26
21.44
23.83
26.19
29.36
32.54
38.89
—
—
—
—
—
—
—
—
—
—
—
11.13
12.70
14.27
18.26
21.44
25.40
27.79
30.96
34.93
38.10
46.02
—
—
—
—
—
—
—
—
—
—
—
—
—
—
20.62
25.40
28.58
31.75
36.53
39.67
44.45
52.37
—
—
4.78
5.56
6.35
6.35
7.14
8.74
9.53
11.13
13.49
15.88
18.26
23.01
28.58
33.32
35.71
40.49
45.24
50.01
59.54
-
REDUCING TEES (B16.9)
C
C
20
180°
Wall Thickness (mm)
sch.
10
STRAIGHT TEES (B16.9)
large
end
D
D
90°
SAME AS X. STG.
Pipe
OD
mm
180°
SAME AS STD. WT.
Nom.
size
DN
45°
D
A
C
m
H
28.6
28.6
38.1
38.1
38.1
47.6
47.6
47.6
47.6
57.2
57.2
57.2
57.2
57.2
63.5
63.5
63.5
63.5
63.5
76.2
76.2
76.2
76.2
76.2
85.7
85.7
85.7
85.7
85.7
85.7
95.3
95.3
95.3
95.3
95.3
28.6
38.1
38.1
47.6
47.6
47.6
57.2
57.2
57.2
57.2
60.3
57.2
50.8
44.5
69.9
66.7
63.5
57.2
82.6
76.2
73.0
69.9
69.9
92.1
88.9
82.6
79.4
38.1
50.8
50.8
50.8
50.8
50.8
63.5
63.5
63.5
63.5
76.2
76.2
76.2
76.2
88.9
88.9
88.9
88.9
88.9
88.9
88.9
88.9
88.9
102
102
102
102
Nominal size
DN
small end
large
end
100
125
150
200
250
300
350
100
90
80
65
50
40
125
100
90
80
65
50
150
125
100
90
80
65
200
150
125
100
80
250
200
150
125
100
300
250
200
150
100
350
300
250
200
150
a
7.47
38
7.82
38
9.09
38
9.70 47.5
10.15
57
11.07
76
14.02
95
15.24 114
16.15 133
17.12 152
19.05 190
21.95 229
22.23 305
25.40 381
25.40 457
—
533
—
610
—
686
—
762
—
914
—
1143
—
1372
B
K
16
19
22
25.4
29
35
44.5
51
57
63.5
79
95
127
159
190
222
254
286
318
381
470
565
47.5
43
55.5
70
82.5
106
132
159
184
210
262
313
414
517
619
711
813
914
1016
1219
1524
—
CONCENTRIC & ECCENTRIC
REDUCERS (B16.9)
M
C
C
X.X.
stg.
D
e. std. Nom.
Wt. & size
ex. stg. DN
V
—
—
19
33
25.4 41
32
52
38
62
51
81
63.5 100
76 121
89 140
102 159
127 197
152 237
203 313
254 390
305 467
356 533
406 610
457 686
508 762
610 914
762 1143
914 1372
H
25.4
25.4
38.1
38.1
38.1
38.1
38.1
50.8
63.5
63.5
76.2
88.9
102
127
152
165
178
203
229
267
267
267
15
20
25
32
40
50
65
80
90
100
125
150
200
250
300
350
400
450
500
600
750
900
H
C
C
m
H
105
105
105
105
105
105
124
124
124
124
124
124
143
143
143
143
143
143
178
178
178
178
178
216
216
216
216
216
254
254
254
254
254
279
279
279
279
279
102
98.4
95.3
88.9
85.7
117
114
111
108
105
137
130
127
124
121
168
162
155
152
203
194
191
184
241
229
219
210
270
257
248
238
102
102
102
102
102
127
127
127
127
127
140
140
140
140
140
152
152
152
152
178
178
178
178
203
203
203
203
330
330
330
330
Nominal size
DN
small end
large
end
400
450
500
600
750
900
400
350
300
250
200
150
450
400
350
300
250
200
500
450
400
350
300
250
200
600
500
450
400
350
300
250
750
600
500
450
400
900
750
600
500
450
C
m
H
305
305
305
305
305
305
343
343
343
343
343
343
381
381
381
381
381
381
381
432
432
432
432
432
432
432
559
559
559
559
559
673
673
673
673
673
305
295
283
273
264
330
330
321
308
298
368
356
356
346
333
324
432
419
406
406
397
384
533
508
495
483
635
610
584
572
356
356
356
356
356
381
381
381
381
381
508
508
508
508
508
508
508
508
508
508
508
508
610
610
610
610
610
610
610
610
NOTE: All dimensions are in millimetres (mm)
3
3
Dimensions - Buttweld Fittings to ASME B16.9, B16.28
3
Flanges - Forged Steel to ASME B16.5
4
MRC Data Chart reproduced with the permission of MRC Global Australia.
© WestOne Services 2013
ENG2068
139
4
4
FlaNGes TO ameriCaN sTaNDarDs
DN 15 to 600 are to ASME B16.5 (BS 1560). DN 750 & 900 are to BS 3293 for Slip-On & Weldneck only.
Threaded Flange
15
20
25
32
40
50
65
80
90
100
125
150
200
250
300
350
400
450
500
600
750
900
length Thru Hub
Dia. of Thickness
Dia. of
Thrd.
Weld
Fig. of Fig. min. slip-On
Bolt
Neck Circle
O
C(1)*
soc/Weld
Y(1)*
Y(1)*
90
11.5
16
48
60.5
100
13.0
16
52
70.0
110
14.5
17
56
79.5
120
16.0
21
57
89.0
130
17.5
22
62
98.5
150
19.5
25
64
120.5
180
22.5
29
70
139.5
190
24.0
30
70
152.5
215
24.0
32
71
178.0
230
24.0
33
76
190.5
255
24.0
36
89
216.0
280
25.5
40
89
241.5
345
29.0
44
102 298.5
405
30.5
49
102 362.0
485
32.0
56
114 432.0
535
35.0
57
127 476.0
600
37.0
64
127 540.0
635
40.0
68
140 578.0
700
43.0
73
145 635.0
815
48.0
83
152 749.5
985
54.0 †
89
130.2 914.0
1170
60.3 †
95
136.5 1086.0
PN150 (Class 900)
Socket Welding (DN 15 - 80)
Blind Flanges up to DN600
(Above DN600 see notes below † )
PN50 (Class 300)
length Thru Hub
Dia.
Dia. of
Thickness
Dia. of Dia. of
Thrd.
No. of of
No. of
Weld Bolt
Bolt
of Fig. min. slip-On
Bolt
Bolts Fig.
Neck Circle Holes Bolts
Holes
C(1)*
soc/Weld
O
Y(1)*
Y(1)*
16
4
95
14.5
22
52
66.5
16
4
16
4
120
16.0
25
57
82.5
20
4
16
4
125
17.5
27
62
89.0
20
4
16
4
135
19.5
27
65
98.5
20
4
16
4
155
21.0
30
68
114.5
22
4
20
4
165
22.5
33
70
127.0
20
8
20
4
190
25.5
38
76
149.0
22
8
20
4
210
29.0
43
79
168.5
22
8
20
8
230
30.5
44
81
184.0
22
8
20
8
255
32.0
48
86
200.0
22
8
22
8
280
35.0
51
98
235.0
22
8
22
8
320
37.0
52
98
270.0
22
12
22
8
380
41.5
62
111 330.0
26
12
26
12
445
48.0
67
117 387.5
30
16
26
12
520
51.0
73
130 451.0
33
16
30
12
585
54.0
76
143 514.5
33
20
30
16
650
57.5
83
146 571.5
36
20
33
16
710
60.5
89
159 628.5
36
24
33
20
775
63.5
95
162 686.0
36
24
36
20
915
70.0
106
168 813.0
42
24
35
28 1090
92.0
210
210 997.0
48
28
41
32 1270
105.0
241
241 1168.0 54
32
PN250 (Class 1500)
length Thru Hub
length Thru Hub
Dia. Thickness
Dia. Thickness
Dia. of Dia. of
Thrd.
No. of of of Fig. min. Thrd. slip- Weld
of of Fig. min.
Weld Bolt
Bolt
slip-On
Fig.
Neck Circle Holes Bolts Fig.
On soc/ Neck
C(2)†
C(2)†
soc/Weld
O
O
Y(2)†
Weld Y(2)† Y(2)†
Y(2)†
15
120
22.5
32
60
20
130
25.5
35
70
25
150
29.0
41
73
32
USE PN250 DIMENSIONS IN THESE SIZES
160
29.0
41
73
40
180
32.0
44
83
50
215
38.5
57
102
65
245
41.5
64
105
80
240
38.5
54
102 190.5
26
8
270
48.0
73
118
100
295
44.5
70
114 235.0
32
8
310
54.0
90
124
125
350
51.0
79
127 279.5
35
8
375
73.5
105
155
150
380
56.0
86
140 317.5
32
12
395
83.0
119
171
200
470
63.5
102
162 393.5
39
12
485
92.0
143
213
250
545
70.0
108
184 470.0
39
16
585
108.0
159
254
300
610
79.5
117
200 533.5
39
20
675
124.0
181
283
350
640
86.0
130
213 559.0
42
20
750
133.5
298
400
705
89.0
133
216 616.0
45
20
825
146.5
311
450
785
102.0
152
229 686.0
52
20
915
162.0
327
500
855
108.0 in millimetres
159
248 749.5
54
20
985
178.0
356
All dimensions
are shown
(mm)
600
1040
140.0
203
292 901.5
68
20 1170
203.5
406
Nominal
size
DN
NOTes:
* 1. The 2mm Raised Face is included in thickness C(1) and length
through hub Y(1). This applies to PN20 and PN50 Pressure
Ratings.
† 2. The 7mm Raised Face is not included in thickness C(2) and length
through hub Y(2). PN100, 150, 250 and 420 Pressure Ratings
are regularly furnished with 7mm Raised Face which is additional to
the flange thickness C(2) and Y(2).
3. Always specify bore when ordering weldneck flanges. Bore
dimensions shown opposite also provide inside pipe diameters.
larGe DiameTer FlaNGes aBOVe DN 600
† For Blind Flanges refer to MSS SP44.
BS 3293 covers Slip-On and Weldneck but excludes Blind Flanges.
MSS SP44 covers Blind and Weldneck but excludes Slip-On Flanges.
BS 3293 Weldneck PN20 flange thickness, C(1), is less than MSS
SP44 equivalents.
API - 605 Dimensions for Large Diameter Flanges vary considerably
from both BS 3293 and MSS SP44 — Details on request.
PN100 (Class 600)
length Thru Hub
Dia. of Dia. of
Dia. of Thickness
Thrd.
No. of
Weld Bolt
Bolt
Fig. of Fig. min. slip-On
Neck Circle Holes Bolts
O
C(2)†
soc/Weld
Y(2)†
Y(2)†
95
14.5
22
52
66.5
16
4
120
16.0
25
57
82.5
20
4
125
17.5
27
62
89.0
20
4
135
21.0
29
67
98.5
20
4
155
22.5
32
70
114.5
22
4
165
26.5
37
73
127.0
20
8
190
29.0
41
79
149.0
22
8
210
32.0
46
83
168.5
22
8
230
35.0
49
86
184.0
26
8
275
38.5
54
102 216.0
26
8
330
44.5
60
114 267.0
30
8
355
48.0
67
117 292.0
30
12
420
55.5
76
133 349.0
33
12
510
63.5
86
152 432.0
36
16
560
66.5
92
156 489.0
36
20
605
70.0
94
165 527.0
39
20
685
76.5
106
178 603.0
42
20
745
83.0
117
184 654.0
45
20
815
89.0
127
190 724.0
45
24
940
102.0
140
203 838.0
52
24
1130
114.0
248
248 1022.0 54
28
1315
124.0
283
283 1194.0 67
28
PN420 (Class 2500)
length Thru Hub
Dia. of Dia. of
Dia. of Thickness
Thrd.
No. of
Weld
Bolt
Bolt
Fig. of Fig. min. slip-On
Bolts
Neck
Circle Holes
O
C(2)†
soc/Weld
Y(2)†
Y(2)†
82.5
22
4
135
30.5
40
73
89.0
22
4
140
32.0
43
79
101.5
26
4
160
35.0
48
89
111.0
26
4
185
38.5
52
95
124.0
30
4
205
44.5
60
111
165.0
26
8
235
51.0
70
127
190.5
30
8
270
57.5
79
143
203.0
33
8
305
67.0
92
168
241.5
36
8
355
76.5
108
190
292.0
42
8
420
92.5
130
229
317.5
39
12
485
108.0
152
273
393.5
45
12
550
127.0
178
318
482.5
52
12
675
165.5
229
419
571.5
56
16
760
184.5
254
464
635.0
60
16
705.0
68
16
774.5
76
16
832.0
80
16
990.5
94
16
Dia. of Dia. of
No. of
Bolt
Bolt
Bolts
Circle Holes
89.0
95.0
108.0
130.0
146.0
171.5
197.0
228.5
273.0
324.0
368.5
438.0
539.5
619.0
22
22
26
30
33
30
33
36
42
48
56
56
68
76
raised Face
approximate Welding Neck Flange Bores - mm
of
Diam.
Nominal O.D.
Pipe
all Press. size DN mm sCH. sCH. sCH. sTD. sCH. sCH. eXT. sCH. sCH. sCH.
ratings mm
10
20
30 WT. 40
60 sTG. 80 100 120
35
15
21.3
15.8
13.9
43
20
26.7
20.9
18.9
51
25
33.4
26.6
24.3
64
32
42.2
35.1
32.5
73
40
48.3
40.9
38.1
92
50
60.3
52.5
49.2
105
65
73.0
62.7
59.0
127
80
88.9
77.9
73.7
140
90
101.6
90.1
85.4
157
100 114.3
102.3
97.2
92.1
186
125 141.3
128.2
122.3
115.9
216
150 168.3
154.1
146.3
139.7
270
200 219.1
206.4 205.0 202.7
198.5 193.7
188.9 182.6
324
250 273.1
260.3 257.5 254.5
247.7 247.7 242.9 236.5 230.2
381
300 323.9
311.1 307.1 304.8 303.2 295.3 298.5 288.9 281.0 273.1
413
350 355.6 342.9 339.8 336.6 336.6 333.3 325.4 330.2 317.5 307.9 300.0
470
400 406.4 393.7 390.6 387.4 387.4 381.0 373.1 381.0 363.5 354.0 344.5
533
450 457.0 444.5 441.4 434.9 438.2 428.7 419.1 431.8 409.5 398.5 387.4
584
500 508.0 495.3 489.0 482.6 489.0 477.8 466.8 482.6 455.6 442.9 431.8
692
600 610.0 596.9 590.6 581.1 590.6 574.6 560.4 584.2 547.7 531.8 517.6
857
750 762.0 746.2 736.6 730.2 743.0
736.6
1022
900 914.0 898.6 889.0 882.6 895.4 876.3
889.0
Same as EXT. STG.
PN20 (Class 150)
Nominal
size
DN
Slip-On Flange
Same as STD. WT.
Welding Neck Flange
4
4
4
4
4
8
8
8
8
8
8
12
12
12
Nominal
size
DN
15
20
25
32
40
50
65
80
90
100
125
150
200
250
300
350
400
450
500
600
750
900
Nominal
size
DN
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
sCH. sCH. X.X
140 160 sTG
11.8 6.4
15.5 11.0
20.7 15.2
29.5 22.8
34.0 27.9
42.9 38.2
54.0 45.0
66.7 58.4
––
––
87.3 80.1
109.6 103.2
131.8 124.4
177.8 173.1 174.6
222.3 215.9 222.3
266.7 257.2 273.1
292.1 284.2
333.3 325.4
377.9 366.7
419.1 408.0
504.9 490.5
MRC Data Chart reproduced with the permission of MRC Global Australia.
140
ENG2068
© WestOne Services 2013
BOlTiNG FOr aNsi FlaNGes
BOlTiNG
To suit R.F. Flange sizes DN 15 to 600 to ASME — B16.5 (BS. 1560) and DN 750 & 900 to BS. 3293
L
L*
Diameter of Bolts is shown in inches. For nominal diameters 1 inch and smaller, threads
are U.N.C.; nominal diameters 1 - 1/8 inch and larger threads are 8 U.N. (8 T.P.I).
Length of Bolts (L) is shown in millimetres rounded to the nearest 5mm. Stud Bolt
lengths (L*) do not include the height of points. Machine Bolt lengths (L) include the
height of point. The length shown includes the height of the Raised Face in all cases.
*Point Height
STUD BOLT WITH NUTS
MACHINE BOLT WITH NUT
PN 20 (Class 150)
Nom
Flge
size
DN
No.
Bolts
Dia.
Bolts
ins.
15
4
20
4
25
PN 50 (Class 300)
l
PN 100 (Class 600)
PN 150 (Class 900)
l
stud
Bolts
mm
PN 250 (Class
1500)
l
Dia.
No.
Bolts stud
Bolts
Bolts
ins.
mm
3/4
4
105
PN 420 (Class
2500)
l
Dia.
No.
Bolts stud
Bolts
Bolts
ins.
mm
3/4
4
125
Nom
Flge
size
DN
stud
Bolts
mm
mach.
Bolts
mm
No.
Bolts
Dia.
Bolts
ins.
l
stud
Bolts
mm
1/2
65
55
4
1/2
80
5/8
75
60
4
5/8
90
4
3/4
115
4
3/4
125
20
4
5/8
80
65
4
5/8
90
4
7/8
125
4
7/8
140
25
55
4
5/8
80
65
4
5/8
100
4
7/8
125
4
150
32
70
60
4
3/4
90
75
4
3/4
105
4
1
140
4
1
1 1/8
170
40
80
65
8
5/8
90
75
8
5/8
105
8
7/8
145
8
1
175
50
75
8
3/4
100
85
8
3/4
120
8
1
160
8
1 1/8
195
65
75
8
3/4
110
90
8
3/4
125
8
7/8
145
8
1 1/8
180
8
1 1/4
220
80
90
75
8
3/4
110
95
8
7/8
140
-
-
-
-
90
8
3/4
110
95
8
7/8
145
8
170
8
195
8
1 1/2
-
75
1 1/4
-
90
1 1/8
255
100
3/4
90
80
8
3/4
120
100
8
1
165
8
8
1 3/4
300
125
100
85
12
3/4
125
105
12
170
12
260
8
2
345
150
8
3/4
110
90
12
7/8
140
110
12
1
1 1/8
1 1/2
1 3/8
250
3/4
195
12
290
12
200
12
7/8
115
95
16
1
155
130
16
215
16
335
12
485
250
300
12
7/8
120
100
16
170
145
20
220
20
12
2 3/4
540
300
12
1
130
110
20
175
150
20
235
20
405
350
400
16
135
115
20
160
20
255
20
400
150
125
24
195
170
20
275
20
495
450
500
20
160
135
24
180
24
290
20
500
175
145
24
230
195
24
1 7/8
330
20
3
3 1/2
540
20
1 1/4
1 1/2
205
600
1 1/8
1 1/4
1 5/8
1 5/8
2 1/2
2 3/4
445
16
1 1/4
1 1/4
190
450
1
1 1/8
1 3/8
1 1/2
2
2 1/4
375
350
1 1/8
1 1/8
1 1/4
1 1/4
2
2 1/2
380
250
1 5/8
1 7/8
615
600
750
28
190
160
28
1 3/4
290
250
28
32
215
180
32
2
325
280
28
2
2 1/2
355
900
1 1/4
1 1/2
stud
Bolts
mm
mach.
Bolts
mm
No.
Bolts
Dia.
Bolts
ins.
1/2
60
45
4
1/2
65
50
4
4
1/2
65
55
32
4
1/2
70
40
4
1/2
50
4
5/8
65
4
5/8
90
80
4
5/8
90
90
8
5/8
100
8
5/8
125
8
150
8
200
l
No.
Bolts
Dia.
Bolts
ins.
USE PN250 DIMENSIONS
IN THESE SIZES
400
1 1/4
1 1/8
190
8
195
12
1 3/8
1 3/8
220
12
235
12
1 3/8
1 1/2
255
16
275
16
1 5/8
1 7/8
285
16
325
16
2
2 1/2
345
16
435
16
asTm a193
Grade B7
Standard specification for alloy steel and stainless steel bolting materials for high temperature
service.
asTm a194
Grade 2H
Standard specification for carbon and alloy steel nuts for bolts for high pressure and high
temperature service.
Standard specification for alloy steel bolting materials for low temperature service.
Grade L7 covers alloy steel stud bolts.
Grade L4 covers alloy steel nuts to suit Grade L7 stud bolts.
FOr
1/2”
5/8”
M14
3/4”
M20
7/8”
M24
1”
M27
1 1/8”
M30
1 1/4”
M33
1 3/8”
M36
1 1/2”
M39
1 5/8”
M42
1 3/4”
M45
1 7/8”
M48
2”
M52
2 1/4”
M56
2 1/2”
M64
2 3/4”
M72
5
5 Bolts & Studs for use with ASME B16.5 Flanges
900
inch/ metric Bolting
interchangeable for asme
B16.5 flanges as below
maTerial sPeCiFiCaTiONs
asTm
A320
750
PN150, 250 & 420 - NOT LISTED IN BS 3293
Raised Face height of 2 mm for PN20 & 50 and 7 mm for PN100, 150, 250 & 420 is included in dimension L (Bolt Length).
15
Use
M16
5
Mass of Fittings & Flanges to ASME Standards
6
MRC Data Chart reproduced with the permission of MRC Global Australia.
© WestOne Services 2013
ENG2068
141
6
6
sTeel PiPe, BUTTWelD FiTTiNGs & FlaNGes TO asme sTaNDarDs
asme B36.10
steel Pipe Dimensions
Pipe
identification
Nominal Outside
Pipe size Diam.
DN
mm
inside
Diam.
mm
std. X.s sch. No.
approximate mass of Popular sizes
a.s.m.e Flanges
Buttweld Fittings
steel
Pipe
kg/m
90o l/r
elbows
kg/ea
Tees
equal
kg/ea
Con.
& ecc.
red.
kg/ea
PN20
(150)
PN50
(300)
PN100 PN150
(600) (900)
sOW/
sW
Thrded
kg/ea
W/N
kg/ea
Blind
kg/ea
sOW/
sW
Thrded
kg/ea
W/N
kg/ea
Blind
kg/ea
W/N
kg/ea
W/N
kg/ea
15
21.3
15.8
13.9
Std.
XS
40
80
1.27
1.62
0.08
0.10
0.16
0.21
-
0.45
0.79
0.57
0.73
0.91
0.79
0.91
2.00
20
26.7
20.9
18.9
Std.
XS
40
80
1.69
2.20
0.08
0.11
0.21
0.27
0.07
0.10
0.68
0.86
0.91
1.25
1.41
1.13
1.59
2.72
25
33.4
26.6
24.3
Std.
XS
40
80
2.50
3.24
0.17
0.21
0.34
0.43
0.14
0.18
0.95
1.09
1.09
1.36
1.81
1.77
1.86
3.86
32
42.2
35.1
32.5
Std.
XS
40
80
3.39
4.47
0.28
0.39
0.64
0.75
0.18
0.23
1.13
1.41
1.25
2.04
2.27
2.68
2.72
4.54
40
48.3
40.9
38.1
Std.
XS
40
80
4.05
5.41
0.39
0.50
0.95
1.13
0.27
0.32
1.36
1.81
1.70
2.81
3.06
2.83
3.74
6.35
50
60.3
52.5
49.2
Std.
XS
40
80
5.44
7.48
0.68
1.00
1.45
1.72
0.41
0.54
2.22
2.83
2.77
3.13
3.74
3.52
4.65
10.89
65
73.0
62.7
59.0
Std.
XS
40
80
8.63
11.41
1.39
1.82
2.45
2.95
0.68
0.91
3.82
4.42
4.04
4.54
5.56
5.44
6.44
16.33
80
88.9
77.9
73.7
Std.
XS
40
80
11.29
15.27
2.18
2.86
3.45
4.30
0.91
1.27
4.08
5.22
5.44
6.12
7.37
7.26
8.50
14.51
90
101.6
90.1
85.4
Std.
XS
40
80
13.57
18.63
3.05
4.1
4.5
5.9
1.36
1.81
4.99
5.44
6.35
7.71
9.53
9.98
12.25
––
100
114.3
102.3
97.2
Std.
XS
40
80
16.07
22.32
4.2
5.7
5.7
7.3
1.59
2.18
5.94
7.48
7.37
9.53
11.79
11.79
17.24
23.13
125
141.3
128.2
122.3
Std.
XS
40
80
21.77
30.97
6.8
10.0
9.1
11.8
2.7
3.8
6.12
9.53
9.07
12.70
15.42
15.88
30.84
39.01
150
168.3
154.1
146.3
Std.
XS
40
80
28.26
42.56
10.9
16.3
13.6
19.0
3.9
5.4
8.16
11.34
12.70
16.33
19.96
20.87
34.02
49.90
200
219.1
202.7
193.7
Std.
XS
40
80
42.55
64.64
21.8
33.1
25
33.5
5.9
8.6
12.70
19.05
21.77
25.40
32.21
38.10
52.16
84.82
250
273.1
254.5
247.7
Std.
XS
40
60
60.31
81.55
38.6
52
41
54
10
14
17.24
25.40
31.75
35.38
44.00
53.34
90.36
121.56
300
323.9
304.8
298.5
Std.
XS
-
73.88
97.46
57
75
57
77
15
20
27.22
38.10
45.36
50.80
64.41
86.18
101.60
168.74
350
355.6
336.6
330.2
Std.
XS
30
-
81.33
107.39
73
97
73
93
28
37
35.38
51.26
58.97
74.39
84.37
107.05
157.40
254.92
400
406.4
387.4
381.0
Std.
XS
30
40
93.27
123.30
98
130
91
120
35
46
42.18
63.50
77.11
101.60
111.58
145.15
209.11
310.71
450
457
438.2
431.8
Std.
XS
-
105.16
139.15
120
165
135
190
40
53
52.62
68.04
102.51
126.10
138.35
181.89
217.27
419.12
500
508
489.0
482.6
Std.
XS
20
30
117.15
155.12
150
200
168
245
61
82
65.32
81.65
123.38
149.69
174.63
231.33
312.98
527.98
600
610
590.6
584.2
Std.
XS
20
-
141.12
187.06
220
280
240
350
77
95
91.63
118.84
203.21
222.26
247.21
342.92
443.16
680.39
750
762
743.0
736.6
Std.
XS
20
176.84
234.67
332
440
388
484
107
143
142.88
163.29
326.59
367.41
421.84
680.39
589.67
975.22
900
914
895.4
889.0
Std.
XS
20
212.56
282.27
481
638
588
731
129
172
217.72
235.87
510.29
544.31
589.67
1031.92 793.79 1564.89
DIMENSIONS
MASS IN KILOGRAMS (kg)
APPROXIMATE MASS PER UNIT FOR AUSTENITIC STAINLESS STEEL PIPE AND FITTINGS CAN BE OBTAINED BY APPLYING A FACTOR OF 1.015
MRC Data Chart reproduced with the permission of MRC Global Australia.
142
ENG2068
© WestOne Services 2013
meDiUm & HeaVY PiPe TO aUsTraliaN sTaNDarDs
sPeCiFiCaTiON
C250 pipe is manufactured and tested
to meet the requirement of the following
specifications:
• AS 1074 Steel tubes and tubulars for
ordinary service.
• AS 1163 Structural steel hollow
sections (Grade C250, C250L0).
WOrKiNG PressUres – WelDeD
JOiNTs
eND PrOCessiNG OPTiONs
Where AS 1074 pipe is used in pressure
piping covered by AS 4041, the maximum
pressure shall not exceed 1210 kPa for AS
1074 pipe up to and including DN 100 and
1030 kPa for AS 1074 pipe exceeding DN
100.
• Roll Grooved
Minimum Yield Strength
250MPa
Minimum Tensile Strength
320MPa
Minimum Elongation in 5.65 √So
20%
sUPPlY CONDiTiONs
Black/Painted/Galvanized/ILG
Straightness
Thickness Tolerance
Dimension Tolerance
Refer to
Australian
Standards
Standard Length
6.5m
Length Tolerance
+50mm/-0mm
CHs Grade C250
Dimensions
• Shouldered
• Threaded
THreaDeD PiPe
Screwed on one or both ends in accordance
with AS 1074. The tapered Whitworth thread
used complies with the requirements of AS
1722, Part 1 and is suitable for both parallel
and taper threaded sockets.
WOrKiNG PressUres – THreaDeD JOiNTs TaPer/Parallel THreaD
meCHaNiCal PrOPerTies
Surface Finish
• Plain End
Nom.
size
DN
Water & inert
Oil
(mm)
25
32
40
50
65
80
100
125
150
kPa
2070
1720
1720
1380
1380
1380
1030
1030
860
med.
Type of service
Fuel Oil
lPG
Heavy med. &
medium
Heavy Press Temp
o
C
kPa
kPa
kPa
2410
140
1030 100
2070
140
1030 100
2070
140
1030 100
1720
140
860
100
1720
–
860
100
1720
–
860
100
1380
–
690
100
1380
–
–
–
1030
–
–
–
Other applications (including
steam & Compressed air)
Heavy
Press Temp
o
kPa
C
1210 192
1030 192
1030 192
860
192
860
192
860
192
850
192
–
–
–
–
medium
Press Temp
o
kPa
C
1210
100
1030
100
1030
100
860
100
860
100
860
100
690
100
–
–
–
–
mass and Bundling Data - Calculated in accordance with as 1163
Bundling
mass
Bundle
Nominal mass
lengths
Per
metres
Per
Dimenions
Bundle
Bundle
kg/m
m/tonne
mm
Heavy
Press Temp
o
kPa
C
1210 192
1030 192
1030 192
860
192
860
192
860
192
690
192
–
–
–
–
mass per Bundle
Designation
t
do
Nominal size
DN
(mm) (mm)
(mm)
WxH
6.5m
m
Black
Galv.
Black
Galv.
Black
20 M
350 306
127
825.5
1.56
1.62
642
613
1.29
1.32
350
372
372
383
383
436
436
422
422
533
533
445
445
508
508
571
571
698
698
660
660
127
91
91
61
61
61
61
37
37
37
37
19
19
19
19
19
19
13
13
10
10
825.5
591.5
591.5
396.5
396.5
396.5
396.5
240.5
240.5
240.5
240.5
123.5
123.5
123.5
123.5
123.5
123.5
84.5
84.5
65
65
1.87
2.41
2.94
3.10
3.80
3.57
4.38
5.03
6.19
6.43
7.93
8.37
10.3
9.63
11.9
12.2
14.5
16.6
17.9
19.7
21.7
1.93
2.49
3.02
3.20
3.90
3.68
4.49
5.18
6.33
6.61
8.12
8.58
10.5
9.88
12.2
12.4
14.3
16.9
18.2
20.1
21.57
535
415
340
322
263
280
228
199
161
156
126
120
96.8
104
84
82.2
69.1
60.2
55.9
50.7
45.9
522
406
330
310
255
270
221
192
157
150
123
116
94.4
100
81.7
79.8
67.4
58.6
54.6
49.3
46
1.54
1.43
1.74
1.23
1.51
1.41
1.74
1.21
1.49
1.55
1.91
1.03
1.28
1.19
1.47
1.5
1.79
1.4
1.51
1.28
1.38
1.59
1.47
1.78
1.27
1.54
1.46
1.78
1.25
1.52
1.59
1.95
1.06
1.30
1.22
1.5
1.54
1.82
1.43
1.54
1.31
1.41
26.9 x 2.6 CHS
3.2 CHS
33.7 x 3.2 CHS
4.0 CHS
42.4 x 3.2 CHS
4.0 CHS
48.3 x 3.2 CHS
4.0 CHS
60.3 x 3.6 CHS
4.5 CHS
76.1 x 3.6 CHS
4.5 CHS
88.9 x 4 CHS
4.9 CHS
101.6 x 4.0 CHS
4.9 CHS
114.3 x 4.5 CHS
5.4 CHS
139.7 x 5.0 CHS
5.4 CHS
165.1 x 5.0 CHS
5.4 CHS
20 H
25 M
25 H
32 M
32 H
40 M
40 H
50 M
50 H
65 M
65 H
80 M
80 H
90 M
90 H
100 M
100 H
125 M
125 H
150 M
150 H
306
327
327
337
337
384
384
374
374
472
472
397
397
454
454
509
509
382
382
451
451
tonnes
Galv.
m = medium, H = Heavy
7
7
7
Pipes to Australian Standards Medium/Heavy
Pipes
to Australian
StandardsLight/Extra
Light/Extra Light
Light
Pipes
to Australian
Standards
8
MRC Data Chart reproduced with the permission of MRC Global Australia.
© WestOne Services 2013
ENG2068
143
8
8
liGHT/eXTra liGHT PiPe TO aUsTraliaN sTaNDarDs
Grade C350 pipe is a lightweight,
high strength pipe for general
mechanical and structural
applications.
C350 is manufactured by coldforming and high frequency
electric resistance welding.
C350 is available in black, ILG and
galvanized finishes.
Also available with one or both
ends swaged as follows:
NB
20
Xl
a
l
X
sPeCiFiCaTiON
GalVaNiZiNG
Grade C350 pipe is manufactured and tested
to meet the requirement of the following
specifications:
Grade C350 pipe is manufactured and tested to
meet the requirement of AS 4792 Galvanized
Coatings.
• AS 1163 Structural Steel Hollow Sections
(Grade C350, C350L0).
Min. Ave Coating Mass
300g/m2
The coating adherence of the galvanizing is
satisfactory for the pipe to be bent to a radius 6
times the diameter of the pipe.
• AS/NZ 4792 Hot dip galvanized (zinc) coatings
on ferrous hollow sections by a continuous or a
specialised process.
meCHaNiCal PrOPerTies
WelDiNG
Minimum Yield Strength
350MPa
Minimum Tensile Strength
450MPa
Minimum Elongation in 5.65 √So
20%
The following consumables are recommended by
AS 1554.1 when welding C350 sections.
Manual metal-arc (MMAW) E41XX, E48XX
Gas metal-arc (MIG) (GMAW) W50X
sUPPlY CONDiTiONs
25
a
a
32
a
a
40
a
50
a
a
X
Surface Finish
Straightness
Thickness Tolerance
Dimension Tolerance
Standard Length
Length Tolerance
Black/ILG/Galvanized
Refer to
Australian
Standards
6.5m
+50mm/-0mm
Designation
do
t
Nominal
size DN
(mm) (mm)
(mm)
mass and Bundling Data - Calculated in accordance with as 1163
Bundling
mass
Nominal mass
Bundle
lengths
metres
Dimenions
Per Bundle Per Bundle
kg/m
m/tonne
mm
WxH
6.5m
m
Black
Galv.
Black
Galv.
26.9 x 2.0 CHS
20 XL
350
306
127
825.5
1.23
1.29
814
767
1.010
1.070
2.3 CHS
20 LT
350
306
127
825.5
1.40
1.46
717
680
1.150
1.200
33.7 x 2.0 CHS
25 XL
372
327
91
591.5
1.56
1.64
640
602
0.920
0.970
2.6 CHS
25 LT
372
327
91
591.5
1.99
2.07
501
497
1.180
1.230
42.4 x 2.0 CHS
32 XL
383
337
61
396.5
1.99
2.10
502
473
0.790
0.830
2.6 CHS
32 LT
383
337
61
396.5
2.55
2.65
392
374
1.010
1.050
48.3 x 2.3 CHS
40 XL
436
384
61
396.5
2.61
2.73
383
364
1.030
1.080
Dimensions
mass per Bundle
tonnes
Black
Galv.
2.9 CHS
40 LT
436
384
61
396.5
3.25
3.36
308
295
1.290
1.330
60.3 x 2.3 CHS
50 XL
422
374
37
240.5
3.29
3.44
304
288
0.790
0.830
2.9 CHS
50 LT
422
374
37
240.5
4.11
4.25
244
234
0.990
1.020
76.1 x 2.3 CHS
65 XL
533
472
37
240.5
4.19
4.33
239
231
1.007
1.040
3.2 CHS
65 LT
533
472
37
240.5
5.75
5.94
174
167
1.380
1.430
88.9 x 2.6 CHS
80 XL
445
397
19
123.5
5.53
5.75
181
174
0.683
0.710
3.2 CHS
80 LT
445
397
19
123.5
6.76
6.98
148
143
0.840
0.860
101.6 x 2.6 CHS
90 XL
508
454
19
123.5
6.35
6.60
158
152
0.784
0.815
3.2 CHS
90 LT
508
454
19
123.5
7.70
8.04
129
124
0.960
0.990
100 XL
572
510
19
123.5
8.77
9.05
114
110
1.083
1.118
114.3 x 3.2 CHS
3.6 CHS
100 LT
572
510
19
123.5
9.83
10.11
102
98.6
1.214
1.249
139.7 x 3.0 CHS
125 XL
698
382
13
84.5
10.11
10.50
98.9
95.2
0.855
0.887
3.5 CHS
125 LT
698
382
13
84.5
11.76
12.10
85.1
82.4
0.993
1.022
165.1 x 3.5 CHS
150 LT
150 LT
660
451
10
65
13.95
14.40
71.7
69.4
0.907
0.936
NOTes:
LT = Light, XL = Extra Light
The term “tube” is synonymous with the term “pipe”.
MRC Data Chart reproduced with the permission of MRC Global Australia.
144
ENG2068
© WestOne Services 2013
FlaNGes TO aUsTraliaN sTaNDarDs
DIAM.
RAISED FACE
DIMENSIONS
FOR LOOSE FLANGES
FLAT FACE
1.6mm
FLAT FACE
COPPer allOY
T.3 – Plate or Boss or Blank
T.10 – Plate or Boss
T.11 – Blank
Table D
Flange
Drilling
Nominal
Thickness
Bolt
Dia. of
size DN OD
** Circle No. of
T3
Bolts
T6
mm
Dia. Bolts
mm
mm
mm
mm
15
95
6
5
67
4
M12
20
100
6
5
73
4
M12
25
115
8
5
83
4
M12
32
120
8
6
87
4
M12
40
135
10
6
98
4
M12
50
150
10
8
114
4
M16
65
165
11
8
127
4
M16
80
185
13
10
146
4
M16
100
215
16
10
178
4
M16
125
255
17
13
210
8
M16
150
280
17
13
235
8
M16
200
335
19
13
292
8
M16
250
405
19
16
356
8
M20
300
455
22
19
406
12
M20
350
525
25
22
470
12
M24
25
22
521
12
M24
400
580
450
640
29
25
584
12
M24
500
705
32
29
641
16
M24
600
825
35
32
756
16
M27
700
910
–
35
845
20
M27
750
995
–
41
927
20
M30
800
1060
–
41
984
20
M33
900
1175
–
48 1092 24
M33
1000 1255
–
51 1175 24
M33
1200 1490
–
60 1410 32
M33
DIAM.
RAISED FACE
OD
mm
95
100
115
120
135
150
165
185
215
255
280
335
405
455
525
580
640
705
825
910
995
1060
1175
1255
1490
Table e
Flange
Drilling
Thickness
Bolt
Dia. of
** Circle No. of
T10 T11
Bolts
T6
Dia. Bolts
mm mm
mm
mm
mm
6
6
6
67
4
M12
6
6
6
73
4
M12
8
8
7
83
4
M12
8
8
8
87
4
M12
10
10
9
98
4
M12
10
10
10
114
4
M16
11
11
10
127
4
M16
13
13
11
146
4
M16
16
16
13
178
8
M16
17
17
14
210
8
M16
17
17
17
235
8
M20
19
20
19
292
8
M20
22
25
22
356
12
M20
25
28
25
406
12
M24
25
32
29
470
12
M24
25
36
32
521
12
M24
29
41
35
584
16
M24
32
46
38
641
16
M24
38
–
48
756
16
M30
–
–
51
845
20
M30
–
–
54
927
20
M33
–
–
54
984
20
M33
–
–
64 1092 24
M33
–
–
67 1175 24
M36
–
–
79 1410 32
M36
Nominal
size DN
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
OD
mm
115
115
120
135
140
165
185
205
230
280
305
370
430
490
550
610
675
735
850
Thickness
T10
mm
T11
mm
10
10
11
11
13
13
14
16
19
22
25
32
35
38
41
44
48
51
57
11
11
12
13
14
16
17
19
23
27
30
39
45
52
58
64
71
78
92
Flange
57
57
64
76
83
102
114
127
152
178
210
260
311
362
419
483
533
597
699
OD
mm
95
100
120
135
140
165
185
205
230
280
305
370
430
490
550
610
675
735
850
935
1015
1060
1185
1275
1530
T10
mm
T11
mm
8
8
10
10
11
11
13
14
17
19
22
25
25
29
32
32
35
38
41
–
–
–
–
–
–
8
8
10
10
11
12
13
15
17
20
23
28
32
37
42
47
52
57
68
–
–
–
–
–
–
**
T6
mm
10
10
10
13
13
16
16
16
19
22
22
25
29
32
35
41
44
51
57
60
67
68
76
83
95
83
83
87
98
105
127
146
165
191
235
260
324
381
438
495
552
610
673
781
4
4
4
4
4
4
8
8
8
8
12
12
12
16
16
20
20
24
24
M16
M16
M16
M16
M16
M16
M16
M16
M16
M20
M20
M20
M24
M24
M27
M27
M30
M30
M33
115
115
120
135
140
165
185
205
230
280
305
370
430
490
550
610
675
735
850
16
16
19
19
22
25
25
32
35
38
38
41
48
51
57
64
70
79
92
57
57
64
76
83
102
114
127
152
178
210
260
311
362
419
483
533
597
699
Drilling
Bolt
Dia. of
Circle No. of
Bolts
Dia. Bolts
mm
mm
67
4
M12
73
4
M12
87
4
M16
98
4
M16
105
4
M16
127
4
M16
146
8
M16
165
8
M16
191
8
M16
235
8
M20
260
12
M20
324
12
M20
381
12
M24
438
16
M24
495
16
M27
552
20
M27
610
20
M30
673
24
M30
781
24
M33
857
24
M33
940
28
M33
984
28
M33
1105 32
M36
1194 36
M36
1441 40
M39
Nominal
size DN
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
700
750
800
900
1000
1200
Table r
Drilling
Bolt
Thickness
Dia.
† Dia. Circle
of Dia. of OD
r/F
r/F Dia. No.
Bolts Bolts
mm
* T6 mm
* T6
mm
mm
mm
mm
mm
13
13
14
17
17
19
19
22
25
29
29
32
35
41
48
54
60
67
76
Table F
Flange
Thickness
Table J
Drilling
1.6mm
WELD NECK FLANGE
FOrGeD Or PlaTe sTeel
T.6 – Plate or Boss or Blank, or Weldneck (except for valves)
T.18– Plate or Blank or Weldneck (except for valves)
FLAT FACE
1.6mm
BOSS FLANGE – SLIP ON WELD OR SCR. B.S.P.
Table H
Flange
DIAM.
RAISED FACE
PLATE FLANGE
SLIP ON WELD
BLANK OR BLIND FLANGE
Flange
Bolt
of OD Thickness Dia.
Circle No. of Dia.
r/F
Dia. Bolts Bolts
mm
* T18
mm
mm
mm
mm
83
83
87
98
105
127
146
165
191
235
260
324
381
438
495
552
610
673
781
4
4
4
4
4
4
8
8
8
8
12
12
12
16
16
20
20
24
24
M16
M16
M16
M16
M16
M20
M20
M20
M20
M24
M24
M24
M27
M27
M30
M30
M33
M33
M36
115
115
125
135
150
165
185
205
240
280
305
370
430
510
585
640
735
805
–
19
19
22
22
25
25
29
32
35
41
44
51
60
70
79
89
98
105
–
64
64
76
76
89
102
114
127
152
178
210
260
311
362
419
483
572
622
–
Drilling
Nominal
Bolt No. Dia. of size DN
Circle of
Bolts
Dia. Bolts mm
mm
83
83
95
98
114
127
146
165
197
235
260
324
387
457
527
584
673
730
–
4
4
4
4
4
8
8
8
8
12
12
12
16
16
16
20
20
20
–
M16
M16
M16
M16
M20
M16
M20
M20
M24
M24
M24
M27
M27
M30
M33
M33
M36
M39
–
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
–
NOTes:
1. All dimensions are in millimetres (mm).
2. Only metric preferred sizes listed, except for DN 750 which is a Nonpreferred size.
** 3. It is impractical to use flange thickness less than 12mm for Steel Plate
Flanges.
* 4. Thickness includes 1.6mm height for the Raised Face.
† 5. The Raised Face is non-preferred for Table “H”.
6. It is normal practice to supply Steel Flanges to Tables A, D, C, E, F
and H. — Flat Faced.
7. All copper alloy flanges shall be Flat Faced.
8. All flanges shall be drilled to Standard Tables unless otherwise
specified. (For Bolt dimensions see separate page).
imPOrTaNT: For DN 150 and DN 200 Flanges, the O.D. of pipe being used must be specified. Dimensions for Flange Tables A, C, K, S and T on application.
9
9
9
Flanges to AS.2129
Metric Bolts for use with AS.2129 Flanges
10
MRC Data Chart reproduced with the permission of MRC Global Australia.
© WestOne Services 2013
ENG2068
145
10
10
i.s.O. meTriC HeXaGON sTeel BOlTs FOr Use
WiTH as.2129 FlaNGes
o
o
Steel hexagon Bolts and Nuts (XOX) are recommended for use within a temperature range of –50 C to +300 C. Outside of this temperature range,
Stud Bolts should be used as recommended in AS.2528.
A quick reference chart for sizing bolts and nuts for a range of regularly used standard flanges is given below:
APPLICABLE TO PLATE & FORGED STEEL LOOSE FLANGES ONLY
NOTe: Integral valve flanges quite often differ in thickness to equivalent loose flanges. When integral flanges are involved due allowance should be
made to bolt lengths.
Table D
Nominal
Flange size
DN
No.
Bolts
Per
Flange
15
4
20
4
25
4
32
4
40
4
50
4
65
4
80
4
100
4
125
8
150
8
200
8
250
8
300
12
350
12
400
12
450
12
500
16
600
16
700
20
750
20
800
20
900
24
1000
24
1200
32
Temp in 0C
-50 to 232
250
275
300
325
350
375
400
425
450
475
Max. Hydrostatic Test
Pressure kPa
Table e
XOX
Bolt & Nut
dia. x lgth
M12 x
40mm*
M12 x
40mm*
M12 x
40mm*
M12 x
40mm*
M12 x
40mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M20 x
55mm*
M20 x
60mm*
M24 x
75mm*
M24 x
75mm*
M24 x
80mm*
M24 x
85mm*
M27 x
100mm*
M27 x
100mm*
M30 x
120mm*
M33 x
120mm*
M33 x
140mm*
M33 x
140mm*
M33 x
160mm*
No.
Bolts
Per
Flange
4
4
4
4
4
4
4
4
8
8
8
8
12
12
12
12
16
16
16
20
20
20
24
24
32
Table F
XOX
Bolt & Nut
dia. x lgth
M12 x
40mm*
M12 x
40mm*
M12 x
40mm*
M12 x
40mm*
M12 x
40mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M16 x
45mm*
M16 x
50mm*
M20 x
60mm*
M20 x
60mm*
M20 x
70mm*
M24 x
80mm*
M24 x
85mm*
M24 x
100mm*
M24 x
100mm*
M24 x
110mm*
M30 x
130mm*
M30 x
140mm*
M33 x
150mm*
M33 x
150mm*
M33 x
170mm*
M36 x
180mm*
M36 x
200mm*
XOX
Bolt & Nut
dia. x lgth
XOX
Bolt & Nut
dia. x lgth
4
M12 X 40mm*
4
M16 x 45mm*
4
M12 X 40mm*
4
M16 x 45mm*
4
M16 X 45mm*
4
M16 x 50mm*
4
M16 X 45mm*
4
M16 x 55mm*
4
M16 X 45mm*
4
M16 x 55mm*
4
M16 X 50mm*
4
M16 x 60mm*
8
M16 X 50mm*
8
M16 x 60mm*
8
M16 X 50mm*
8
M16 x 65mm*
8
M16 X 60mm*
8
M16 x 70mm*
8
M20 X 70mm*
8
M20 x 80mm*
12
M20 X 70mm*
12
M20 x 80mm*
12
M20 X 75mm*
12
M20 x 90mm*
12
M24 X 85mm*
12
16
16
20
20
24
24
24
28
28
32
36
40
M24 X
100mm*
M27 X
100mm*
M27 X
120mm*
M30 X
130mm*
M30 X
140mm*
M33 X
150mm*
M33 X
160mm*
M33 X
170mm*
M33 X
180mm*
M36 X
200mm*
M36 X
220mm*
M39 X
240mm*
16
16
20
20
24
24
Temperature / Pressure ratings for Carbon steel Flanges
maximum allowable Pressure in kPa by Flange Tables
(For approximate Psi divide by 7)
D
e
F
700
1400
2100
650
1300
2000
600
1200
1800
570
1100
1700
550
1000
1600
500
950
1400
450
900
1300
400
800
1200
350
700
1000
1050
2100
3150
Length
Table H
No.
Bolts
Per
Flange
No.
Bolts
Per
Flange
M24 x
100mm*
M24 x
110mm*
M27 x
130mm*
M27 x
140mm*
M30 x
160mm*
M30 x
170mm*
M33 x
190mm*
Bolt
Diam.
Flat faced joint illustrated
Bolt lengths listed apply to flat-faced or
1.6mm raised face flanges with allowance
for 1.6mm gasket thickness.
*For approximate Stud Bolt Lengths take
the XOX Bolt Length and add the metric
diameter in mm rounded to the nearest
5mm increment up.
Note: (This does not include length of
point)
This chart shows bolt diameters as
recommended in AS.2129. Some of
these are Non-preferred sizes e.g. (M27),
(M33) and (M39) which are not readily
available in Australia.
Stud Bolts should be used as alternatives
to bolts where the size is greater than
M24 and it is therefore suggested that
Stud Bolts as specified in AS.2528 or
BS.4882 should be used.
Inch series bolts interchangeable as
follows:
FOr
Use
FOr
1/4 “
5/16”
M6
7/8”
M24
M8
1”
1 1/8”
(M27)
(M33)
(M39)
3/8”
M10
1/2”
M12
5/8”
M16
1 1/4”
1 3/8”
3/4”
M20
1 1/2”
Use
M30
M36
BOlT HOle DiameTers
For bolts to M24, clearance hole 2mm
larger.
Above M24, clearance hole 3mm larger.
XOX BOlTs & NUTs
XOX is the trade term used for H.R.H.
commercial steel bolts and nuts.
H.R.H. denotes Hexagon Head x Round
Shank x Hexagon Nut.
XOX Bolting
H
3500
3300
3100
2900
2600
2400
2200
2000
1700
1300
900
Temp. Range: -50oC to +3000C
Flange Specifications
Table
Bolts
Nuts
D, E, F
AS 1110
Gr.4.6
or AS 1111
Gr.4.6
AS 1110
Gr8.8
AS 1112
Gr.5
H
AS 1112
Gr.8
5250
MRC Data Chart reproduced with the permission of MRC Global Australia.
146
ENG2068
© WestOne Services 2013
mass CONVersiON CHarT
The si unit of mass is the KilOGram – symbol kg
The mass of an object is the quantity of matter it contains and is constant irrespective of the location or altitude.
The weight of an object is the force exerted on it by gravity and thus varies from place to place and according to height above sea level or the distance
from the Earth’s centre. (Hence weightlessness of astronauts in outer space).
mass CONVersiON CHarT
(A) To use, locate “given mass” in “given mass” column (coloured grey) whether lbs. or kg.
(B) If “given mass” is in pounds (lbs.), read kilograms (kg) in right hand column.
(C) If “given mass” is in kilograms (kg), read pounds (lbs.) in left hand column.
(D) Example: (i) Given mass is 70 lbs = 31.75 kg from right hand column
(ii) Given mass is 70 kg = 154.32 lbs. from left hand column
lbs.
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
44.09
46.30
48.50
50.71
52.91
55.12
57.32
59.52
61.73
63.93
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.77
85.98
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
110.23
112.43
114.64
116.84
119.05
121.25
123.46
125.66
127.87
130.07
132.28
134.48
136.69
138.89
141.09
143.30
1 to 65
Given
mass
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
kg
lbs.
0.45
0.91
1.36
1.81
2.27
2.72
3.18
3.63
4.08
4.54
4.99
5.44
5.90
6.35
6.80
7.26
7.71
8.16
8.62
9.07
9.53
9.98
10.43
10.89
11.34
11.79
12.25
12.70
13.15
13.61
14.06
14.52
14.97
15.42
15.88
16.33
16.78
17.24
17.69
18.14
18.60
19.05
19.50
19.96
20.41
20.87
21.32
21.77
22.23
22.68
23.13
23.59
24.04
24.49
24.95
25.40
25.86
26.31
26.76
27.22
27.67
28.12
28.58
29.03
29.48
145.50
147.71
149.91
152.12
154.32
156.53
158.73
160.94
163.35
165.35
167.55
169.75
171.96
174.16
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.0
196.21
198.41
200.62
202.82
205.03
207.23
209.44
211.64
213.85
216.05
218.26
220.46
222.67
224.87
227.07
229.28
231.48
233.69
235.89
238.10
240.30
242.51
244.71
246.92
249.12
251.32
253.53
255.73
257.94
260.14
262.35
264.55
266.76
268.96
271.17
273.37
275.58
277.78
279.98
282.19
284.39
286.60
66 to 130
Given
mass
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
kg
lbs.
29.94
30.39
30.84
31.30
31.75
32.21
32.66
33.11
33.57
34.02
34.47
34.93
35.38
35.83
36.29
36.74
37.20
37.65
38.10
38.56
39.01
39.46
39.92
40.37
40.82
41.28
41.73
42.18
42.64
43.09
43.55
44.00
44.45
44.91
45.36
45.81
46.28
46.72
47.17
47.63
48.08
48.54
48.99
49.44
49.90
50.35
50.80
51.26
51.71
52.16
52.62
53.07
53.53
53.98
54.43
54.89
55.34
55.79
56.25
56.70
57.15
57.61
58.06
58.51
58.97
288.80
291.01
293.21
295.42
297.62
299.83
302.03
304.24
306.44
308.64
310.85
313.05
315.26
317.46
319.67
321.87
324.08
326.28
328.49
330.69
341.71
352.74
363.76
374.78
385.80
396.83
407.85
418.87
429.90
440.92
451.94
462.97
473.99
485.01
496.04
507.06
518.08
529.10
540.13
551.15
562.17
573.20
584.22
595.24
606.27
617.30
628.31
639.33
650.36
661.38
672.40
683.43
694.45
705.47
716.50
727.52
738.54
749.56
760.59
771.61
782.63
793.66
804.68
815.70
826.73
131 to 375
Given
mass
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
kg
lbs.
59.42
59.88
60.33
60.78
61.24
61.69
62.14
62.60
63.05
63.50
63.96
64.41
64.87
65.32
65.77
66.23
66.68
67.13
67.59
68.04
70.31
72.58
74.84
77.11
79.38
81.65
83.92
86.18
88.45
90.72
92.99
95.26
97.52
99.79
102.06
104.33
106.60
108.86
111.13
113.40
115.67
117.94
120.20
122.47
124.74
127.01
129.28
131.54
133.81
136.08
138.35
140.62
142.88
145.15
147.42
149.69
151.96
154.22
156.49
158.76
161.03
163.30
165.56
167.83
170.10
838
849
860
871
882
893
904
915
926
937
948
959
970
981
992
1003
1014
1025
1036
1047
1058
1069
1080
1091
1102
1113
1124
1135
1146
1157
1168
1179
1190
1202
1213
1224
1235
1246
1257
1268
1279
1290
1301
1312
1323
1334
1345
1356
1367
1378
1389
1400
1411
1422
1433
1444
1455
1466
1477
1488
1499
1510
1521
1532
1543
380 to 700
Given
mass
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650
655
660
665
670
675
680
685
690
695
700
kg
lbs.
172.37
174.64
176.90
179.17
181.44
183.71
185.98
188.24
190.51
192.78
195.05
197.32
199.58
201.85
204.12
206.39
208.66
210.92
213.19
215.46
217.73
220.00
222.26
224.53
226.80
229.07
231.34
233.60
235.87
238.14
240.41
242.68
244.94
247.21
249.48
251.75
254.02
256.28
258.55
260.82
263.09
265.36
267.62
269.89
272.16
274.43
276.70
278.96
281.23
283.50
285.77
288.04
290.30
292.57
294.84
297.11
299.38
301.64
303.91
306.18
308.45
310.72
312.98
315.25
317.52
1554
1565
1576
1587
1598
1609
1620
1631
1642
1653
1664
1676
1687
1698
1709
1720
1731
1742
1753
1764
1775
1786
1797
1808
1819
1830
1841
1852
1863
1874
1885
1896
1907
1918
1929
1940
1951
1962
1973
1984
1995
2006
2017
2028
2039
2050
2061
2072
2083
2094
2105
2116
2127
2138
2149
2161
2172
2183
2194
2205
2425
2646
2866
3086
3307
705 to 1500
Given
mass
705
710
715
720
725
730
735
740
745
750
755
760
765
770
775
780
785
790
795
800
805
810
815
820
825
830
835
840
845
850
855
860
865
870
875
880
885
890
895
900
905
910
915
920
925
930
935
940
945
950
955
960
965
970
975
980
985
990
995
1000
1100
1200
1300
1400
1500
kg
319.79
322.06
324.32
326.59
328.86
331.13
333.40
335.66
337.93
340.20
342.47
344.74
347.00
349.27
351.54
353.81
356.08
358.34
360.61
362.88
365.15
367.42
369.68
371.95
374.22
376.49
378.76
381.02
383.29
385.56
387.83
390.10
392.36
394.63
396.90
399.17
401.44
403.70
405.97
408.24
410.51
412.78
415.04
417.31
419.58
421.85
424.12
426.38
428.65
430.92
433.19
435.46
437.72
439.99
442.26
444.53
446.80
449.06
451.33
453.60
498.96
544.32
589.68
635.04
680.40
CONVersiON FaCTOrs
1 Pound (lb.) x 0.4536 = kilograms (kg)
1 kilogram (kg) x 2.2046 = pounds (lbs.)
11
11
Mass Conversion Chart
© WestOne Services 2013
11
MRC Data Chart reproduced with the permission of MRC Global Australia.
Flange Identification
ENG2068
12
147
12
12
FlaNGe iDeNTiFiCaTiON CHarT
A guide to the key dimensions of popular steel flange types
size (mm)
15
20
25
32
40
50
65
80
100
Table / Class
Diam. of Flange
Bolt Circle
Diam.
No. of Bolts
Diam. / length
Bolts / studs
steel Flanges
Diam. Holes
Flange
Thickness Cast
/ Forged steel
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
95
95
115
89
95
95
95
100
100
115
98
117
117
105
115
115
120
108
124
124
115
120
120
135
117
133
133
140
135
135
140
127
156
156
150
150
150
165
152
165
165
165
165
165
185
178
191
191
185
185
185
205
191
210
210
200
215
215
230
229
254
273
220
67
67
83
60.3
66.7
66.7
65
73
73
83
69.8
82.5
82.5
75
83
83
87
79.4
88.9
88.9
85
87
87
98
88.9
98.4
98.4
100
98
98
105
98.4
114.3
114.3
110
114
114
127
120.6
127
127
125
127
127
146
139.7
149.2
149.2
145
146
146
165
152.4
168.3
168.3
160
178
178
191
190.5
200
215.9
180
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
8
8
4
4
4
8
4
8
8
4
4
4
8
4
8
8
8
4
8
8
8
8
8
8
M12 x 45
M12 x 45
M16 x 60
1/2 x 60
1/2 x 65
1/2 x 80
––
M12 x 45
M12 x 45
M16 x 60
1/2 x 65
5/8 x 75
5/8 x 90
––
M12 x 45
M12 x 45
M16 x 60
1/2 x 65
5/8 x 80
5/8 x 105
––
M12 x 50
M12 x 50
M16 x 65
1/2 x 70
5/8 x 80
5/8 x 100
––
M12 x 50
M12 x 50
M16 x 65
1/2 x 70
3/4 x 90
3/4 x 105
––
M16 x 60
M16 x 60
M16 x 75
5/8 x 80
5/8 x 90
5/8 x 105
––
M16 x 60
M16 x 60
M16 x 75
5/8 x 90
3/4 x 100
3/4 x 120
––
M16 x 60
M16 x 60
M16 x 75
5/8 x 90
3/4 x 110
3/4 x 125
––
M16 x 65
M16 x 65
M16 x 85
5/8 x 90
3/4 x 110
7/8 x 145
––
14
14
18
16
16
16
14
14
14
18
16
20
20
14
14
14
18
16
20
20
14
14
14
18
16
20
20
18
14
14
18
16
23
23
18
18
18
18
20
20
20
16
18
18
18
20
23
23
18
18
18
18
20
23
23
18
18
18
18
20
23
26
18
5*
6*
13
11.5
14.5
14.5
––
5*
6*
13
14
16
16
––
5*
7*
14
14
18
18
––
6*
8*
17
16
22
22
––
6*
9*
17
17
22
22
––
8*
10*
19
20
22
26
––
8*
10*
19
23
26
30
––
10*
11*
22
24
32
32
––
10*
13
25
24
32
38
––
*It is impractical to use thickness less than 12.00mm for plate flanges.
Dimensions AS 2129 – ANSI/ASME B16.5
MRC Data Chart reproduced with the permission of MRC Global Australia.
148
ENG2068
© WestOne Services 2013
FlaNGe iDeNTiFiCaTiON CHarT
size (mm)
125
150
200
250
300
350
375
400
450
500
600
Table / Class
Diam. of Flange
Bolt Circle
Diam.
No. of Bolts
Diam. / length
Bolts / studs
steel Flanges
Diam. Holes
Flange
Thickness Cast
/ Forged steel
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
ANSI 600
PN 10
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 600
PN 10
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
PN 10
PN 16
Table D
Table E
Table H
ANSI 150
ANSI 300
Table D
Table E
Table D
Table E
Table H
ANSI 150
ANSI 300
Table D
Table E
Table H
ANSI 150
ANSI 300
Table D
Table E
Table H
ANSI 150
ANSI 300
Table D
Table E
Table H
ANSI 150
ANSI 300
255
255
280
254
279
330
250
280
280
305
279
318
356
285
335
335
370
343
381
419
340
340
405
405
430
406
510
395
405
455
455
490
483
520
445
450
525
525
550
535
585
550
550
580
580
610
597
650
640
640
675
635
710
705
705
735
700
775
825
825
850
815
915
210
210
235
215.9
234.9
266.7
210
235
235
260
241.3
269.9
292.1
240
292
292
324
298.4
330.2
349.2
295
280
356
356
381
361.9
431.8
350
350
406
406
438
431.8
450.8
400
410
470
470
495
476.2
514.3
495
495
521
521
552
539.7
571.5
584
584
610
577.8
628.6
641
641
673
635
685.8
756
756
781
749.3
812.8
8
8
8
8
8
8
8
8
8
12
8
12
12
8
8
8
12
8
12
12
8
12
8
12
12
12
16
8
12
12
12
16
12
16
12
12
12
12
16
12
20
12
12
12
12
20
16
20
12
16
20
16
24
16
16
24
20
24
16
16
24
20
24
M16 x 65
M16 x 65
M20 x 95
3/4 x 90
3/4 x 120
1 x 165
––
M16 x 65
M20x 65
M20 x 95
3/4 x 100
3/4 x 125
1 x 170
––
M16 x 65
M20 x 65
M20 x 100
3/4 x 110
7/8 x 140
1 1/8 x 195
––
––
M20 x 75
M20 x 75
M24 x 120
7/8 x 115
1 1/4 x 215
––
––
M20 x 85
M24 x 85
M24 x 110
7/8 x 120
1 1/8 x 170
––
––
M24 x 95
M24 x 95
M27 x 130
1 x 130
1 1/8 x 175
M24 x 95
M24 x 95
M24 x 95
M24 x 100
M27 x 140
1 x 130
1 1/4 x 190
M24 x 95
M24 x 120
M30 x 160
1 1/8 x 150
1 1/4 x 195
M24 x 110
M24 x 110
M30 x 170
1 1/8 x 160
1 1/4 x 205
M27 x 120
M30 x 140
M33 x 200
1 1/4 x 175
1 1/2 x 230
18
18
22
23
23
29
18
18
22
22
23
23
29
22
18
22
22
23
26
32
22
22
22
22
26
29
35
22
22
22
26
26
26
32
22
25
26
26
30
29
32
26
26
26
26
30
29
35
26
26
33
32
35
26
26
33
32
35
30
33
36
35
42
22
14
29
24
35
45
––
13
17
29
26
37
48
––
13
19
32
29
41
56
––
––
––
22
35
30
64
––
––
22
25
41
32
51
––
––
25
29
48
35
54
22
32
22
32
54
37
57
25
35
60
40
60
29
38
67
43
64
32
48
76
48
70
*It is impractical to use thickness less than 12.00mm for plate flanges.
Dimensions AS 2129 – ANSI/ASME B16.5
13
13
© WestOne
Services
2013
Flange
Identification
13
MRC Data Chart reproduced with the permission of MRC Global Australia.
ENG2068
Pressure - Stress Conversion
Charts
14149
14
14
PressUre - sTress CONVersiON CHarT
The SI unit of pressure and stress is the NEWTON PER SQUARE METRE which has been given the special name PASCAL – Symbol Pa.
The pascal is too small for most normal uses and suitable multiple units preferred for Australia are:
kilopascal: Symbol – kPa (= 1000 Pa)
(1 N/m2 = 0.000145 lbf/in2 = 1Pa)
megapascal: Symbol – MPa (= 1,000,000 Pa)
(1 N/mm2 = 145 lbf/in2 = 1MPa)
PSI (lbf/in2) to kPa • PRESSURE – STRESS CONVERSION CHART
To use, locate “given pressure” in “given pressure” column (coloured grey) whether lbf/in2 or kPa.
If “given pressure” is in pounds force per square inch (lbf/in2), read kilopascals (kPa) in right hand column.
If “given pressure” is in kilopascals (kPa), read pounds force per square inch (lbf/in2) in left hand column.
Example:
(i)
Given pressure is 100 lbf/in2 = 689 kPa from right hand column
(ii) Given pressure is 100kPa = 14.50 lbf/in2 from left hand column
(A)
(B)
(C)
(D)
1 to 35
Given
Pressure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
lbf/in2
0.15
0.29
0.44
0.58
0.73
0.87
1.02
1.16
1.31
1.45
1.60
1.74
1.89
2.03
2.18
2.32
2.47
2.61
2.76
2.90
3.05
3.19
3.34
3.48
3.63
3.77
3.92
4.06
4.21
4.35
4.50
4.64
4.79
4.93
5.08
kPa
lbf/in2
6.89
13.79
20.68
27.58
34.47
41.37
48.26
55.16
62.05
68.95
75.84
82.74
89.63
96.53
103.42
110.32
117.21
124.11
131.00
137.90
144.79
151.69
158.58
165.47
172.37
179.26
186.16
193.05
199.95
206.84
213.74
220.63
227.53
234.42
241.32
5.22
5.37
5.51
5.66
5.80
5.95
6.09
6.24
6.38
6.53
6.67
6.82
6.96
7.11
7.25
7.40
7.54
7.69
7.83
7.98
8.12
8.27
8.41
8.56
8.70
8.85
8.99
9.14
9.28
9.43
9.57
9.72
9.86
10.01
10.15
36 to 70
Given
Pressure
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
kPa
lbf/in2
248.21
255.11
262.00
268.9
275.79
282.69
289.58
296.48
303.37
310.26
317.16
324.05
330.95
337.84
344.74
351.63
358.53
365.42
372.32
379.21
386.11
393.00
399.90
406.79
413.69
420.58
427.48
434.37
441.26
448.16
455.05
461.95
468.84
475.74
482.63
10.30
10.44
10.59
10.73
10.88
11.02
11.17
11.31
11.46
11.60
11.75
11.89
12.04
12.18
12.33
12.47
12.62
12.70
12.91
13.05
13.20
13.34
13.49
13.63
13.78
13.92
14.07
14.21
14.34
14.50
15.23
15.95
16.68
17.40
18.13
71 to 125
Given
Pressure
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
105
110
115
120
125
kPa
lbf/in2
490
496
503
510
517
524
531
538
545
552
558
565
572
579
586
593
600
607
614
621
627
634
641
648
655
662
669
676
683
689
724
758
793
827
862
18.85
19.58
20.31
21.03
21.76
22.48
23.21
23.93
24.61
25.38
26.11
26.83
27.56
28.28
29.01
36.26
43.51
58.02
72.52
108.78
145.04
217.56
290.08
435.11
580.15
725.19
1,450.38
2,175.57
2,900.76
4,351.14
5,801.52
7,251.90
8,702.28
10,152.70
11,603.00
130 to 80,000
Given
kPa
Pressure
130
896
135
931
140
965
145
1000
150
1034
155
1069
160
1103
165
1138
170
1172
175
1207
180
1241
185
1276
190
1310
195
1344
200
1379
250
1724
300
2068
400
2758
500
3447
750
5171
1000
6894
1500
10,342
2000
13,790
3000
20,684
4000
27,579
5000
34,473
68,948
10,000
15,000 103,421
20,000 137,895
30,000 206,843
40,000 275,790
50,000 344,738
60,000 413.686
70,000 482,633
80,000 551,581
=
mPa
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
0.90
0.93
0.97
1.00
1.03
1.07
1.10
1.14
1.17
1.21
1.24
1.28
1.31
1.34
1.38
1.73
2.07
2.76
3.45
5.17
6.89
10.34
13.79
20.68
27.58
34.47
68.95
103.4
137.9
206.8
275.8
344.7
413.7
482.6
551.6
NOTe: iT is UsUal FOr PressUres iN eXCess OF 1000 kPa TO Be eXPresseD iN meGaPasCals – mPa
1 megapascal (mPa) = 1000 kilopascals (kPa) = 1 newton per mm2 (N/mm2) = 145 lbf/in2
UseFUl CONVersiON FaCTOrs – aPPrOXimaTe
mUlTiPlY
TO OBTaiN
Bars
kg f/cm2
kg f / mm2
BY
BY
1.0197
100.0
14.504
0.1
14.223
98.07
0.09807
1422.33
9.807
0.635
TO OBTaiN
DiViDe
kg f/cm2
kPa
lbf/in2
MPa
lbf/in2
kPa
MPa
lbf/in2
MPa
ton f/in2
mUlTiPlY
TO OBTaiN
lb f/in2 (PSI)
ton f/in2
BY
BY
6.895
0.00689
15.444
TO OBTaiN
DiViDe
kPa
MPa
MPa
aPPrOXimaTe eQUiValeNTs
1 Atmosphere (atm) = 14.696 lbf/in2
1 bar = 14.50 lbf/in2
1 kg f/cm2 = 14.22 lbf/in2
100 kPa (1 bar) = 14.50 lbf/in2
NOTE: lbf/in2 (pounds force per square inch) is
often expressed as PSI (pounds per square inch)
MRC Data Chart reproduced with the permission of MRC Global Australia.
150
ENG2068
© WestOne Services 2013
TemPeraTUre - CONVersiON CHarT
The SI Unit of thermodynamic temperature is the KELVIN – Symbol K. For most practical purposes of temperature measurement and
most calculations involving temperatures, DEGREE CELSIUS, symbol oC will be used. The name CELSIUS was adopted internationally in
1948 instead of Centigrade, to avoid possible confusion with the identically named unit of angle used in some European countries.
TEMPERATURE CONVERSION CHART
(A) To use, locate “given temperature” in “given temperature” column (coloured grey) whether oC or oF.
(B) If “given temperature” is in degrees Celsius (oC), read degrees Fahrenheit (oF) in right hand column.
(C) If “given temperature” is in degrees Fahrenheit (oF), read degrees Celsius (oC) in left hand column.
(D) Example: (i) Given temperature is 35oC = 95oF from right hand column
(ii) Given temperature is 35oF = 1.7oC from left hand column
–320 to 27
C
Given
Temp.
–196
–184
–173
–162
–151
–140
–129
–115
–101
– 90
– 84
– 79
– 73
– 68
– 62
– 57
– 51
– 46
– 40
– 34
– 29
– 23
– 17.8
– 17.2
– 16.7
– 16.1
– 15.6
– 15.0
– 14.4
– 13.9
– 13.3
– 12.8
– 12.2
– 11.7
– 11.1
– 10.6
– 10.0
– 9.4
– 8.9
– 8.3
– 7.8
– 7.2
– 6.7
– 6.1
– 5.6
– 5.0
– 4.4
– 3.9
– 3.3
– 2.8
–320
–300
–280
–260
–240
–220
–200
–175
–150
–130
–120
–110
–100
– 90
– 80
– 70
– 60
– 50
– 40
– 30
– 20
– 10
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
o
28 to 77
C
Given
Temp.
– 2.2
– 1.7
– 1.1
– 0.6
0.0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
21.1
21.7
22.2
22.8
23.3
23.9
24.4
25.0
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
F
o
––
––
––
–436
–400
–364
–328
–283
–238
–202
–184
–166
–148
–130
–112
– 94
– 76
– 58
– 40
– 22
– 4
14
32
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
o
78 to 235
o
F
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
C
Given
Temp.
25.6
26.1
26.7
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
37.8
41
43
46
49
52
54
57
60
63
66
68
71
74
77
79
82
85
88
91
93
96
99
102
104
107
110
113
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
o
240 to 485
o
F
172.4
174.2
176.0
177.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
221
230
239
248
257
266
275
284
293
302
311
320
329
338
347
356
365
374
383
392
401
410
419
428
437
446
455
C
Given
Temp.
116
118
121
124
127
129
132
135
138
141
143
146
149
152
154
157
160
163
166
168
171
174
177
179
182
185
188
191
193
196
199
202
204
207
210
213
216
218
221
224
227
229
232
235
238
241
243
246
249
252
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
o
490 to 2400
o
F
464
473
482
491
500
509
518
527
536
545
554
563
572
581
590
599
608
617
626
635
644
653
662
671
680
689
698
707
716
725
734
743
752
761
770
779
788
797
806
815
824
833
842
851
860
869
878
887
896
905
C
Given
Temp.
254
257
260
266
271
277
282
288
293
299
304
310
316
321
327
332
338
343
349
354
360
366
371
377
382
388
393
399
404
410
416
421
427
432
438
443
454
468
482
510
538
566
593
621
649
704
760
816
1093
1316
490
495
500
510
520
530
540
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700
710
720
730
740
750
760
770
780
790
800
810
820
830
850
875
900
950
1000
1050
1100
1150
1200
1300
1400
1500
2000
2400
o
F
o
914
923
932
950
968
986
1004
1022
1040
1058
1076
1094
1112
1130
1148
1166
1184
1202
1220
1238
1256
1274
1292
1310
1328
1346
1364
1382
1400
1418
1436
1454
1472
1490
1508
1526
1562
1607
1652
1742
1832
1922
2012
2102
2192
2372
2552
2732
3632
4352
CONVersiON FaCTOrs
DeGrees FaHreNHeiT TO CelsiUs
(oF – 32) x 5/9 = oC
DeGrees CelsiUs TO FaHreNHeiT
(oC x 9/5) + 32 = oF
MRC Data Chart reproduced with the permission of MRC Global Australia.
15
© WestOne
Services 2013
15
15
Temperature Conversion
Conversion Chart
Chart
Temperature
ENG2068
American
AmericanStandard
StandardFlanges
Flanges
15 151
16
16
16
16
ameriCaN sTaNDarD FlaNGes TemPeraTUre / PressUre raTiNGs
Temperature / Pressure ratings
Carbon steel Pipe Flanges to aNsi / asme 16.5 - 1988 (Bs 1560) Forgings to asTm a105 and a350 - lF2 Forgings to asTm a181 Grade
ii for Class 150 and 300 Only
Temperature
(oC)
maximum Working Pressure in kPa by Classes (for approximate Psi divide by 7)
Class 150
(PN20)
Class 300
(PN50)
Class 600
(PN100)
Class 900
(PN150)
Class 1500
(PN250)
Class 2500
(PN420)
-29 to 38
1960
5110
10210
15320
25530
42550
50
1920
5010
10020
15020
25040
41730
100
1770
4640
9280
13910
23190
38650
150
1580
4520
9050
13570
22610
37690
200
1400
4380
8760
13150
21910
36520
250
1210
4170
8340
12520
20860
34770
300
1020
3870
7750
11620
19370
32280
350
840
3700
7390
11090
18480
30800
375
740
3650
7290
10940
18230
30390
400
650
3450
6900
10350
17250
28750
425
560
2880
5750
8630
14380
23960
450
470
2000
4010
6010
10020
16690
475
370
1350
2710
4060
6770
11290
500
280
880
1760
2640
4400
7330
525
190
520
1040
1550
2590
4320
540
130
330
650
980
1630
2720
NOTe: Flanges above 600 NPA are not included in ANSI B16.5 and the class designations in these large diameters
do not imply specific temperature / pressure ratings.
MRC Data Chart reproduced with the permission of MRC Global Australia.
152
ENG2068
© WestOne Services 2013
aPi - Valve standards
An Overview of the American Petroleum Institute - API - Valve Standards
standard
Description
aPi sPeC 6D
Specification for Pipeline Valves. API Specification 6D is an adoption of IO 14313: 1999, Petroleum & Natural Gas
Industries-Pipeline Transportation Systems-Pipeline Valves. This International Standard specifies requirements and gives
recommendations for the design, manufacturing, testing and documentation of ball, check, gate and plug valves for application
in pipeline systems.
aPi 526
Flanged Steel Pressure Relief Valves. The standard is a purchase specification for flanged steel pressure relief valves. Basic
requirements are given for direct spring-loaded pressure relief valves and pilot-operated pressure relief valves as follows: orifice
designation and area / valve size and pressure rating, inlet and outlet; materials; pressure-temperature limits; and centre-toface dimensions, inlet and outlet.
aPi 527
Seat Tightness of Pressure Relief Valves R(2002). Describes methods of determining the seat tightness of metal and softseated pressure relief valves, including those of conventional, bellows and pilot-operated designs.
aNsi / aPi sTD
594
Check Valves: Flanged, Lug, Wafer and Butt-Welding. API Standard 594 covers design, material, face-to-face dimensions,
pressure-temperature ratings and examination, inspection and test requirements for two types of check valves.
aPi 598
Valve Inspection & Testing. The standard covers inspection, supplementary examination and pressure test requirements for
both resilient-seated and metal-to-metal seated gate, globe, plug, ball, check and butterfly valves. Pertains to inspection by the
purchaser and to any supplementary examinations the purchaser may require at the valve manufacturer’s plant.
aNsi / aPi 599
Metal Plug Valves - Flanged, Threaded & Welding Ends. A purchase specification that covers requirements for metal plug
valves with flanged or butt-welding ends, and ductile iron plug valves with flanged ends, in sizes NPS 1 through to NPS 24,
which correspond to nominal pipe sizes in ASME B36.10M. Valve bodies conforming to ASME B16.34 may have flanged end
and one butt-welding end. It also covers both lubricated and non-lubricated valves that have two-way coaxial ports, and includes
requirements for valves fitted with internal body, plug or port linings or applied hard facings on the body, body ports, plug or plug
port.
aNsi / aPi 600
Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries - Modified National Adoption of ISO 10434: 1998.
aPi 602
Compact Steel Gate Valves - Flanged, Threaded, Welding and Extended-Body Ends. The standard covers threaded-end, socketwelding-end, butt-welding-end and flanged-end compact carbon steel gate valves in sizes NPS4 and smaller.
aNsi / aPi 603
Corrosion-Resistant, Bolted Bonnet Gate Valves - Flanged and Butt-Welding ends. The standard covers corrosion-resistant
bolted bonnet gate valves with flanged or butt weld ends in sizes NPS 1/2 through 24, corresponding to nominal pipe sizes in
ASME B36.10M, and Classes 150, 300 and 600, as specified in ASME B16.34.
aNsi / aPi 607
Fire Test for Soft-Seated Quarter Turn Valves. The standard covers the requirements for testing and evaluating the
performance of straightway, soft-seated quarter turn valves when the valves are exposed to certain fire conditions defined
in this standard. The procedures described in this standard apply to all classes and sizes of such valves that are made of
materials listed in ASME B16.34.
aPi 609
Butterfly Valves: Double Flanged, Lug and Wafer-Type. The standard covers design, materials, face-to-face dimensions, pressuretemeprature ratings and examination, inspection and test requirements for gray iron, ductile iron, bronze, steel, nickel-base
alloy, or special alloy butterfly valves that provide tight shutoff in the closed position and are suitable for flow regulation.
aPi 6Fa
Specification for Fire Test for Valves. The standard covers the requirements for testing and evaluating the performance of API
Spec 6A and Spec 6D valves with automatic backseats when exposed to specifically defined fire conditions.
aPi 6rs
References Standards for Committee 6, Standardisation of Valves and Wellhead Equipment.
aPi 11V6
Design of Continuous Flow Gas Lift Installation Using Injection Pressure Operated Valves. The standard sets guidelines for
continuous flow gas lift installation designs using injection pressure operated valves.
aNsi / aPi rP
11V7
Recommended Practice for Repair, Testing and Setting Gas Lift Valves. The standard applies to repair, testing and setting gas
lift valves and reverse flow (check) valves.
aPi 520-1
Sizing, Selection and Insallation of Pressure-Relieving Devices in Refineries: Part I - Sizing and Selection. The recommended
practice applies to the sizing and selection of pressure relief devices used in refineries and related industries for equipment that
has a maximum allowable working pressure of 15 psig (1.03 bar g or 103 kPa g) or greater.
aPi 520-2
Recommended Practice 520: Sizing, Selection and Installation of Pressure-Relieving Devices in Refineries: Part II - Installation.
The recommended practice covers methods of installation for pressure-relief devices for equipment that has a maximum
allowable working pressure of 15 psig (1.03 bar g or 103 kPa g) or greater. It covers gas, vapor, steam, two-phase and
incompressible fluid service.
aNsi / aPi 574
Inspection Practices for Piping System Components. The standard covers the inspection of piping, tubing, valves (other than
control valves) and fittings used in petroleum refineries.
aNsi / aPi 576
Inspection of Pressure-Relieving Devices. The recommended practice describes the inspection and repair practices for
automatic pressure-relieving devices commonly used in the oil and petrochemical industries.
aNsi / aPi 608
Metal Ball Valves - Flanged and Butt-Welding Ends. The standard covers Class 150 and Class 300 metal ball valves that have
either butt-welding or flanged ends and are for use in on-off service.
17
17
© WestOne
2013
APIServices
-- Valve
API
ValveStandards
Standards
17
MRC Data Chart reproduced with the permission of MRC Global Australia.
ENG2068
UsefulConversion
Conversion
Factors
Useful
Factors
18
18153
18
18
UseFUl CONVersiON FaCTOrs – imPerial TO meTriC (approx.)
“SI” denotes the International System of Metric Units adopted in Australia
This table may be used in two ways: (1) Multiply Column A by Column B to obtain Column C; or (2) Divide Column C by Column B to obtain Column A.
area: symbol m2
The SI unit of AREA is the
SQUARE METRE.
Square Inches
Square Feet
Square Yards
Acre
Hectare (ha)
DeNsiTY: symbol kg/m3
lb/in3
The SI unit of DENSITY is the lb/ft3
kilogram per cubic metre.
lb/yd3
eNerGY: symbol J
C
To Obtain
645.16
0.929
0.836
4047
10000
mm
m2
m2
m2
m2
27.68
16.02
0.5933
t/m3
kg/m3
kg/m3
1.eleCTriCal eNerGY
kilowatt hour (kW.h)
The SI unit of ENERGY is the 2.HeaT eNerGY
JOULE.
British thermal unit (Btu)
Btu/gal
1 J = 1 N.m
Btu/ft3
A joule is the energy
expended or the work
done when a force of one
newton moves the point of
application a distance of one
metre in the direction of
that force.
B
By
a
multiply
remarks
3.6
1.055
0.2321
37.26
MJ
kJ
kJ/L ††
kJ/m3
3.meCHaNiCal eNerGY
foot poundal (ft.pdl)
inch pound-force (in.lbf)
foot pound-force (ft.lbf)
foot ton force (ft.tonf)
Metre kilogram force (m.kgf)
The SI unit of FORCE (kg.m/ Poundal (pdl)
s2) has been given the
special name – NEWTON.
Pound-force (lbf)
The newton is the force
ton-force (tonf)
which when applied to a
body having a mass of
*kilogram-force (kgf)
one kilogram, causes an
acceleration of one metre
*also known as kilopond (kp)
per second in the direction
of application of the force.
pounds-force per inch
.04214
0.1130
1.356
3.037
9.807
J
J
J
kJ
J
N
4.448
N
9.964
kN
9.807
N
N/m
14.59
N/m
32.69
kN/m
25.4
0.3048
0.9144
20.12
1609
1.609
millimetres (mm)
metres (m)
metres (m)
metres (m)
metres (m)
kilometres (km)
ounce
pound
slug
ton (2240 lb)
short ton (2000 lb)
ton (2240 lb)
28.35
0.4536
14.59
1016.05
907.2
1.016
grams (g)
kilograms (kg)
kg
kg
kg
tonne (t)
pounds per foot (lb/ft)
pounds per yard (lb/yd)
1.488
0.4961
kg/m
kg/m
pounds-force per foot
ton/ft
inches
leNGTH: symbol m
feet
yards
The SI unit of LENGTH is the
chain
METRE.
mile
mile
The SI unit of MASS is the
KILOGRAM.
0.1383
175.1
lbf/in
The SI unit is NEWTON PER lbf/ft
METRE: symbol N/m
ton-force per foot
mass: symbol kg
PressUre: symbol Pa
The SI unit of PRESSURE
or stress is the NEWTON
PER SQUARE METRE which
has been given the name
PASCAL.
1 N/m2 = 1Pa =
0.000145lbf/in2
A pascal is the pressure or
stress which arises when
a force of one newton is
applied uniformly over an
area of one square metre.
6.895
kPa
6.895
MPa
47.88
Pa
kgf/cm2
98.07
kPa
100
kPa
bar
Vertical column
(head) of water.
(H20 at 20oC)
metres of water
9.79
kPa
2.984
kPa
torr (vacuum)
0.1333
kPa
1mm Hg. (mercury)
0.1333
kPa
1in. Hg. (mercury)
3.386
kPa
atmosphere (atm)
101.325
kPa
0.133
Pa
0.04214
N.m
0.1130
1.152
N.m
kgf.cm
1.356
13.83
N.m
kgf.cm
3.037
kN.m
9.807
0.09807
N.m
N.m
0.3048
0.00508
0.4470
1.609
m/s
m/s
m/s
km/h
16387
0.02832
0.7646
1 000 000
0.001
0.004546
mm3
m3
m3
mm3
m3
m3
28.41
568.3
1.137
4.546
3.785
1.000
4.536
millilitre (ml)
millilitre (ml)
litre (L) ††
litre (L) ††
litre (L) ††
kilogram (kg)
kilogram (kg)
m3/s
feet of water
Poundal-foot
pdl.ft
pound-force inch
lbf.inch
The SI unit of TORQUE is
lbf.inch
the NEWTON METRE. The
pound-force feet
newton metre is the work
lbf.ft
done when a force of one
lbf.ft
newton moves the point of
application a distance of one ton-force feet
tonf.ft
metre in the direction of
kilogram-force
that force.
kgf.m
1 N.m = 1 J
kgf.cm
The SI unit of VELOCITY is
the METRE PER SECOND.
VOlUme: CaPaCiTY:
symbol m3
The SI unit of VOLUME is
the CUBIC METRE.
NOTE: ††
Capital “L” is now the legal
preferred symbol for litre in
Australia.
ft. per second (ft/s)
ft. per minute (ft/min)
miles per hour
miles per hour
DrY:
cubic inch (in3)
cubic foot (ft3)
cubic yard (yd3)
litre (L) ††
litre (L) ††
gallons (lmp.)
imPerial liQUiD
fluid ounce
pint (20 fl. oz)
quart (2 pints)
gallon (lmp.)
gallon (US)
litre (water 4oC)
Imp. gallons (water 20oC)
Imp. gal. per minute (gal/
min)
VOlUme: raTe OF FlOW
symbol m3/s
Imp. gal. per minute
Imp. gal. per minute
The SI unit of VOLUME RATE
OF FLOW is the CUBIC
METRE PER SECOND.
cubic ft. per minute
cubic ft. per minute
POWer: symbol W
The SI unit of POWER is the
WATT.
Btu per hour (Btu/hr)
horsepower (hp)
ton of refrigeration
0.2931
0.7457
3.517
W
kW
kW
sUNDrY iTems:
C
To Obtain
kip/in2 (1000 psi)
lbf/ft2
TOrQUe: symbol N.m
(moment of force)
VelOCiTY: symbol m/s
B
By
lbf/in2
microns
FOrCe: symbol N
(NeWTON)
FOrCe Per UNiT leNGTH:
a
multiply
remarks
2
miles per gallon
gallons per mile
0.0000758
0.272765
0.0758
0.000472
m3/hr
litre per second
(L/s)
m3/s
0.472
litre per second
(L/s) 1 m3 = 1 kL
0.3540
2.825
km per litre
litres per km
TemPeraTUre
The SI unit of TEMPERATURE is the KELVIN – Symbol K
For most practical purposes of temperature measurement and most calculations involving temperatures,
degrees Celsius, symbol oC will be used.
DeGrees FaHreNHeiT TO CelsiUs:
DeGrees CelsiUs TO FaHreNHeiT:
(oF – 32) x 5/9 = oC
(oC x 9/5) + 32 = oF
MRC Data Chart reproduced with the permission of MRC Global Australia.
154
ENG2068
© WestOne Services 2013
PIPE FABRICATION
MATERIALS, DRAWING AND FABRICATION METHODS
DESCRIPTION
This resource covers content relating to units from the MEM training package in relation to the
pipe fabrication context. It supports the units MEM09003B and MEM09211A, and partially
supports MEM09217A, MEM05010C, MEM04011D, and MEM04045B.
Topics include:
• safety, plant and equipment
• codes and standards
• abbreviations and symbols
• materials, systems and fittings
• drawing and dimensioning
• fabrication methods and processes.
The book includes many technical drawings to support learning.
EDITION
Edition 1, 2013
TRAINING PACKAGE
• METALS AND ENGINEERING
COURSE / QUALIFICATION
• MEM40412 Certificate IV in Engineering (Drafting)
• MEM50212 Diploma of Engineering – Technical
• MEM40105 Certificate IV in Engineering
• MEM50105 Diploma of Engineering – Advanced Trade
UNITS OF COMPETENCY
This resource supports the unit:
• MEM09211A Producre drawings or models for industrial piping
It also partially supports:
• MEM09217A Prepare plans for pipe and duct fabrication
• MEM05011D Assemble fabricated components
ENG2068
PIPE FABRICATION
ISBN 978-1-74205-902-0
ORDERING INFORMATION:
Contact WestOne Services on Tel: (08) 9229 5200 Fax: (08) 9227 8393 Email: sales@westone.wa.gov.au
Orders can also be placed through the website: www.westone.wa.gov.au
9
781742 059020