Contents

Material receiving inspection 3

Document verification 4
Petrofac E & C Cutting 4
Piping spool fabrication 5
Welding general 9
Release and storage of fabricated spools 12
Piping erection 14
PIPING INSPECTION HANDBOOK Bolting of flanged joints 16
Flange identification 18
Flange face imperfections 19
Spacer & Blind Standard 23
ASME 16.5 flanges 32
Bolt tightening sequence 38
Groupings for bolt tensioning 44
Nut / bolt material specification 45
Bolts with corresponding wrench size 46
Pipe flange misalignment tolerances 47
Mill tolerances for pipe & wrought fittings 50
Lubricants for nuts / bolts 52
Colour coding for gaskets 53
Pre-test checklist 54
Pressure testing 60
Safety in Piping (Slings & Shackles) 66
Permissible reductions in pipe wall thickness 74
Blind flange dimension chart 75
Piping schedule wall thickness chart 79
Quality Metric / imperial conversion factors 83
Department

Introduction Material Receiving Inspection

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: …………………………………………….
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 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.

2 3
 Document Verification
Prior to the start of fabrication the following documents should
be approved for construction by Petrofac and the client :
- 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 :
• 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.
4 5
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 carried out prior to welding.
• CRA’s should be fabricated in a dedicated separate facility
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.
During fabrication the following should be checked by the
inspector :
• Check revision of isometric drawing.
• Check material 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 numbers are identified as per the Isometric and
any additional welds are identified and added to the
Isometric.
6 7
Cutting
Prior to cutting straight pipes, the following checks shall be
made:
• Correct material as per Isometric Bill of Materials
• Dimensions as per Isometric, length, diameter
• Heat 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 :
• 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
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.
Piping Spool Fabrication
• Reinforcing pads around branch connections shall be
pneumatically tested for any leaks as required by the project
specifications.
• Root penetration of welds on orifice flanges shall be ground
flush and smooth.
• Special Requirements for Stainless Steel, Nickel & Non-
Ferrous Alloys
1. It shall be ensured that all the supervisors and 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 be
adequately clad or otherwise covered with stainless steel
material to prevent direct contact with the pipe or fitting.
 Piping Spool Fabrication Welding General

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.
8. 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.
9. Only non-metallic slings shall be used for lifting and
handling stainless steel and non-ferrous materials.
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.
• 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.

8 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
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.
• 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
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.
14
Fabricated Spool Release, Storage & Preservation
• 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.
13
Piping Erection
• 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
15
 Bolting of Flanged Joints Bolting of Flanged Joints

Correct procedure for bolting of flange joints is extremely

Checklist for Correct Bolt Tightening
important to ensure that there are no leaks during pressure
testing and operation of process pipework.
Torque Tightening:
Checklist for Correct Bolt Tightening • Thread engagement between bolts and nuts.
st
• Torque value 1 pass is correct.
Manual Tightening; nd
• Torque value 2 pass is correct.
rd
• Correct tools wrenches available. • Torque value 3 pass is correct.
• Check flange faces for damage and cleanliness. • Torque Tightening Report
• Check flange face alignment is within tolerance.
• Gasket is correct type as per BOM and is color coded. Tensioning:
• Tensioning equipment is calibrated
• Correct bolt/nut type as per BOM and no thread damage.
• Check flange faces for damage and cleanliness.
• Lubricant applied to nuts/bolts.
• Check flange face alignment is within tolerance.
• Numbering of bolt holes on flange, correct sequence.
• Gasket is correct type as per ISO BOM and is color coded.
• Thread engagement between bolts and nuts.
• Correct bolt/nut type as per ISO BOM and no thread
• Check tightness & bolt projection
damage
• Thread engagement between bolts and nuts.
Torque Tightening:
• 50% of pressure Group A.
• Torque wrench is calibrated.
• 100% pressure Group A.
• Check flange faces for damage and cleanliness.
• 50% of pressure Group B.
• Check flange face alignment is within tolerance.
• 100% pressure Group B.
• Gasket is correct type as per BOM and is color coded.
• Numbering and grouping of bolt holes on flange, correct
• Correct bolt/nut type as per BOM and no thread damage.
sequence.
• Lubricant applied to nuts/bolts. • Lubricant applied to nuts/bolts.
• Numbering of bolt holes on flange, correct sequence.
16 17

Flange Identification Flange Facing Finish Imperfections

Imperfections in the flange facing finish shall not exceed the

Manufactures Size rating & thickness
Symbol at weld preparation
S A105N 2x1/2 S80150 29E
(CBXB)
dimensions shown in the next table. Adjacent imperfections
Heat No. shall be separated by a distance at least four times the
Or (Test No.) 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
ITALY permitted.

Damage deeper
than serrations
Material Country of Origin UNACCEPTABLE
Damage not
Grade (optional) deeper than
serrations
5 ACCEPTABLE
Colour code
If required
5

18 19
 Flange Facing Finish Imperfections Permissible imperfections in flange facing finish for
raised flange face and large male and female flange
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 Maximum radial Maximum radial
projection of projection of
the acceptance criteria below should be used.
NPS imperfections no imperfections deeper
deeper than the bottom than the bottom of the
Examples of Acceptable and Unacceptable Flange Face of the serrations (mm) serrations (mm)
Imperfections:
½ 3.0 1.5
¾ 3.0 1.5
Damage not deeper than serrations 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

Damage deeper than serrations 4 6.0 3.0

5 6.0 3.0
6 6.0 3.0

20 21

Permissible imperfections in flange facing finish for Spacer & Blind Standard
raised flange face and large male and female flange

Maximum radial Maximum radial

projection of projection of
NPS imperfections no imperfections deeper
deeper than the than the bottom of the
bottom of the serrations
serrations

8 8.0 4.5
10 8.0 4.5
12 8.0 4.5
14 8.0 4.5 O : Outside diameter, B : Inside diameter, t : Thickness
16 10.0 4.5
C : Handle length, W : Handle width, a : Handle Thickness

18 12.0 6.0 Notes:

20 12.0 6.0 1. All dimensions are in mm unless otherwise specified.
24 12.0 6.0 2. The words “Spacer” or “Blind” as applicable, shall be in
26-36 12.7 6.0 bold (min letter height 10mm) on both sides of the handle.
3. A raised face may be specified optionally. The height of the
38-48 14 7.0
raise face shall be in addition to the thickness “t”.
50-60 16 8.0

22 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 O : Outside diameter, B : Inside diameter, t : Thickness
70.
C : Handle length, W : Handle width, a : Handle Thickness
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.
24 25

Spacer & Blind Standard Spacer & Blind Standard

CLASS 150 CLASS 300

NPS NPS
Outside Inside Handle Handle Handle Outside Inside Handle Handle Handle
Thk Thk
Dia Dia Length Width Thk Dia Dia Length Width Thk
6” - - - - - - 6” - - - - - -
8” - - - - - - 8” - - - - - -
10” - - - - - - 10” - - - - - -
12” - - - - - - 12” 419 324 28.4 155 50 20
14” 448 356 19.1 150 50 12 14” 483 356 31.8 155 45 20
16” 511 406 22.4 150 50 16 16” 536 406 31.8 165 50 20
18” 546 457 25.4 150 50 16 18” 594 457 41.1 170 40 24
20” 603 508 28.4 155 50 20 20” 651 508 44.5 170 45 24
24” 714 610 31.8 160 50 20 24” 772 610 50.8 180 50 32
26” 771 660 37 160 50 24 26” 832 660 59 180 45 40
28” 829 711 39 160 50 24 28” 895 711 63 180 50 40
30” 879 762 41 160 50 24 30” 949 762 67 180 50 40
32” 937 813 44 170 50 24 32” 1003 813 71 190 50 50
34” 987 864 46 170 50 32 34” 1054 864 75 190 50 50
36” 1045 914 48 170 50 32 36” 1115 914 79 190 50 50
38” 1108 965 51 170 50 32 38” 1051 965 83 190 50 50
40” 1159 1016 54 170 50 32 40” 1111 1016 87 190 50 50
42” 1216 1067 56 170 50 32 42” 1162 1067 91 190 50 50
44” 1273 1118 59 175 50 40 44” 1216 1118 96 190 50 50
46” 1324 1168 61 175 50 40 46” 1270 1168 100 190 50 50
48” 1381 1219 63 175 50 40 48” 1321 1219 104 190 50 50

26 27
 Spacer & Blind Standard Spacer & Blind Standard

CLASS 600 CLASS 900

NPS NPS
Outside Inside Handle Handle Handle Outside Inside Handle Handle Handle
Thk Thk
Dia Dia Length Width Thk Dia Dia Length Width Thk
6” - - - - - - 6” - - - - - -
8” - - - - - - 8” 356 212 35.1 165 50 24
10” 397 265 35.1 165 40 24 10” 432 265 41.1 165 50 24
12” 454 315 41.1 165 38 24 12” 495 315 47.8 165 40 32
14” 489 346 44.5 165 40 24 14” 518 346 53.8 170 40 32
16” 562 397 50.8 170 45 32 16” 572 397 60.5 175 45 40
18” 610 448 53.8 175 50 32 18” 635 448 66.5 185 50 40
20” 679 497 63.5 175 45 40 20” 696 497 73.2 190 50 50
24” 787 597 73.2 185 50 50 24” 835 597 88.9 210 50 50
26” 864 644 82 190 45 50 26” 879 644 100 220 50 50
28” 911 695 88 190 50 50 28” 943 695 107 220 50 50
30” 968 746 94 190 50 50 30” 1007 746 115 220 50 50
32” 1019 797 100 190 50 50 32” 1070 797 122 240 50 50
34” 1070 848 105 190 50 50 34” 1134 848 129 240 50 50
36” 1127 898 112 190 50 50 36” 1197 898 137 240 50 50
38” 1101 949 116 195 50 50 38” 1197 949 148 260 50 50
40” 1152 1000 122 195 50 50 40” 1248 1000 157 260 50 50
42” 1216 1050 129 195 50 50 42” 1299 1050 164 260 50 50
44” 1267 1101 136 195 50 50 44” 1365 1101 172 280 50 50
46” 1324 1151 141 195 50 50 46” 1432 1151 181 280 50 50
48” 1387 1202 148 195 50 50 48” 1483 1202 188 280 50 50

29
28

Spacer & Blind Standard Spacer & Blind Standard

CLASS 1500 CLASS 2500

NPS NPS
Outside Inside Handle Handle Handle Outside Inside Handle Handle Handle
Thk Thk
Dia Dia Length Width Thk Dia Dia Length Width Thk
6” - - - - - - 6” 314 154 41.1 190 50 24
8” 349 203 41.1 175 50 24 8” 384 198 53.8 190 50 32
10” 432 255 50.8 185 50 32 10” 473 248 66.5 210 50 40
12” 518 303 60.5 185 50 40 12” 546 289 79.2 215 50 50
14” 575 333 66.5 195 50 40 14” - - - - - -
16” 638 381 76.2 200 50 50 16” - - - - - -
18” 702 429 85.9 215 50 50 18” - - - - - -
20” 752 478 95.3 225 50 50 20” - - - - - -
24” 899 575 111.3 245 50 50 24” - - - - - -
26” - - - - - - 26” - - - - - -
28” - - - - - - 28” - - - - - -
30” - - - - - - 30” - - - - - -
32” - - - - - - 32” - - - - - -
34” - - - - - - 34” - - - - - -
36” - - - - - - 36” - - - - - -
38” - - - - - - 38” - - - - - -
40” - - - - - - 40” - - - - - -
42” - - - - - - 42” - - - - - -
44” - - - - - - 44” - - - - - -
46” - - - - - - 46” - - - - - -
48” - - - - - - 48” - - - - - -

30 31
ASME 16.5 Class 150 Flange Number & Dia of Bolts ASME 16.5 Class 300 Flange Number & Dia of Bolts

NPS Diameter of Bolts No. of Bolts NPS Diameter of Bolts No. of Bolts
Inches mm Inches mm Inches mm Inches mm
½ 12.7 1/2 12.7 4 ½ 12.7 1/2 12.7 4
¾ 19.05 5/8 15.88 4
¾ 19.05 1/2 12.7 4
1 25.4 5/8 15.88 4
1 25.4 1/2 12.7 4
1¼ 31.75 5/8 15.88 4
1¼ 31.75 1/2 12.7 4 1½ 38.10 3/4 19.07 4
1½ 38.10 1/2 12.7 4 2 50.8 5/8 15.88 8
2 50.8 5/8 15.88 4 2½ 63.5 3/4 19.05 8
2½ 63.5 5/8 15.88 4 3 76.2 3/4 19.05 8
3 76.2 5/8 15.88 4 3½ 88.9 3/4 19.05 8
3½ 88.9 5/8 15.88 8 4 101.6 3/4 19.05 8
5 127 3/4 19.05 8
4 101.6 5/8 15.88 8
6 152.4 3/4 19.05 12
5 127 3/4 19.05 8
8 203.2 7/8 22.23 12
6 152.4 3/4 19.05 8 10 254 1 25.40 16
8 203.2 3/4 19.05 8 12 304.8 1 1/8 28.58 16
10 254 7/8 22.23 12 14 355.6 1 1/8 28.58 20
12 304.8 7/8 22.23 12 16 406.4 1¼ 31.75 20
14 355.6 1 25.4 12 18 457.2 1¼ 31.75 24
16 406.4 1 25.4 16 20 508 1 1/4 31.75 24
22 558.8 1 1/2 38.10 24
18 457.2 1 1/8 28.58 16
24 609.6 1 1/2 38.10 24
20 508 1 1/8 28.58 20
22 558.8 1¼ 31.75 20
24 609.6 1¼ 31.75 20

32 33

ASME 16.5 Class 600 Flange Number & Dia of Bolts ASME 16.5 Class 900 Flange Number & Dia of Bolts

NPS Diameter of Bolts No. of Bolts NPS Diameter of Bolts No. of Bolts
Inches mm Inches mm
Inches mm Inches mm
½ 12.7 1/2 12.7 4
½ 12.7 ¾ 19.05 4
¾ 19.05 5/8 15.88 4
1 25.4 5/8 15.88 4 ¾ 19.05 ¾ 19.05 4
1¼ 31.75 5/8 15.88 4 1 25.4 7/8 22.23 4
1½ 38.10 3/4 19.05 4 1¼ 31.75 7/8 22.23 4
2 50.8 5/8 15.88 8 1½ 38.10 1 25.4 4
2½ 63.5 3/4 19.05 8 2 50.8 7/8 22.23 8
3 76.2 3/4 19.05 8 2½ 63.5 1 25.4 8
3½ 88.9 7/8 22.23 8
3 76.2 7/8 22.23 8
4 101.6 7/8 22.23 8
5 127 1 25.40 8 4 101.6 1 1/8 28.58 8
6 152.4 1 25.40 12 5 127 1¼ 31.75 8
8 203.2 1 1/8 28.58 12 6 152.4 1 1/8 28.58 12
10 254 1 1/4 31.75 16 8 203.2 1 3/8 34.93 12
12 304.8 1 1/4 31.75 20 10 254 1 3/8 34.93 16
14 355.6 1 3/8 34.93 20 12 304.8 1 3/8 34.93 20
16 406.4 1 1/2 38.10 20 14 355.6 1½ 38.10 20
18 457.2 1 5/8 41.28 20
16 406.4 1 5/8 41.28 20
20 508 1 5/8 41.28 24
22 558.8 1 3/4 44.45 24 18 457.2 1 7/8 47.63 20
24 609.6 1 7/8 47.63 24 20 508 2 50.80 20
24 609.6 2½ 63.50 20

34 35
ASME 16.5 Class 1500 Flange Number & Dia of Bolts ASME 16.5 Class 2500 Flange Number & Dia of Bolts

NPS Diameter of Bolts No. of Bolts

NPS Diameter of Bolts No. of Bolts
Inches mm Inches mm
Inches mm Inches mm
½ 12.7 ¾ 19.05 4
½ 12.7 3/4 19.05 4
¾ 19.05 ¾ 19.05 4
¾ 19.05 3/4 19.05 4
1 25.4 7/8 22.23 4
1 25.4 7/8 22.23 4
1¼ 31.75 7/8 22.23 4
1¼ 31.75 1 25.40 4
1½ 38.10 1 25.4 4
1½ 38.10 1 1/8 28.58 4
2 50.8 7/8 22.23 8
2 50.8 1 25.40 8
2½ 63.5 1 25.4 8
2½ 63.5 1 1/8 28.58 8
3 76.2 1 1/8 28.58 8
3 76.2 1¼ 31.75 8
4 101.6 1¼ 31.75 8
4 101.6 1½ 38.10 8
5 127 1 1/2 38.10 8
5 127 1 3/4 44.45 8
6 152.4 1 3/8 34.93 12
6 152.4 2 50.80 8
8 203.2 1 5/8 41.28 12
8 203.2 2 50.80 12
10 254 1 7/8 47.63 12
10 254 2 1/2 63.50 12
12 304.8 2 50.80 16
12 304.8 2 3/4 69.85 12
14 355.6 2 1/4 57.15 16
16 406.4 2 1/2 63.50 16
18 457.2 2 3/4 69.85 16
20 508 3 76.20 16
24 609.6 3 1/2 88.90 16

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

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

42 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. Bolts Nuts
• Group A1 and A2 or Group B1 and B2 should be tightened at the
same time when tools are available. A193-B7 A194-2H
No. of bolt
GROUP – A GROUP – B A193-B7M A194-2HM
per flange
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
A193-B8 A194-Gr.7
24 No. 1 to No. 12 No. 13 to No. 24
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
GROUP GROUP GROUP GROUP
A1 A2 B1 B2 A320-L7M A194-8M
No. 1 to No. 9 to No. 19 to No. 29 to
36
No. 8 No. 18 No. 28 No. 36 A320-B8M A194-8MA
No. 1 to No. 9 to No. 21 to No. 33 to
40
No. 8 No. 20 No. 32 No. 40 A453-GR.660 A194-Gr.3
No. 1 to No. 17 to No. 23 to No. 29 to
44
No. 16 No. 22 No. 28 No. 44 A193-B8 Class 2 Heavy Hexagonal Nuts
No. 1 to No. 33 to No. 77 to No. 1 to
92
No. 32 No. 46 No. 76 No. 92

44 45

Bolts with Corresponding Wrench Size Pipe Flange Misalignment Tolerances

Bolt Diameter PFI Standard ES-3:

Wrench Size
Inches Millimetres
½ 12.7 7/8 Maximum Vertical/Horizontal Offset
5/8 15.8 1 1/16
¾ 19.05 1¼
7/8 22.2 1 7/16 2mm for 4” and below
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 3mm for >4”
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
2mm for 4” and below
• Adjustable spanners shall not be used to tighten or loosen 3mm >4”
flange bolts.

46 47
 Pipe Flange Misalignment Tolerances Pipe Flange Misalignment Tolerances

Maximum Face Misalignment 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

O.D.
fitting out of roundness and circumference. If the Size
mm
Roundness Circumference - 0.5% + 0.5%
measurement data is within tolerance as per below table, (in) 1% mm
start fit up work. Difference of inside diameter shall be 20 508 5.1 1595.1 1587.1 1603.1
equally divided around the circumference. 22 559 5.6 1755.3 1746.5 1764
Circumference: +/- 0.5% 24 610 6.1 1915.4 1905.8 1925
Out of roundness: 1% 26 660 6.6 2072.4 2062 2082.8
Diameter: +/- 0.5% 28 711 7.1 2232.5 2221.4 2243.7
30 762 7.7 2392.7 2380.7 2404.6
• In case of mismatch at the weld preparation the bores shall
be matched as shown below. 32 813 8.1 2552.8 2540.1 2565.6
• Additional weld metal to be deposited to compensate for 34 864 8.7 2713 2699.4 2726.5
material removed from the bore for alignment purposes. 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
o
18-30 Taper 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

50 51
 Lubricants for nuts / bolts Colour coding for gaskets

• Make sure bolts are lubricated along their entire length prior • Color Coding Scheme For Gaskets ASME B16.20
to tightening. • Gasket Type Is Specified On Isometric Bill Of Materials.
Spiral Wound Gaskets
Commercial Lubricant Types: Material Outer Ring Colour
304 Stainless Steel Yellow
316L Stainless Steel Green
Service Temperature 317L Stainless Steel Maroon
Lubricant Bolting Material
Limits 321 Stainless Steel Turquoise
347 Stainless Steel Blue
Carbon & Low
Graphite & Oil -46 to 400oC Monel Orange
Alloy Steel
Molybdenum-disulphide Nickel Red
and graphite base. (e.g.
Carbon & Low -46 to 400oC Titanium Purple
Fel-Pro Moly Paste, Jet
Alloy Steel 20Cb Alloy 20 Black
Lube 550 Anti seize
compound Inconel 600 Gold
Copper & Graphite Base. Hastelloy B Brown
Carbon & Low -46 to 540oC
(e.g. Fel-Pro C5-A, Jet
Alloy Steel Hastelloy C Beige
Lube Kopr-Kote)
Incoloy 800 White
Copper Base (e.g. Jet-
Stainless Steel -196 to 870oC Non Metallic Gaskets
Lube SS-30)
Material Stripe Colour
Nickel Base (e.g. Fel-Pro
-196 to 870oC Flexible Graphite Gray
Nickel anti-seize, Jet Stainless Steel
Lube Nickel) 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”. No Check Item
• The following checklist provides guidance on items to be
verified. 3.0 Supports Guides & Shoes
Are the supports the correct type as shown on the
No Check Item 3.1 drawing? For bolted supports are the nuts/bolts
tightened?
1.0 Weld Joints Butts & Fillets
Are all supports, guides welded as shown on the
1.1 Are all welds on the line shown on the isometric? 3.2
support drawings?
Are the weld profiles acceptable and free from
1.2 Are the supports in the correct position as per the
unacceptable visible defects? 3.3
drawing?
1.3 Has all slag spatter been removed from the joint? Are all anchors and stops in position as shown on the
3.4
1.4 Are there any arc strikes visible? isometric?
2.0 Socket Welds Where U bolt is used as a guide does it have two
3.5
2.1 Are socket welds free from paint and primer? nuts on either end?
2.2 Is the weld free form unacceptable visible defects? Is there a gap of 2mm between the U bolt and the
3.6
pipe?
Is the weld profile symmetrical extending to the edge
2.3 Is there a stainless steel shim between stainless
of the fitting and an equal distance up the pipe? 3.7
pipes and carbon steel U bolts?
3.8 Check the tag number of spring supports.
Are any additional temporary supports required for
3.9
the hydro test?

54 55
 Pre-Test Checklist Pre-Test Checklist

NO Check Item NO Check Item

4.0 Screwed Fittings
Is the line required to slope on either the Isometric or
Check thread engagement; are there no more than 4 6.4
4.1 P&ID? If so does it comply?
threads showing?
Do the line and its components comply with the
4.2 Is there any damage to visible threads? 6.5
Isometric and P&ID?
Is there any damage to the fitting caused by
4.3 6.6 Are horizontal lines level as required
wrenches?
Has the correct sealant for the service class been Are vertical lines plum?
4.4 6.7
applied to the threads?
5.0 Weep Holes Is there a drain with valve and plug installed either side
6.8
For vertical trunions is there a weep hole 25mm from of control valves?
5.1 Where there are two adjacent trunion supports e.g.
the bottom?
6.9 around a control valve has one been left free to move
For horizontal trunions is there a weep hole in the 6
5.2 and the other fixed with anchors and stops.
o’ clock position close to the run pipe?
Have all instrument lines been broken and blinded for
For reinforcing pad is there a weep hole in place. Is it 6.10
5.3 the test?
threaded?
Are the blinds the correct material and rating? Are they
6.0 Piping 6.11
identified?
6.1 Does the high point in the system have a vent? 6.12 Does the blinding conform to the limits on the P&ID.?
Does the low point in the system have a valved Piping over walkways, has the minimum clearance been
6.2 6.13
drain? complied with?
Does the isometric show all the welds on a line? Are
6.3 Check that piping does not in any way load or stress
there any extra or have any been deleted? 6.14
connecting equipment.

56 57

Pre-Test Checklist Pre-Test Checklist

No Check Item No Check Item

7.0 Flanges 10.0 Valves
7.1 Are they the correct rating?
10.1 Is the orientation/flow as indicated on the P&ID?
7.2 Is there any unacceptable flange alignment.
Has check valve been rotated for the test? If so note as
10.2
7.3 Do the bolt holes straddle the centre line of the pipe? a “B” item on the punch list.
7.4 For slip on flanges is the visible weld acceptable. Have check valve flappers been wedged open or
10.3 removed for the test? If so note as a “B” item on the
For orifice flanges have any unused tapping points been punch list.
7.5
plugged and seal welded. Are small bore valves (3” dia and below) near vibration
8.0 Gaskets 10.4
points braced in two directions?
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 11.2 Shut Down Valves
8.3
“B” item.
11.3 Emergency Shut Down Valves
9.0 Bolts
Are all bolts in place the correct size and material as per 11.4 Ball Valves
9.1
the Isometric? 11.5 Pressure Relief Valves
Has the correct lubricant been applied to the threads?
9.2 Carbon steel Molycote. 11.6 Blow Down Valves
Stainless steel Nickel Base. 11.7 Anti surge Valves
Is there between one and three threads protruding
9.3 11.8 Soft Seated Valves 22” dia and below
through each nut?
9.4 For bolts that have been tensioned is there a tag in place?

58 59
 Pressure Testing
The following items must be checked by the piping inspector
before the pressure testing:
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
Flushing
• 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
Flushing
• 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, orifice 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 re-
installed 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.
61
Hydro Testing
Test Pressure
• 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
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
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
Pressure Testing
• 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 re-
testing 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)
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:
• 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
• A broken weld or broken brazed joint along the sling edge.
• A broken wire in any part of the mesh.
• Reduction in wire diameter of 25% due to abrasion or 15%
due to corrosion.
• Lack of flexibility.
• 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) Safety in Piping (Slings & Shackles)
SHACKLES
Weldless Construction Forged Alloy Steel
6- Rope clips:
Stock Inside Width at Max. Safe Working Load Single
diameter(Inch) Pin(Inch) Vertical(pound)
When two clips are required, apply the second clip as near to 3/16 3/8 665
the loop or thimble as possible. Tighten the nuts evenly, 1/4 15/32 1000
alternating until reaching the recommended torque. When 5/16 17/32 1500
3/8 21/32 2000
more than two clips are required, apply the second clip as 7/16 23/32 3000
near the loop or thimble or loop as possible, turn the nuts on 1/2 13/16 4000
second clip firmly, but do not tighten. Proceed to step three. 5/8 1 1/16 6500
When three or more clips are required, space the additional 3/4 1 1/4 9500
clips equally between the first two, take up the rope slack, 7/8 1 7/16 13000
1 1 11/16 17000
tighten the nuts on each U-bolt evenly, alternating from one
1 1/8 1 13/16 19000
nut to the other until reaching the recommended torque. 1 1/4 2 1/32 24000
1 3/8 2 1/4 27000
IMPORTANT: Apply a load test to the assembly prior to use. 1 1/2 2 3/8 34000
This load shall be equal or greater than the intended load. 1 3/4 2 7/8 50000
Next check and retighten the nuts evenly to the recommended 2 3 1/4 70000
2 1/2 4 1/8 100000
torque. Inspect the assembly periodically for wear, abuse and 3 5 150000
general adequacy.
Never replace a
shackle pin with a Check for wear
Never use wire rope clips to make slings / chokers. bolt
Check for wear
7- Record Retention: and straightness

All inspection logs must be retained on the project site for the Check that pin
duration of the project. is always seated
Check that
shackle is
The load will bend not opening
the bolt
70 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
A reduction of up to 12.5% of the nominal
A106
specified wall thickness

A reduction of up to 12.5% of the nominal

A333
specified wall thickness
A reduction of up to 12.5% of the nominal
A335
specified wall thickness
A reduction of up to 0.25mm of the nominal
A671
specified wall thickness
A reduction of up to 0.30mm of the nominal
A672
specified wall thickness
A reduction of up to 12.5 % of the nominal
A312
specified wall thickness

API 5L Line Pipe

Grade X42 and higher A reduction of up to 12.5% of the nominal
(NPS 2 7/8” and below) specified wall thickness
Grade X42 and higher A reduction of up to 12.5% of the nominal
(NPS >2 7/8 but < 20”) specified wall thickness

Type 3 Type 4 Type 5 NPS 20” and above:

Welded Pipe A reduction of up to 8% of the nominal
specified wall thickness
Seamless Pipe A reduction of up to 10% of the nominal
(NPS 20” and above) specified wall thickness

74 75
 Blind Flange Dimension Chart Flange Rating
Line
Size 150# 300# 600#
Flange Rating inches
Line O.D. Thkns O.D. Thkns O.D. Thkns
Size 150# 300# 600#
inches 14 17 5/8 ¾ 19 1¼ 19 ¼ 1¾
O.D Thkns O.D Thkns O.D Thkns
16 20 1/8 7/8 21 1/8 1½ 22 1/8 2
½ 1 3/4 5/16 2 5/16 2 5/16
18 21 ½ 1 23 3/8 1 5/8 24 2 1/8
¾ 2 1/8 5/16 2½ 5/16 2½ 5/16
20 23 ¾ 1 1/8 25 5/8 1¾ 26 ¾ 2½
1 2½ 5/16 2¾ 5/16 2¾ 5/16
22 25 7/8 1¼ 27 5/8 1 7/8 28 ¾ 2¾
1¼ 2 7/8 5/16 3 1/8 5/16 3 1/8 3/8
24 28 1/8 1 3/8 30 3/8 2 31 2 7/8
1½ 3¼ 5/16 3 5/8 5/16 3 5/8 3/8
26 30 3/8 1½ 32 ¾ 2 34 3 1/8
2 4 5/16 4¼ 3/8 4¼ 3/8
28 32 5/8 1 5/8 35 ¼ 2 1/8 35 7/8 3 3/8
2½ 4¾ 5/16 5 3/8 5 ½
30 34 5/8 1¾ 37 3/8 2 3/8 38 1/8 3 5/8
3 5¼ 5/16 5¾ 3/8 5¾ ½
32 36 7/8 1¾ 39 ½ 2½ 40 1/8 3¾
3½ 6¼ 3/8 6 3/8 3/8 6¼ 5/8
34 38 7/8 1 7/8 41 ½ 2 5/8 42 1/8 4 1/8
4 6¾ 3/8 7 ½ 7½ 5/8
36 41 1/8 2 43 7/8 2¾ 44 3/8 4¼
5 7 5/8 3/8 8 3/8 5/8 9 3/8 3/4
38 43 5/8 2 1/8 41 3/8 3 43 3/8 4½
6 8 5/8 ½ 9¾ 5/8 10 3/8 7/8
40 45 5/8 2¼ 43 ¾ 3 1/8 45 7/8 4¾
8 10 7/8 ½ 12 7/8 12 ½ 1 1/8
42 47 7/8 2 3/8 45 ¾ 3¼ 47 7/8 5
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

76 77

Flange Rating
Flange Rating Line
Line
900# 1500# 2500# Size 900# 1500# 2500#
Size
inches
inches O.D. Thkns O.D. Thkns O.D. Thkns
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 16 22 ½ 2 3/8 25 1/8 3

¾ 2 5/8 5/16 2 5/8 3/8 2 7/8 3/8 18 25 2 5/8 27 5/8 3 3/8

1 3 5/16 3 3/8 3¼ 3/8 20 27 3/8 2 7/8 29 5/8 3¾

1¼ 3 3/8 3/8 3 3/8 3/8 4 ½ 22

1½ 3 3/4 3/8 3¾ ½ 4½ 5/8 24 32 7/8 3½ 35 3/8 4 3/8

2 5½ ½ 5½ ½ 5 5/8 5/8 26 34 5/8 3¾

2½ 6 3/8 ½ 6 3/8 5/8 6½ 3/4 28 37 1/8 4 1/8

3 6 1/2 5/8 6¾ 3/4 7 5/8 7/8 30 39 5/8 4 3/8

3½ 32 42 1/8 4¾

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

1/2
14 20 2 1/8 22 5/8 2 5/8 46 56 3/8 6¾
3/8
48 58 3/8 7

78 79
 Piping Schedule Wall Thickness Chart Piping Schedule Wall Thickness Chart

Nominal OD Sch Sch Sch Sch Sch Sch Sch Sch Sch Sch Sch
Pipe Std XS XXS
(mm) 5 10 20 30 40 60 80 100 120 140 160
Size (in)
1/8 10.29 0.89 1.24 1.73 1.73 2.41 2.41
1/4 13.7 1.24 1.65 2.24 2.24 3.02 3.02

3/8 17.1 1.24 1.65 2.31 2.31 3.20 3.20

1/2 21.3 1.65 2.11 2.77 2.77 3.73 3.73 4.75 7.46

3/4 26.7 1.65 2.11 2.87 2.87 3.91 3.91 5.53 7.82
1 33.4 1.65 2.77 3.38 3.38 4.55 4.55 6.35 9.09

1 1/4 42.2 1.65 2.77 3.56 3.56 4.48 4.85 6.35 9.70
1 1/2 48.3 1.65 2.77 3.68 3.68 5.08 5.08 7.13 10.16

2 60.3 1.65 2.77 3.91 3.91 5.54 5.54 8.71 11.07

2 1/2 73 2.11 3.05 5.16 5.16 7.01 7.01 9.53 14.02

3 88.9 2.11 3.05 5.49 5.49 7.62 7.62

11.10
3 1/2 101.6 2.11 3.05 5.74 5.74 8.08 8.08

4 114.3 2.11 3.05 6.02 6.02 8.56 8.56 11.10 13.48

5 141.3 2.77 3.40 6.55 6.55 9.53 9.53 12.70 15.87

6 168.3 2.77 3.40 7.11 7.11 10.97 10.97 14.27 18.23

8 219.1 2.77 3.76 6.35 7.04 8.18 8.18 10.31 12.70 12.70 15.06 18.23 20.62 23.01

80 81

Piping Schedule Wall Thickness Chart Piping Schedule Wall Thickness Chart

Nominal OD Sch Sch Sch Sch Sch

Std Sch Sch Sch Sch Sch Sch
Pipe (mm) 5 10 20 30 40 XS XXS
60 80 100 120 140 160
Size (in)
10 273.1 3.4 3.40 6.35 7.79 9.27 9.27 12.70 12.70 15.06 18.23 21.41 25.40 28.57
12 323.9 4.19 4.19 6.36 8.38 9.53 10.31 14.27 12.70 17.45 21.41 25.40 28.57 33.32
14 355.6 6.35 7.92 9.53 9.53 11.12 15.06 12.70 19.05 23.80 27.76 31.75 35.71
16 406.4 6.35 7.92 9.53 9.53 12.70 16.66 12.70 21.41 26.19 30.93 36.52 40.46
18 457.2 6.35 7.92 11.10 9.53 14.27 19.05 12.70 23.80 29.36 34.92 39.67 45.24
20 508 6.35 9.53 12.70 9.53 15.06 20.62 12.70 26.19 32.51 38.10 44.45 49.99
22 558.8 6.35 9.53 12.70
24 609.6 6.35 9.53 14.27 9.53 17.45 24.59 12.70 30.94 38.89 46.02 52.37 59.51
26 660.4 9.53 12.70
28 711 7.92 12.7 15.88 9.53 12.70
30 762 9.53 12.70
32 813 12.7 15.88 9.53 17.48 12.70
34 863.6 9.53 12.70
36 914 9.53 12.70

38 965 9.53 12.70

82 83
 Metric / Imperial Conversion Factor Metric / Imperial Conversion Factor

Multiply Value by the Multiply Value by the

following factors to following factors to
Quantity Imperia Quantity Imperial Metric
Metric Units convert from: convert from
Type l Units Type Units Units
Imperial to Metric to Imperial Metric to
Metric Imperial to Metric Imperial
Pounds Kilogram Square
0.454 2.20 Square feet 0.0929 10.8
(lb) (kg) meter
Short Area Square
Square inch 645 0.00155
Ton millimetre
Metric Ton 0.907 1.10
(2000 Acres Hectares 0.406 2.47
Mass
lbs) Cubic
Long Cubic inches 16.4 0.061
centimetres
Ton Cubic
Metric Ton 1.02 0.984 Volume Cubic Feet 0.0283 35.3
(2240 meters
lbs)
Gallons (US) Litre 3.79 0.264
Inches Millimetres 25.4 0.0391
Pounds/cubi Kilogram/cu
Feet Millimetres 305 0.00328 Density 27700 0.0000361
c inch bic metre
Linear
Feet Meters 0.305 3.28 Energy Foot pound Joule 1.36 0.738
Measure
Yard Meter 0.914 1.09 Pounds/foot Kilo/meter 1.49 0.672
Mass/Uni
Miles Kilometre 1.61 0.621 t length Metric
Tons/Mile 0.564 1.77
Ton/Meter
Temperat Fahrenh o o
Celsius 5.9 x ( F-32) 9.5 x( C+32)
ure eit
Pounds/ Kilopascal 6.89 0.145
Pressure Square
Inch Megapascal 0.00689 145

84 85

NOTES NOTES

86 87
NOTES NOTES

88 89
 90 91
Contents

Material receiving inspection ………………………………3

Material receiving inspection 3

Document verification 4
Cutting 4
Piping spool fabrication 5
Welding general 9
Release and storage of fabricated spools 12
Piping erection 14
Bolting of flanged joints 16
Flange identification 18
Flange face imperfections 19
Spacer & Blind Standard 23
ASME 16.5 flanges 32
Bolt tightening sequence 38
Groupings for bolt tensioning 44
Nut / bolt material specification 45
Bolts with corresponding wrench size 46
Pipe flange misalignment tolerances 47
Mill tolerances for pipe & wrought fittings 50
Lubricants for nuts / bolts 52
Colour coding for gaskets 53
Pre-test checklist 54
Pressure testing 60
Safety in Piping (Slings & Shackles) 66
Permissible reductions in pipe wall thickness 74
Blind flange dimension chart 75
Piping schedule wall thickness chart 79
Metric / imperial conversion factors 83