Petrofac Piping Inspection Handbook pdf.pdf

Contents

Petrofac E & C

PIPING INSPECTION HANDBOO HANDBOOK K

Quality Department

Material receiving inspection Document verification Cutting Piping spool fabrication Welding general Release and storage of fabricated spools Piping erection Bolting of flanged joints Flange identification Flange face imperfections Spacer & Blind Standard  ASME 16.5 flanges flanges Bolt tightening sequence Groupings for bolt tensioning Nut / bolt material specification Bolts with corresponding wrench size Pipe flange misalignment tolerances Mill tolerances for pipe & wrought fittings Lubricants for nuts / bolts Colour coding for gaskets Pre-test checklist Pressure testing Safety in Piping (Slings & Shackles) Permissible reductions in pipe wall thickness Blind flange dimension chart Piping schedule wall thickness chart Metric / imperial conversion factors

3 4 4 5 9 12 14 16 18 19 23 32 38 44 45 46 47 50 52 53 54 60 66 74 75 79 83

1

Introduction This handbook has been prepared to provide PEC piping QC and construction personnel with a set of general inspection guidelines and technical information to ensure a consistent Quality of construction works on all E&C projects.

Received By: ………………………………….. Date: ……………………………………… ……………………………………………. …….

2

Material Receiving Inspection The following items to be checked upon receipt of piping bulk materials, valves, fittings, flanges, bolting materials, and gaskets. • Check all mill certificates are available and are in compliance with the material specification. •  Check correct quantities have been delivered as per the purchase order. •  Check that all end caps are fitted and are not damaged; raised face flanges are correctly protected. •  Check materials are correctly identified, marked, and color coded as per the purchase order and project specifications. • Check for any damage, dents, scratches, damage damage to beveled ends, ovality of pipes, fittings. •  Check dimensions are as per the purchase order, length, diameter and schedule. • Check materials are stored correctly, piping if stored off the ground on proper dunnage or sleepers. Flanges and fittings are stored on palates or in racks. • Check that CRA material, SS, DSS, CuNi, Hastelloy, Inconel are stored correctly in a segregated area. •  Any discrepancies should be documented on OSDR, Over Shortage Damage Report.

3

Document Verification

Cutting

Prior to the start of fabrication the following documents should be approved for construction by Petrofac and the client :

Prior to cutting straight pipes, the following checks shall be made:

- Required ITP’s. - Required QCP’s. - Construction Method Statements. - Latest AFC drawing index and isometrics. - Approved Welding Procedures. - Approved NDE Procedures. - Welder Qualification Certificates, ID Cards.

Cutting The following cutting methods should be used for various material types :

• Correct material as per Isometric Bill of Materials • Dimensions as per Isometric, length, diameter • Heat numbers numbers transferred on items to be cut •  Drawing number and spool number clearly marked on the pieces to be cut. •  Identification marks shall also to be transferred on the balance piece

Piping Spool Fabrication Prior to fabrication of piping spools the following should be checked by the inspector :

4

• Carbon steel, Stainless steel and LTCS are not fabricated in the same area where they may be mixed up. Ideally they should be fabricated in separate shops, where this not practical the inspector should ensure that fabrication areas are clearly segregated and identified. • Cleaning, grinding tools used for these materials should be be different and carbon steel tools should not be used on stainless steel to avoid contamination. Proper color coding during material storage and use shall be maintained. Before fitment of members, the material should be identified and checked against bill of materials / drawings. 5

Piping Spool Fabrication

Piping Spool Fabrication

•  Ensure that pipes are kept on proper fabrication table or support. Whenever purging is required, it has to be properly monitored by using a purge monitor. •  During fit up stage, check bevel preparation, weld joint design, straightness and alignment of the assembly being  joined. Dimensional survey to be carr ied out prior to welding. • CRA’s should be fabricated in a dedicated separate fac ility to carbon and low alloy steels to avoid contamination. All carbon steel pipe stands should be clad with either rubber or wood to ensure no direct contact with the CRA. Only tools dedicated to CRA fabrication should be used and preferably color coded to identify them. This includes hand tools, hammers, files, hacksaw blades, grinding disks and mechanical cutting equipment.

• Reinforcing pads around branch connections shall be pneumatically tested for any leaks as required by the project specifications.

•  Carbon Steel, Low Temperature Carbon Steel and Low  Alloy Steels: These materials can be cut using, thermal methods, oxy propane or oxy acetylene. Mechanical methods, reciprocating saws or cutting discs. Adequate protection should be provided to the internal wall of the pipe when flame cutting holes for branch connections. • CRA’s can be cut by plasma method or mechanical methods, reciprocating saws or cutting discs.

• Root penetration of welds on orifice flanges shall be ground flush and smooth. •  Special Requirements for Stainless Steel, Nickel & NonFerrous Alloys 1.

It shall be ensured that all the supervisors and workers workers have been properly trained in handling and fabrication of stainless steel or non-ferrous alloys. Regular Tool box talks shall be held to provide the training.

2.

Shop fabrication shall proceed in a fabrication shop exclusively assigned for stainless steel or non-ferrous alloys.

3.

All tools shall be exclusive to the material being fabricated and shall not have previously been used on carbon steel materials.

4.

Work benches, supports shall be lined with rubber or wood with no carbon steel nails or screws protruding from the surface.

5.

Galvanized or copper /bronze earth return clamps shall shall be adequately clad or otherwise covered with stainless steel material to prevent direct contact with the pipe or fitting.

During fabrication the following should be checked by the inspector : • Check revision of isometric drawing. • Check material conforms conforms to isometric bill of materials. • Check transfer of identification markings to cut pieces before cutting. Heat No. Drawing no. Spool No. • Check flange hole orientation and fitting orientation. • Dimensional check prior to welding. • All weld joint num bers are identified as per the Isom etric and any additional welds are identified and added to the Isometric.

6

7

Piping Spool Fabrication 6.

Carbon steel line pipe clamps shall not come into direct contact with the pipe surface; adequate cladding or stainless steel shims shall be provided to prevent direct contact.

7.

Only marking materials specifically approved by the Contractor, for stainless steel or non-ferrous alloys shall be used. The root pass of single sided GTAW welds shall be protected from oxidation by an inert gas purge maintained until at least two layers are completed. In special circumstances where back purge is not possible, flux cored TGX filler wire may be used subject to written approval by the contractor. Only non-metallic slings shall be used for lifting and handling stainless steel and non-ferrous materials.

8.

9.

10. All materials for purge dams shall be approved prior to fabrication. 11. Pipe spools temporarily laid down at the job site prior to erection shall be placed on proper wooden sleepers, 100mm minimum height, covered with plastic sheeting and segregated from other material. All open ends shall be capped and raised face flanges shall be protected from mechanical damage.

8

Welding General • Prior to any welding including tack welding, weld preparations shall be cleaned to sound bright metal to a minimum distance of 50mm from weld preparation. Welding shall not be performed on rust, paint, primer, grease, or oil. •  Welding including tack welding shall be performed by a qualified welder using an approved WPS. • Welding consumable shall be issued and handled in accordance with approved welding procedure. •  Earth return clamps shall be connected directly to t he weldment as close to the joint as possible. • Any pre-heat required shall be applied prior to tack welding •  Bridge tacks shall be made inside the weld preparation across the bevel faces but not on the root. Bridge piece material shall be cut from the same piping material • Tack welds intended to be an integral part of the root shall be ground to a feathered edge to fuse smoothly with the root pass. Such tacks shall be a minimum of 25 mm long and be equally spaced around the circumference of the pipe in sufficient number to support the weldment. •  Inspector shall check and accept or reject the fit-up of all  joints prior to welding. Open pipe or fitting ends shall be capped during welding to prevent air flow through the spool.

9

Welding General •  Welding parameters shall be as specified on the approved WPS. QCI shall perform random checks to verify parameters and essential variables using the Welding Process Control. When pre-heat is specified the weld should be completed before the joint is allowed to cool. When this is not practical a minimum of 30% of the pipe wall thickness shall be completed before the joint is allowed to cool. • Completed welds shall have t he welders’ ID number(s) for root, fill and cap marked adjacent to the weld. This shall be verified by QCI during visual inspection of the completed weld. Post weld heat treatment, NDT & Hardness testing • PWHT shall be performed on welded pipe spools in accordance with B31.3 Table 331.1 or as specified in the project piping specifications. • PWHT may be performed locally or in a furnace in compliance with the approved procedure of the Contractor. • Hardness testing shall be performed by an approved method at the locations and frequency specified in the project specifications. •  NDE shall be performed to procedures approved by the contractor. The frequency and method of NDE shall be specified in the project specifications or by the construction code e.g. B31.3 Table 341.3.2 for Normal Fluid Service. 10

11

Fabricated Spool Release, Storage & Preservation

Fabricated Spool Release, Storage & Preservation

Once fabrication, NDE, and PWHT completed, the fabricated spool will be released for painting, by means of a spool release note, the inspector needs to check the following before signing the release note.

• Spools released for painting should be identified as such by means of a label affixed to the spool. • Once released spools are stored in a designated lay down area the inspector should monitor the following : • Spools fabricated from different materials are segregated. • Spools are stored off the floor on proper sleepers or palates. • End caps and flange face protectors are in position and not damaged. •  Flange serrated raised faces shall be protected by 5 to 15mm thick plywood disks tied to the flange. • Flange faces and threads shall be coated with a suitable rust preventive prior to storage.

• All welds are identified on the Isometric drawing. • All welds are completed and visually accepted. • If required post weld heat treatment and hardness check has been completed. • All required NDE, (RT, PT, MPI, UT, PMI, Ferrite count) has been completed and accepted. • Required heat numbers have been documented for material traceability. • Flange faces are free from damage and are protected. • Pipe spools are internally cleaned and end caps are fitted. • Dimensions are correct to the Isometric. • The root pass on orifice flanges has been ground flush and a report generated. • Reinforcing pads around branches have a weep hole which is threaded and a pneumatic leak test has been completed and a report generated. • All spools have a tag so they can be identified after blasting and painting. 12

13

Piping Erection

Piping Erection

•  Check spools are identified and have a spool release note signed by QC. • Check flange faces, beveled ends for damage. • Check for internal cleanliness prior to erection. • All valves and special items are inspected before installation to ensure that the protective packaging, covers, wrapping and internal preservatives such as silica gel bags are removed. • Ensure that valves are correct size, type and pressure rating and they are installed at the correct location and orientation. • Ensure that orientation of valve handles and direction of flow are as shown on the Isometric. • Welded type valves shall be half opened during PWHT, but not fully opened. •  Flanged control valves, ball valves and other soft seated valves shall be removed before PWHT and line flushing operations. They shall be properly identified, protected and stored until they are installed in the line. • All Teflon seat valves must be removed before welding. •  All manually operated valves shall be checked to ensure operability prior to erection. • Check all supports are installed and are the correct type at the correct location.

•  Ensure that anchor stoppers are installed according to approved drawings. •  Pipe supports shall be designed and located to effectively sustain the weight and thermal effects of the piping system and to prevent vibration. Location and design of pipe supports shall be as per the relevant drawings. • No pipe shoe/cradle shall be offset unless specially shown in the drawing. • Hanger rods shall be installed inclined in a direction opposite to the direction in which the pipe moves during expansion. • Weld proximity between adjacent welds has to be checked and conformed to the specific requirements of the project. • Following points shall be checked after installation: • All restraints have been installed correctly • Clearances have been maintained as per support drawing • Insulation does not restrict thermal expansion • All temporary tack welds provided during erection have been fully removed • All welded supports have been fully welded • Verify anchor stopper gap

14

15

Bolting of Flanged Joints

Bolting of Flanged Joints

Correct procedure for bolting of flange joints is extremely important to ensure that there are no leaks during pressure testing and operation of process pipework. Checklist for Correct Bolt Tightening Manual Tightening; • • • • • • • • •

Correct tools wrenches available. Check flange faces for damage and cleanliness. Check flange face alignment is within tolerance. Gasket is correct type as per BOM and is color coded. Correct bolt/nut type as per BOM and no thread damage. Lubricant applied to nuts/bolts. Numbering of bolt holes on flange, correct sequence. Thread engagement between bolts and nuts. Check tightness & bolt projection

Torque Tightening: • Torque wrench is calibrated. • Check flange faces for damage and cleanliness. • Check flange face alignment is within tolerance. • Gasket is correct type as per BOM and is color coded. • Correct bolt/nut type as per BOM and no thread damage. • Lubricant applied to nuts/bolts. • Numbering of bolt holes on flange, correct sequence.

Torque Tightening: • Thread engagement between bolts and nuts. st • Torque value 1  pass is correct. nd • Torque value 2  pass is correct. rd • Torque value 3  pass is correct. • Torque Tightening Report Tensioning: • Tensioning equipment is calibrated • Check flange faces for damage and cleanliness. • Check flange face alignment is within tolerance. • Gasket is correct type as per ISO BOM and is color coded. •  Correct bolt/nut type as per ISO BOM and no thread damage • Thread engagement between bolts and nuts. • 50% of pressure Group A. • 100% pressure Group A. • 50% of pressure Group B. • 100% pressure Group B. •  Numbering and grouping of bolt holes on flange, correct sequence. • Lubricant applied to nuts/bolts.

16

17

Flange Identification

Flange Facing Finish Imperfections

Manufactures Size rating & thickness Symbol at weld preparation

S

Checklist for Correct Bolt Tightening

A105N 2x1/2 S80150 29E (CBXB)

Material Grade

Heat No. Or (Test No.)

ITALY

Imperfections in the flange facing finish shall not exceed the dimensions shown in the next table. Adjacent imperfections shall be separated by a distance at least four times the maximum radial projection. A radial projection shall be measured by the difference between an outer radius and an inner radius encompassing the imperfection where the radii are struck from the centerline of the bore. Imperfections less than half the depth of the serrations shall not be considered cause for rejection. Protrusions above the serrations are not permitted.

Damage deeper than serrations UNACCEPTABLE

Country of Origin (optional)

Damage not deeper than serrations  ACCEPTABLE

5

Colour code If required

5

18

19

Flange Facing Finish Imperfections The raised serrated face of the flange should be checked for any damage to the serrations. If any scratches are deeper than the serrations then the face will have to be re-machined. If the damage does not reach the bottom of the serrations then the acceptance criteria below should be used.

Permissible imperfections in flange facing finish for raised flange face and large male and female flange

NPS

Maximum radial projection of imperfections no deeper than the bottom of the serrations (mm)

Maximum radial projection of imperfections deeper than the bottom of the serrations (mm)

½

3.0

1.5

¾

3.0

1.5

1

3.0

1.5

11/4

3.0

1.5

11/2

3.0

1.5

2

3.0

1.5

21/2

3.0

1.5

3

4.6

1.5

31/2

6.0

3.0

4

6.0

3.0

5

6.0

3.0

6

6.0

3.0

Examples of Acceptable and Unacceptable Flange Face Imperfections:

Damage not deeper than serrations

Damage deeper than serrations

20

21

Permissible imperfections in flange facing finish for raised flange face and large male and female flange

Spacer & Blind Standard

Maximum radial projection of imperfections no deeper than the bottom of the serrations

Maximum radial projection of imperfections deeper than the bottom of the serrations

8

8.0

4.5

10

8.0

4.5

12

8.0

4.5

14

8.0

4.5

16

10.0

4.5

18

12.0

6.0

Notes:

20

12.0

6.0

24

12.0

6.0

26-36

12.7

6.0

38-48

14

7.0

1. All dimensions are in mm unless otherwise specified. 2. The words “Spacer” or “Blind” as applicable, shall be in bold (min letter height 10mm) on both sides of the handle. 3. A raised face may be specified optionally. The height of the raise face shall be in addition to the thickness “t”.

50-60

16

8.0

NPS

22

O : Outside diameter, B : Inside diameter, t : Thickness C : Handle length, W : Handle width, a : Handle Thickness

23

Spacer & Blind Standard

Spacer & Blind Standard 4. The spacers/blinds are suitable for raised face flanges complying with: - ASME B16.5 for NPS ≤ 24” -  ASME B16.47 series A for NPS ≥ 26” 5. Dimensions of spacers / blinds for NPS ≤ 24” are based on  ASME B16.48 6. Thickness tolerances are: - NPS 18 and smaller – ZERO + 3.0 mm - NPS 20 and larger – ZERO + 4.8 mm 7. The gasket seating surface finish shall be in accordance with  ASME B16.5 8. No corrosion allowance shall be added to the thickness “t” for NPS ≤ 24” 9. For NPS ≥ 26”, corrosion allowance of 3 mm (min) is already included in the thickness “t”. For higher corrosion allowance, the thickness shall be checked as per ASME B31.3 Para 304.5.3 considering corrosion on one side. 10.The material grade of spacers/blinds shall be same or equivalent to the piping material. For CS & LTCS piping, the material grade of spacers / blinds shall be ASTM A516 Gr 70. 11.For high tensile & exotic piping materials (e.g. duplex SS, alloy 625, etc.) the thicknesses of spacers/blinds for NPS ≥ 26” may be economised by calculation as per ASME B31.3 Para 304.5.3.

.

O : Outside diameter, B : Inside diameter, t : Thickness C : Handle length, W : Handle width, a : Handle Thickness

24

25

Spacer & Blind Standard

Spacer & Blind Standard CLASS 300

CLASS 150 NPS 6” 8” 10” 12” 14” 16” 18” 20” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48”

Outside Dia 448 511 546 603 714 771 829 879 937 987 1045 1108 1159 1216 1273 1324 1381

Inside Dia 356 406 457 508 610 660 711 762 813 864 914 965 1016 1067 1118 1168 1219

Thk 19.1 22.4 25.4 28.4 31.8 37 39 41 44 46 48 51 54 56 59 61 63

26

Handle Length 150 150 150 155 160 160 160 160 170 170 170 170 170 170 175 175 175

Handle Width 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50

Handle Thk 12 16 16 20 20 24 24 24 24 32 32 32 32 32 40 40 40

NPS 6” 8” 10” 12” 14” 16” 18” 20” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48”

Outside Dia 419 483 536 594 651 772 832 895 949 1003 1054 1115 1051 1111 1162 1216 1270 1321

Inside Dia 324 356 406 457 508 610 660 711 762 813 864 914 965 1016 1067 1118 1168 1219

Thk 28.4 31.8 31.8 41.1 44.5 50.8 59 63 67 71 75 79 83 87 91 96 100 104

27

Handle Length 155 155 165 170 170 180 180 180 180 190 190 190 190 190 190 190 190 190

Handle Width 50 45 50 40 45 50 45 50 50 50 50 50 50 50 50 50 50 50

Handle Thk 20 20 20 24 24 32 40 40 40 50 50 50 50 50 50 50 50 50

Spacer & Blind Standard

Spacer & Blind Standard

CLASS 600 NPS 6” 8” 10” 12” 14” 16” 18” 20” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48”

Outside Dia 397 454 489 562 610 679 787 864 911 968 1019 1070 1127 1101 1152 1216 1267 1324 1387

Inside Dia 265 315 346 397 448 497 597 644 695 746 797 848 898 949 1000 1050 1101 1151 1202

Thk 35.1 41.1 44.5 50.8 53.8 63.5 73.2 82 88 94 100 105 112 116 122 129 136 141 148

Handle Length 165 165 165 170 175 175 185 190 190 190 190 190 190 195 195 195 195 195 195

CLASS 900 Handle Width 40 38 40 45 50 45 50 45 50 50 50 50 50 50 50 50 50 50 50

Handle Thk 24 24 24 32 32 40 50 50 50 50 50 50 50 50 50 50 50 50 50

NPS 6” 8”  10” 12” 14” 16” 18” 20” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48”

Outside Dia 356 432 495 518 572 635 696 835 879 943 1007 1070 1134 1197 1197 1248 1299 1365 1432 1483

Inside Dia 212 265 315 346 397 448 497 597 644 695 746 797 848 898 949 1000 1050 1101 1151 1202

Thk 35.1 41.1 47.8 53.8 60.5 66.5 73.2 88.9 100 107 115 122 129 137 148 157 164 172 181 188

Handle Length 165 165 165 170 175 185 190 210 220 220 220 240 240 240 260 260 260 280 280 280

Handle Width 50 50 40 40 45 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50

Handle Thk 24 24 32 32 40 40 50 50 50 50 50 50 50 50 50 50 50 50 50 50

29 28

Spacer & Blind Standard

Spacer & Blind Standard

CLASS 1500 NPS 6” 8”  10” 12” 14” 16” 18” 20” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48”

Outside Dia 349 432 518 575 638 702 752 899 -

Inside Dia 203 255 303 333 381 429 478 575 -

Thk 41.1 50.8 60.5 66.5 76.2 85.9 95.3 111.3 -

30

Handle Length 175 185 185 195 200 215 225 245 -

CLASS 2500 Handle Width 50 50 50 50 50 50 50 50 -

Handle Thk 24 32 40 40 50 50 50 50 -

NPS 6”  8”  10” 12” 14” 16” 18” 20” 24” 26” 28” 30” 32” 34” 36” 38” 40” 42” 44” 46” 48”

Outside Dia 314 384 473 546 -

Inside Dia 154 198 248 289 -

Thk 41.1 53.8 66.5 79.2 -

31

Handle Length 190 190 210 215 -

Handle Width 50 50 50 50 -

Handle Thk 24 32 40 50 -

ASME 16.5 Class 150 Flange Number & Dia of Bolts NPS

Diameter of Bolts Inches mm

ASME 16.5 Class 300 Flange Number & Dia of Bolts NPS

No. of Bolts

Inches

mm

½ ¾ 1 1¼ 1½

12.7 19.05 25.4 31.75 38.10

1/2 1/2 1/2 1/2 1/2

12.7 12.7 12.7 12.7 12.7

4 4 4 4 4

2 2½ 3 3½

50.8 63.5 76.2 88.9

5/8 5/8 5/8 5/8

15.88 15.88 15.88 15.88

4 4 4 8

4 5 6 8

101.6 127 152.4 203.2

5/8 3/4 3/4 3/4

15.88 19.05 19.05 19.05

8 8 8 8

10 12 14 16

254 304.8 355.6 406.4

7/8 7/8 1 1

22.23 22.23 25.4 25.4

12 12 12 16

18 20 22 24

457.2 508 558.8 609.6

1 1/8 1 1/8 1¼ 1¼

28.58 28.58 31.75 31.75

16 20 20 20

Inches ½ ¾ 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 12 14 16 18 20 22 24

mm 12.7 19.05 25.4 31.75 38.10 50.8 63.5 76.2 88.9 101.6 127 152.4 203.2 254 304.8 355.6 406.4 457.2 508 558.8 609.6

Diameter of Bolts Inches mm 1/2 12.7 5/8 15.88 5/8 15.88 5/8 15.88 3/4 19.07 5/8 15.88 3/4 19.05 3/4 19.05 3/4 19.05 3/4 19.05 3/4 19.05 3/4 19.05 7/8 22.23 1 25.40 1 1/8 28.58 1 1/8 28.58 1¼ 31.75 1¼ 31.75 1 1/4 31.75 1 1/2 38.10 1 1/2 38.10

No. of Bolts 4 4 4 4 4 8 8 8 8 8 8 12 12 16 16 20 20 24 24 24 24

32

33

ASME 16.5 Class 600 Flange Number & Dia of Bolts

ASME 16.5 Class 900 Flange Number & Dia of Bolts

NPS Inches ½ ¾ 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 12 14 16 18 20 22 24

mm 12.7 19.05 25.4 31.75 38.10 50.8 63.5 76.2 88.9 101.6 127 152.4 203.2 254 304.8 355.6 406.4 457.2 508 558.8 609.6

Diameter of Bolts Inches mm 1/2 12.7 5/8 15.88 5/8 15.88 5/8 15.88 3/4 19.05 5/8 15.88 3/4 19.05 3/4 19.05 7/8 22.23 7/8 22.23 1 25.40 1 25.40 1 1/8 28.58 1 1/4 31.75 1 1/4 31.75 1 3/8 34.93 1 1/2 38.10 1 5/8 41.28 1 5/8 41.28 1 3/4 44.45 1 7/8 47.63

34

No. of Bolts 4 4 4 4 4 8 8 8 8 8 8 12 12 16 20 20 20 20 24 24 24

NPS Inches mm

Diameter of Bolts Inches mm

No. of Bolts

½ ¾ 1 1¼ 1½ 2 2½ 3 4 5 6 8 10 12 14 16

12.7 19.05 25.4 31.75 38.10 50.8 63.5 76.2 101.6 127 152.4 203.2 254 304.8 355.6 406.4

¾ ¾ 7/8 7/8 1 7/8 1 7/8 1 1/8 1¼ 1 1/8 1 3/8 1 3/8 1 3/8 1½ 1 5/8

19.05 19.05 22.23 22.23 25.4 22.23 25.4 22.23 28.58 31.75 28.58 34.93 34.93 34.93 38.10 41.28

4 4 4 4 4 8 8 8 8 8 12 12 16 20 20 20

18 20 24

457.2 508 609.6

1 7/8 2 2½

47.63 50.80 63.50

20 20 20

35

ASME 16.5 Class 1500 Flange Number & Dia of Bolts NPS Inches mm

Diameter of Bolts Inches mm

No. of Bolts

½ ¾

12.7 19.05

¾ ¾

19.05 19.05

4 4

1 1¼ 1½ 2 2½ 3 4 5 6 8 10 12 14 16 18 20

25.4 31.75 38.10 50.8 63.5 76.2 101.6 127 152.4 203.2 254 304.8 355.6 406.4 457.2 508

7/8 7/8 1 7/8 1 1 1/8 1¼ 1 1/2 1 3/8 1 5/8 1 7/8 2 2 1/4 2 1/2 2 3/4 3

22.23 22.23 25.4 22.23 25.4 28.58 31.75 38.10 34.93 41.28 47.63 50.80 57.15 63.50 69.85 76.20

4 4 4 8 8 8 8 8 12 12 12 16 16 16 16 16

24

609.6

3 1/2

88.90

16

ASME 16.5 Class 2500 Flange Number & Dia of Bolts NPS Inches mm

Diameter of Bolts Inches mm

No. of Bolts

½ ¾ 1 1¼

12.7 19.05 25.4 31.75

3/4 3/4 7/8 1

19.05 19.05 22.23 25.40

4 4 4 4

1½ 2 2½ 3

38.10 50.8 63.5 76.2

1 1/8 1 1 1/8 1¼

28.58 25.40 28.58 31.75

4 8 8 8

4 5 6 8

101.6 127 152.4 203.2

1½ 1 3/4 2 2

38.10 44.45 50.80 50.80

8 8 8 12

10 12

254 304.8

2 1/2 2 3/4

63.50 69.85

12 12

36

37

Bolt Tightening Sequence

Bolt Tightening Sequence

Bolts should always be tightened in the correct sequence to ensure even compression of the Gasket. The next figures show the tightening bolt sequence for flanges with 4 bolts up to 48 bolts. The piping inspector shall refer to the QCP No. (………………….) for the figures of tightening bolt sequence of flanges with 52 bolts up to 92 bolts.

For tightening bolt sequence of flanges with 52 bolts up to 92 bolts, refer to the QCP No. (………………………….)

For tightening bolt sequence of flanges with 52 bolts up to 92 bolts, refer to the QCP No. (………………………….)

38

39

Bolt Tightening Sequence

Bolt Tightening Sequence

For tightening bolt sequence of flanges with 52 bolts up to 92 bolts, refer to the QCP No. (………………………….)

For tightening bolt sequence of flanges with 52 bolts up to 92 bolts, refer to the QCP No. (………………………….)

40

41

Bolt Tightening Sequence

Bolt Tightening Sequence

For tightening bolt sequence of flanges with 52 bolts up to 92 bolts, refer to the QCP No. (………………………….)

42

For tightening bolt sequence of flanges with 52 bolts up to 92 bolts, refer to the QCP No. (………………………….) 43

Grouping of Bolts for Tensioning

Nut / Bolt Material Specification

• Sequence of tensioning shall be Group-A then Group-B, or Group A1, A2, B1 and B2 in series. • Group A1 and A2 or Group B1 and B2 should be tightened at the same time when tools are available.

Bolts

Nuts

 A193-B7

A194-2H

No. of bolt per flange

GROUP  – A

GROUP – B

 A193-B7M

A194-2HM

16

No. 1 to No. 8

No. 9 to No. 16

 A193-B16

A194-Gr.4

20

No. 1 to No. 10

No. 11 to No. 20

24

No. 1 to No. 12

No. 13 to No. 24

 A193-B8

A194-Gr.7

28

No. 1 to No. 14

No. 15 to No. 28

 A193-B8M

A194-Gr7M

32

No. 1 to No. 16

No. 17 to No. 32

 A320-L7

A194-8

 A320-L7M

A194-8M

 A320-B8M

A194-8MA

 A453-GR.660

A194-Gr.3

 A193-B8 Class 2

Heavy Hexagonal Nuts

36 40 44 92

GROUP  A1 No. 1 to No. 8 No. 1 to No. 8 No. 1 to No. 16 No. 1 to No. 32

GROUP  A2 No. 9 to No. 18 No. 9 to No. 20 No. 17 to No. 22 No. 33 to No. 46

GROUP B1 No. 19 to No. 28 No. 21 to No. 32 No. 23 to No. 28 No. 77 to No. 76

GROUP B2 No. 29 to No. 36 No. 33 to No. 40 No. 29 to No. 44 No. 1 to No. 92

44

45

Bolts with Corresponding Wrench Size

Pipe Flange Misalignment Tolerances

Bolt Diameter Inches Millimetres

Wrench Size

½

12.7

7/8

5/8

15.8

1 1/16

¾

19.05

1¼

7/8

22.2

1 7/16

1

25.4

1 5/8

1 1/8

28.5

1 13/16

1¼

31.7

2

1 3/8

34.9

2 3/16

1½

38.1

2 3/8

1 5/8

41.2

2 9/16

1¾

44.4

2¾

1 7/8

47.6

2 15/16

2

50.8

3 1/8

2¼

57.1

3½

2½

63.5

3 7/8

2¾

69.8

4¼

3

76.2

4 5/8

•  Adjustable spanners shall not be used to tighten or loosen flange bolts.

46

PFI Standard ES-3: Maximum Vertical/Horizontal Offset

2mm for 4” and below

3mm for >4”

2mm for 4” and below 3mm >4”

47

Pipe Flange Misalignment Tolerances

Maximum Face Misalignment

Pipe Flange Misalignment Tolerances

Face Separation

Maximum Flange Rotation

1.5mm

2.5mm/m flange diameter

Gasket Requirement + 0.8mm

48

49

Mill tolerances for pipe & wrought fittings

Mill tolerances for pipe & wrought fittings

•  In case of mismatch between pipe and fitting, measure fitting out of roundness and circumference. If the measurement data is within tolerance as per below table, start fit up work. Difference of inside diameter shall be equally divided around the circumference. Circumference: +/- 0.5% Out of roundness: 1% Diameter: +/- 0.5% • In case of mismatch at the weld preparation the bores shall be matched as shown below. •  Additional weld metal to be deposited to compensate for material removed from the bore for alignment purposes.

o

18-30  Taper

50

Fitting Size (in)

O.D. mm

Out of Roundness 1% mm

Circumference

- 0.5%

+ 0.5%

20

508

5.1

1595.1

1587.1

1603.1

22

559

5.6

1755.3

1746.5

1764

24

610

6.1

1915.4

1905.8

1925

26

660

6.6

2072.4

2062

2082.8

28

711

7.1

2232.5

2221.4

2243.7

30

762

7.7

2392.7

2380.7

2404.6

32

813

8.1

2552.8

2540.1

2565.6

34

864

8.7

2713

2699.4

2726.5

36

914

9.1

2870

2855.6

2884.3

38

965

9.7

3030.1

3014.9

3045.3

40

1016

10.2

3190.2

3174.3

3206.2

42

1067

10.7

3350.4

3333.6

3367.1

44

1118

11.2

3510.5

3493

3528.1

46

1168

11.7

3667.5

3649.2

3685.9

48

1219

12.2

3827.7

3808.5

3846.8

52

1321

13.2

4147.9

4127.2

4168.7

56

1422

14.2

4465.1

4442.8

4487.4

60

1524

15.2

4785.4

4761.4

4809.3

64

1626

16.3

5108.9

5083.3

5134.4

72

1829

18.3

5743.1

5714.3

5771.8

51

Lubricants for nuts / bolts

Colour coding for gaskets

• Make sure bolts are lubricated along their entire length prior to tightening.

• Color Coding Scheme For Gaskets ASME B16.20 • Gasket Type Is Specified On Isometric Bill Of Materials. Spiral Wound Gaskets Material Outer Ring Colour Yellow 304 Stainless Steel Green 316L Stainless Steel

Commercial Lubricant Types:

Lubricant

Bolting Material

Service Temperature Limits

Graphite & Oil

Carbon & Low  Alloy Steel

-46 to 400 C

Molybdenum-disulphide and graphite base. (e.g. Fel-Pro Moly Paste, Jet Lube 550 Anti seize compound Copper & Graphite Base. (e.g. Fel-Pro C5-A, Jet Lube Kopr-Kote)

Carbon & Low  Alloy Steel

o

o

-46 to 400 C

o

Carbon & Low  Alloy Steel

-46 to 540 C

Copper Base (e.g. JetLube SS-30)

Stainless Steel

-196 to 870 C

Nickel Base (e.g. Fel-Pro Nickel anti-seize, Jet Lube Nickel)

Stainless Steel

317L Stainless Steel

Maroon

321 Stainless Steel

Turquoise

347 Stainless Steel

Blue

Monel

Orange

Nickel

Red

Titanium

Purple

20Cb Alloy 20

Black

Inconel 600

Gold

Hastelloy B

Brown

Hastelloy C

Beige

White Incoloy 800 Non Metallic Gaskets Material Stripe Colour Gray Flexible Graphite

o

o

-196 to 870 C

PTFE

White

Ceramic

Light Green

Verdicarb (Mica Graphite)

Pink

52

53

Pre-Test Checklist

Pre-Test Checklist

• Before pressure testing the piping inspector shall carry out a “Pre-Test Line Check”. •  The following checklist provides guidance on items to be verified.

No

Check Item

3.0

Supports Guides & Shoes

3.1

 Are the supports the correct type as shown on the drawing? For bolted supports are the nuts/bolts tightened?

No

Check Item

1.0

Weld Joints Butts & Fillets

1.1

Are all welds on the line shown on the isometric?

3.2

 Are all supports, guides welded as shown on the support drawings?

1.2

 Are the weld profiles acceptable and free from unacceptable visible defects?

3.3

 Are the supports in the correct position as per the drawing?

1.3

Has all slag spatter been removed from the joint?

1.4

Are there any arc strikes visible?

3.4

 Are all anchors and stops in position as shown on the isometric?

2.0

Socket Welds

2.1

Are socket welds free from paint and primer?

3.5

Where U bolt is used as a guide does it have two nuts on either end?

2.2

Is the weld free form unacceptable visible defects?

3.6

Is there a gap of 2mm between the U bolt and the pipe?

2.3

Is the weld profile symmetrical extending to the edge of the fitting and an equal distance up the pipe?

3.7

Is there a stainless steel shim between stainless pipes and carbon steel U bolts?

3.8

Check the tag number of spring supports.

3.9

 Are any additional temporary supports required for the hydro test?

54

55

Pre-Test Checklist NO

Check Item

4.0

Screwed Fittings

Pre-Test Checklist

NO

Check Item

4.1

Check thread engagement; are there no more than 4 threads showing?

6.4

Is the line required to slope on either the Isometric or P&ID? If so does it comply?

4.2

Is there any damage to visible threads?

6.5

Do the line and its components comply with the Isometric and P&ID?

6.6

Are horizontal lines level as required

4.3 4.4 5.0 5.1

Is there any damage to the fitting caused by wrenches? Has the correct sealant for the service class been applied to the threads? Weep Holes

For horizontal trunions is there a weep hole in the 6 o’ clock position close to the run pipe?

5.3

For reinforcing pad is there a weep hole in place. Is it threaded?

6.0

Piping

6.1

Does the high point in the system have a vent?

6.3

Does the low point in the system have a valved drain? Does the isometric show all the welds on a line? Are there any extra or have any been deleted?

 Are vertical lines plum?

6.8

Is there a drain with valve and plug installed either side of control valves?

6.9

Where there are two adjacent trunion supports e.g. around a control valve has one been left free to move and the other fixed with anchors and stops.

For vertical trunions is there a weep hole 25mm from the bottom?

5.2

6.2

6.7

6.10 6.11

Have all instrument lines been broken and blinded for the test?  Are the blinds the correct material and rating? Are they identified?

6.12

Does the blinding conform to the limits on the P&ID.?

6.13

Piping over walkways, has the minimum clearance been complied with?

6.14

Check that piping does not in any way load or stress connecting equipment.

56

57

Pre-Test Checklist

Pre-Test Checklist

No

Check Item

7.0

Flanges

7.1

Are they the correct rating?

7.2

Is there any unacceptable flange alignment.

7.3

Do the bolt holes straddle the centre line of the pipe?

7.4

For slip on flanges is the visible weld acceptable.

7.5

For orifice flanges have any unused tapping points been plugged and seal welded.

8.0

Gaskets

8.1

Are they the correct rating as per the Isometric?

11.0

Valves To Be Removed For Testing

8.2

Are they correctly colour coded?

11.1

Flow Control Valves

Temporary gaskets to be recorded on the Punch List as a “B” item. Bolts  Are all bolts in place the correct size and material as per the Isometric? Has the correct lubricant been applied to the threads? Carbon steel Molycote. Stainless steel Nickel Base. Is there between one and three threads protruding through each nut? For bolts that have been tensioned is there a tag in place?

11.2

Shut Down Valves

11.3

Emergency Shut Down Valves

11.4

Ball Valves

11.5

Pressure Relief Valves

11.6

Blow Down Valves

11.7

Anti surge Valves

11.8

Soft Seated Valves 22” dia and below

8.3 9.0 9.1 9.2 9.3 9.4

58

No

Check Item

10.0

Valves

10.1

Is the orientation/flow as indicated on the P&ID?

10.2 10.3 10.4

Has check valve been rotated for the test? If so note a s a “B” item on the punch list. Have check valve flappers been wedged open or removed for the test? If so note as a “B” item on the punch list.  Are small bore valves (3” dia and below) near vibration points braced in two directions?

59

Pressure Testing

Flushing

The following items must be checked by the piping inspector before the pressure testing:

• Flushing of all lines shall be done prior to hydro testing. •  Flushing shall be done by fresh potable water or dry compressed air, where ever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign material. •  Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure. For air flushing, the line / system shall be pressurized by compressed air at the required pressure which shall be 50 psi maximum. The pressure shall then be released by quick opening of a valve, already in line or installed temporarily for this purpose. The procedure shall be repeated as many times as required till the inside of the pipe is fully cleaned. • In line instruments like control valves, or ifice plates, rotameters, safety valves and other instruments like thermowells which may interefere with flushing shall not be included in the flushing circuit. • The screens / meshes shall be removed from all permanent strainers before flushing. Screens / meshes shall be reinstalled after flushing but before testing. • In case an equipment such as Column, Vessel, Exchanger etc form part of piping circuit during flushing, this shall be done with the approval of the QC in-charge. However, equipments thus included in the circuit shall be completely drained and dried with compressed air after flushing is complete.

1- Test pack to be ready for review before planning for test. 2- Punching to be done and A punches to be cleared before test. 3- Calibration of gauges, dead weight tester, safety valves to be confirmed wherever applicable. 4- Water certificate to be checked wherever applicable de mineralized water certificate to be checked for testing of DSS, Duplex, CRA & wherever applicable. 5- Safety precautions to be followed before proceeding for test 6- Pressure gauges used should have a range between 1 ½ times & 4 times the test pressure. 7- Two pressure gauges to be used, one at the maximum height & the other near the pressure pump. 8- Remove air during the process of pressurizing (There should be no air entrapment in the system being tested). 9- Holding time (min) to be such as physically verify the  joint/component for any sign of leakage. 10- After the test, release the pressure from the top gauge slowly and check the fall in gauge pressure.

60

61

Flushing

Hydro Testing Test Pressure

• Precautions shall be taken to prevent entry of water / foreign matter into equipments, electric motors, instruments, electrical installations etc in the vicinity of the lines being flushed.

Hydro Testing Test Media • In general all pressure tests shall be hydrostatic using iron free water, which is clean and free of silt. Maximum chlorine content of water for hydrostatic testing for SS /DSS piping shall be 15-20 PPM. •  Air shall be used for testing only if water would cause corrosion of the system or overloading of supports etc. • Where air/water test are undesirable, substitute fluids such as gas oil, kerosene, methanol etc shall be used as the testing media, with due considerations to the hazards involved. These test fluids shall be specified in the line list with the contractor. Test Pressure • Pressurization shall be achieved gradually from the bottom associated with venting from the top. 62

• The hydrostatic/pneumatic test pressure shall be indicated in the line list. •  The selection of the piping system for one individual test shall be based on the following: 1-The test pressure required as per line list 2-Maximum allowable pressure for the material of construction of piping •  Depending upon the above requirements and based on construction progress, the maximum length of piping shall be included in each test. Test Pressure Gauge •  All the gauges used for field testing shall have suitable range so that the test pressure of the various systems falls in 40% to 80% of the gauge scale range. Gauges shall have valid calibration in good working condition. • Prior to the start of any test or periodically during the field test program, all test gauges shall be calibrated using a standard dead weight gauge tester or other suitable approved test apparatus. Any gauge showing an incorrect zero reading or error of more than 2 percent of full scale shall be discarded. The accuracy of the master gauge used for calibration shall also be verified. 63

Pressure Testing

Pressure Testing

Testing procedure guidelines • All vents and other connections used as vents shall be left open while filling the line with test fluid for complete removal of air. In all lines for pressurizing and de-pressurizing the system, temporary isolating valves shall be provided if valved vents, drains do not exist in the system. • Pressure shall be applied only after the line / system is ready and approved by the QC-incharge. • Pressure shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system as soon as the test pressure is reached and stabilized in the system. • A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the required pressure. • The pump shall be attended constantly during the test by an authorized person. The pump shall be isolated from the system whenever the pump is left unattended. • Test pressure shall be maintained for a sufficient length of time to permit thorough inspection for all joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be re-tested to the specified pressure after repair. Minimum test period shall be maintained as per the applicable specification. • Spring hanger supports shall be in the locked position during hydrotests. 64

• The pump and the piping system to be tested are to be provided with separate pressure indicating test gauges. These gauges are to be checked by standard test gauge before each pressure test. • Care shall be taken to avoid increase in the pressure due to temperature variation during the test. • After hydrotest has been completed, the pressure shall be released in a manner and at a rate so as not to endanger personnel or damage equipments. • All vents and drains shall be opened before the system is to be drained and shall remain open until all draining is complete, so as to prevent formation of vacuum in the system. After draining, lines / system shall be dried by air. • After testing is competed the test blinds shall be removed and equipment/piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop / circuit including equipments (except rotary equipments). •  Pressure test shall be considered complete only after approved by the QC in-charge. Defects, if any, noticed during the testing shall be rectified immediately and retesting the system /line shall be done by the contractor. •  Usage of manifolds with adequately fitted and tested pressure relief valves shall be used during the hydrotests for safe operations. 65

Safety in Piping (Slings & Shackles)

Safety in Piping (Slings & Shackles)

Sling Inspection Instructions: Slings are generally used with other material handling equipment for the movement of material by hoisting. Slings are made of alloy steel chain, wire rope, metal mesh, natural or synthetic fibre, or fibre woven into web. The inspector must determine, using the instructions below, when the sling shall be replaced. 1- General: •  Each day before use, slings and all fastening and attachments must be inspected for damage or defects. Damaged slings shall be removed from service. •  Additionally monthly inspections shall be performed and documented by a competent person. • Wire rope slings shall not be used if, in any length of eight (8) diameters, the total number of visible broken wires exceeds 10% of total number of wires, or if the rope shows other signs of excessive wear, corrosion, or defect. •  In case of alloy steel chain slings, the inspection shall include a thorough check for wear, defective weld or deterioration are present, the chain must be immediately removed from use.

66

2- Wire Rope: Wire rope slings shall be removed from service when the following conditions are present: • For strand laid and single part slings, ten randomly distributed broken wires in one rope lay or five broken wires in one rope lay or five broken wires in one strand in one rope lay. • Severe localized abrasions or scraping. • Kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure • Evidence of heat damage • End attachments that are cracked, deformed, or worn to the extent that the strength of the sling is substantially affected. • Hooks that are cracked, spreading (more than 15%), and /or missing throat latches. • Severe corrosion of the rope or end attachment. 3- Chain Slings: Conduct a visual inspection to check for stretched, bent, or worn or gouged links. Multi-leg slings can be hung on hook to check legs are the same length. All chain slings must have a tag with the grade, size, capacity & manufacturer stamp on it.

67

Safety in Piping (Slings & Shackles)

Safety in Piping (Slings & Shackles)

4- Synthetic web slings:

5- Metal mesh slings:

Inspect the label. The following information shall be legible on the label:

• A broken weld or broken brazed joint along the sling edge.

• • • •

• Reduction in wire diameter of 25% due to abrasion or 15% due to corrosion. • Lack of flexibility.

The manufacturer’s name or identification trade mark, The rated capacity for the type of hitch, and The type of synthetic material. The sling must be removed from service when the following conditions exist: • Acid or caustic marks are present. • Melting or charring of any part of the sling. • Holes, cuts, tears, or excessive fraying or snags. • Broken or worn stitching in load bearing splices. • Knots in any part of the sling. •  Excessive pitting or corrosion or cracked, distributed or broken fittings. • Other visible damage that causes doubt as to the strength of the sling. 5- Metal mesh slings: Manufacturer’s tag with their trade mark or name must be present. The rated load in vertical basket and choker hitch configuration must be listed. Metal mesh slings shall be removed from service when the following conditions exist: 68

Safety in Piping (Slings & Shackles)

• A broken wire in any part of the mesh.

• Distortion of either end fitting such that the width of the eye opening is decreased by more than 10%. •  Distortion of choker fittings so the depth of the slot is increased by more than 10%. •  A 15% reduction of the original cross-sectional area of metal around the hook opening or end fitting. 6- Rope clips: • Wire rope clips are used to attach fixtures to wire rope and to make guy lines. To attach rope clips: • Turn back the required amount of wire rope from thimble or loop. Apply the first clip one base width from the dead end of the wire rope. Apply the U-bolt over the dead end of wire rope; the live end rests in the saddle. Tighten the nuts evenly, alternate from one nut to the other until reaching the recommended torque.

69

Safety in Piping (Slings & Shackles) SHACKLES Weldless Construction Forged Alloy Steel Stock Inside Width at Max. Safe Working Load Single diameter(Inch) Pin(Inch) Vertical(pound)

6- Rope clips: When two clips are required, apply the second clip as near to the loop or thimble as possible. Tighten the nuts evenly, alternating until reaching the recommended torque. When more than two clips are required, apply the second clip as near the loop or thimble or loop as possible, turn the nuts on second clip firmly, but do not tighten. Proceed to step three. When three or more clips are required, space the additional clips equally between the first two, take up the rope slack, tighten the nuts on each U-bolt evenly, alternating from one nut to the other until reaching the recommended torque. IMPORTANT: Apply a load test to the assembly prior to use. This load shall be equal or greater than the intended load. Next check and retighten the nuts evenly to the recommended torque. Inspect the assembly periodically for wear, abuse and general adequacy. Never use wire rope clips to make slings / chokers.

3/16 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 3/4 2 2 1/2 3

3/8 15/32 17/32 21/32 23/32 13/16 1 1/16 1 1/4 1 7/16 1 11/16 1 13/16 2 1/32 2 1/4 2 3/8 2 7/8 3 1/4 4 1/8 5

665 1000 1500 2000 3000 4000 6500 9500 13000 17000 19000 24000 27000 34000 50000 70000 100000 150000

Never replace a shackle pin with a bolt

Check for wear Check for wear and straightness

7- Record Retention:

Check that pin is always seated

 All inspection logs must be retained on t he project site for the duration of the project.

70

Check that shackle is not opening

The load will bend the bolt

71

Safety in Piping (Slings & Shackles)

Safety in Piping (Slings & Shackles)

Type 1

Type 2

72

73

Safety in Piping (Slings & Shackles)

Permissible Reductions In Pipe Wall Thickness ASTM Pipes  A106

 A reduction of up to 12.5% of the nominal specified wall thickness

 A333

 A reduction of up to 12.5% of the nominal specified wall thickness

 A335

 A reduction of up to 12.5% of the nominal specified wall thickness

 A671

 A reduction of up to 0.25mm of the nominal specified wall thickness

 A672

 A reduction of up to 0.30mm of the nominal specified wall thickness

 A312

 A reduction of up to 12.5 % of the nominal specified wall thickness

API 5L Line Pipe Grade X42 and higher (NPS 2 7/8” and below) Grade X42 and higher (NPS >2 7/8 but < 20”)

Type 3

Type 4

74

Type 5

 A reduction of up to 12.5% of the nominal specified wall thickness  A reduction of up to 12.5% of the nominal specified wall thickness

Welded Pipe

NPS 20” and above:  A reduction of up to 8% of the nominal specified wall thickness

Seamless Pipe (NPS 20” and above)

 A reduction of up to 10% of the nominal specified wall thickness

75

Blind Flange Dimension Chart

Line Size inches

Line Size inches

Flange Rating 150#

300#

600#

Flange Rating 150#

300#

600#

O.D.

Thkns

O.D.

Thkns

O.D.

Thkns

14

17 5/8

¾

19

1¼

19 ¼

1¾

16

20 1/8

7/8

21 1/8

1½

22 1/8

2

18

21 ½

1

23 3/8

1 5/8

24

2 1/8

20

23 ¾

1 1/8

25 5/8

1¾

26 ¾

2½

22

25 7/8

1¼

27 5/8

1 7/8

28 ¾

2¾

24

28 1/8

1 3/8

30 3/8

2

31

2 7/8

26

30 3/8

1½

32 ¾

2

34

3 1/8

28

32 5/8

1 5/8

35 ¼

2 1/8

35 7/8

3 3/8

30

34 5/8

1¾

37 3/8

2 3/8

38 1/8

3 5/8

32

36 7/8

1¾

39 ½

2½

40 1/8

3¾

34

38 7/8

1 7/8

41 ½

2 5/8

42 1/8

4 1/8

36

41 1/8

2

43 7/8

2¾

44 3/8

4¼

38

43 5/8

2 1/8

41 3/8

3

43 3/8

4½

40

45 5/8

2¼

43 ¾

3 1/8

45 7/8

4¾

42

47 7/8

2 3/8

45 ¾

3¼

47 7/8

5

O.D

Thkns

O.D

Thkns

O.D

Thkns

1 3/4

5/16

2

5/16

2

5/16

¾

2 1/8

5/16

2½

5/16

2½

5/16

1

2½

5/16

2¾

5/16

2¾

5/16

1¼

2 7/8

5/16

3 1/8

5/16

3 1/8

3/8

1½

3¼

5/16

3 5/8

5/16

3 5/8

3/8

2

4

5/16

4¼

3/8

4¼

3/8

2½

4¾

5/16

5

3/8

5

½

3

5¼

5/16

5¾

3/8

5¾

½

3½

6¼

3/8

6 3/8

3/8

6¼

5/8

4

6¾

3/8

7

½

7½

5/8

5

7 5/8

3/8

8 3/8

5/8

9 3/8

3/4

6

8 5/8

½

9¾

5/8

10 3/8

7/8

8

10 7/8

½

12

7/8

12 ½

1 1/8

10

13 ¼

5/8

14 1/8

1

15 5/8

1 3/8

44

50 1/8

2½

47 7/8

3 3/8

49 7/8

5¼

12

16

¾

16 ½

1 1/8

17 5/8

1 5/8

46

52 1/8

2½

50

3 5/8

51 7/8

5½

48

54 3/8

2 5/8

52

3¾

54 5/8

5¾

½

76

Line Size inches

77

Flange Rating 900#

1500#

Line Size inches

2500#

Flange Rating 900#

1500#

2500#

O.D.

Thkns

O.D.

Thkns

16

22 ½

2 3/8

25 1/8

3

3/8

18

25

2 5/8

27 5/8

3 3/8

3¼

3/8

20

27 3/8

2 7/8

29 5/8

3¾

3/8

4

½

22

3¾

½

4½

5/8

24

32 7/8

3½

35 3/8

4 3/8

½

5½

½

5 5/8

5/8

26

34 5/8

3¾

6 3/8

½

6 3/8

5/8

6½

3/4

28

37 1/8

4 1/8

6 1/2

5/8

6¾

3/4

7 5/8

7/8

30

39 5/8

4 3/8

32

42 1/8

4¾

O.D.

Thkns

O.D.

Thkns

O.D.

Thkns

½

2 3/8

5/16

2 3/8

5/16

2 5/8

3/8

¾

2 5/8

5/16

2 5/8

3/8

2 7/8

1

3

5/16

3

3/8

1¼

3 3/8

3/8

3 3/8

1½

3 3/4

3/8

2

5½

2½ 3 3½ 4

8

3/4

8 1/8

7/8

9 1/8

1 1/8

34

44 5/8

5

5

9 5/8

7/8

9 7/8

1 1/8

10 7/8

1 3/8

36

47 1/8

5¼

6

11

1

11

1 3/8

12 3/8

1 5/8

38

47 1/8

5½

8

14

1 3/8

13 ¾

1 5/8

15 1/8

2 1/8

40

49 1/8

5 7/8

10

17

1 5/8

17

2

18 5/8

2 5/8

42

51 1/8

6 1/8

12

19

1 7/8

20 3/8

2 3/8

21 1/2

3 1/8

44

53 ¾

6 3/8

14

20

2 1/8

22 5/8

2 5/8

46

56 3/8

6¾

48

58 3/8

7

78

79

O.D.

Thkns

Piping Schedule Wall Thickness Chart Nominal Pipe Size in 1/8 1/4

OD (mm)

Sch 5

Sch 10

10.29 13.7

0.89 1.24

3/8 1/2

17.1 21.3

3/4 1

Piping Schedule Wall Thickness Chart

XS

Sch 80

Sch 160

XXS

1.73 2.24

2.41 3.02

2.41 3.02

2.31 2.77

2.31 2.77

3.20 3.73

3.20 3.73

4.75

7.46

2.11 2.77

2.87 3.38

2.87 3.38

3.91 4.55

3.91 4.55

5.53 6.35

7.82 9.09

1.65 1.65

2.77 2.77

3.56 3.68

3.56 3.68

4.48 5.08

4.85 5.08

6.35 7.13

9.70 10.16

60.3 73

1.65 2.11

2.77 3.05

3.91 5.16

3.91 5.16

5.54 7.01

5.54 7.01

8.71 9.53

11.07 14.02

3 3 1/2

88.9 101.6

2.11 2.11

3.05 3.05

5.49 5.74

5.49 5.74

7.62 8.08

7.62 8.08

11.10

4 5

114.3 141.3

2.11 2.77

3.05 3.40

6.02 6.55

6.02 6.55

8.56 9.53

8.56 9.53

6 8

168.3 219.1

2.77 2.77

3.40 3.76

7.11 8.18

7.11 8.18

10.97 12.70

10.97 12.70

Sch 20

Std

Sch 40

1.24 1.65

1.73 2.24

1.24 1.65

1.65 2.11

26.7 33.4

1.65 1.65

1 1/4 1 1/2

42.2 48.3

2 2 1/2

6.35

Sch 30

7.04

Sch 60

10.31

Sch 100

Sch 120

Sch 140

11.10 12.70 15.06

14.27 18.23

13.48 15.87 20.62

18.23 23.01

80

81

Piping Schedule Wall Thickness Chart

Piping Schedule Wall Thickness Chart

Nominal Pipe Size in 10 12

OD (mm)

Sch 5

Sch 10

Sch 20

Sch 30

Std

Sch 40

Sch 60

XS

Sch 80

Sch 100

Sch 120

Sch 140

Sch 160

273.1 323.9

3.4 4.19

3.40 4.19

6.35 6.36

7.79 8.38

9.27 9.53

9.27 10.31

12.70 14.27

12.70 12.70

15.06 17.45

18.23 21.41

21.41 25.40

25.40 28.57

28.57 33.32

14 16

355.6 406.4

6.35 6.35

7.92 7.92

9.53 9.53

9.53 9.53

11.12 12.70

15.06 16.66

12.70 12.70

19.05 21.41

23.80 26.19

27.76 30.93

31.75 36.52

35.71 40.46

18 20

457.2 508

6.35 6.35

7.92 9.53

11.10 12.70

9.53 9.53

14.27 15.06

19.05 20.62

12.70 12.70

23.80 26.19

29.36 32.51

34.92 38.10

39.67 44.45

45.24 49.99

22 24

558.8 609.6

6.35 6.35

9.53

14.27

9.53 9.53

17.45

24.59

12.70 12.70

30.94

38.89

46.02

52.37

59.51

26 28

660.4 711

7.92

12.7

15.88

9.53 9.53

30 32

762 813

12.7

15.88

9.53 9.53

34 36

863.6 914

9.53 9.53

12.70 12.70

38

965

9.53

12.70

82

12.70 12.70 17.48

12.70 12.70

83

XXS

Metric / Imperial Conversion Factor

Quantity Type

Imperia l Units

Mass

Pounds (lb) Short Ton (2000 lbs) Long Ton (2240 lbs)

Linear Measure

Temperat ure Pressure

Metric Units

Kilogram (kg)

Metric / Imperial Conversion Factor

Multiply Value by the following factors to convert from: Imperial to Metric to Metric Imperial 0.454

Quantity Type

Square feet

2.20  Area

Metric Ton

0.907

Imperial Units

1.10

Square inch  Acres Cubic inches

Metric Ton

1.02

0.984

Inches

Millimetres

25.4

0.0391

Feet

Millimetres

305

0.00328

Feet

Meters

0.305

3.28

Yard

Meter

0.914

1.09

Miles Fahrenh eit

Kilometre

1.61

0.621

Celsius

5.9 x ( F-32)

o

9.5 x( C+32)

Pounds/ Square Inch

Kilopascal

6.89

0.145

Megapascal

0.00689

145

84

o

Volume

Cubic Feet

Metric Units Square meter Square millimetre Hectares Cubic centimetres Cubic meters

Multiply Value by the following factors to convert from Imperial Metric to to Metric Imperial 0.0929

10.8

645

0.00155

0.406

2.47

16.4

0.061

0.0283

35.3

Gallons (US)

Litre

3.79

0.264

Density

Pounds/cubi c inch

Kilogram/cu bic metre

27700

0.0000361

Energy

Foot pound

Joule

1.36

0.738

Pounds/foot

Kilo/meter

1.49

0.672

Tons/Mile

Metric Ton/Meter

0.564

1.77

Mass/Uni t length

85

NOTES

NOTES

86

87

NOTES

NOTES

88

89

90

91

Contents Material receiving inspection ………………………………3 Material receiving inspection Document verification Cutting Piping spool fabrication Welding general Release and storage of fabricated spools Piping erection Bolting of flanged joints Flange identification Flange face imperfections Spacer & Blind Standard  ASME 16.5 flanges Bolt tightening sequence Groupings for bolt tensioning Nut / bolt material specification Bolts with corresponding wrench size Pipe flange misalignment tolerances Mill tolerances for pipe & wrought fittings Lubricants for nuts / bolts Colour coding for gaskets Pre-test checklist Pressure testing Safety in Piping (Slings & Shackles) Permissible reductions in pipe wall thickness Blind flange dimension chart Piping schedule wall thickness chart Metric / imperial conversion factors

3 4 4 5 9 12 14 16 18 19 23 32 38 44 45 46 47 50 52 53 54 60 66 74 75 79 83