Best Book For Piping Safety Engineers 1615724976

PIPE FABRICATION
MATERIALS, DRAWING AND FABRICATION METHODS
METALS AND ENGINEERING
ENG2068
Pipe fabrication
ENG2068
Materials, drawing and fabrication methods

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Training Sector Services

Telephone: 08 6212 9789
Email: sectorcapability.ip@dtwd.wa.gov.au
Website: www.dtwd.wa.gov.au
First published 2013
ISBN 978-1-74205-902-0
© WestOne Services 2013
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Data Chart at Appendix 1 has been reproduced with the permission of MRC Global
Australia.
Contents
Chapter 1 – Introduction to pipe fabrication 5
About pipe fabrication.......................................................................................................5
Codes and standards.......................................................................................................6
Approval of piping systems..............................................................................................7
Pipe fabrication abbreviations..........................................................................................8
Chapter 2 – Materials 13
Piping systems...............................................................................................................13
Pipe................................................................................................................................16
Pipe fittings.....................................................................................................................18
Flanges...........................................................................................................................29
Gaskets..........................................................................................................................37
Valves.............................................................................................................................40
Bolts...............................................................................................................................54
Brackets and hangers (support).....................................................................................58
Identification of piping.....................................................................................................73
Chapter 3 – Drawing 75
Types of drawings..........................................................................................................75
Types of projection.........................................................................................................82
Parallel line.....................................................................................................................92
Piping symbols...............................................................................................................98
Dimensioning and line types........................................................................................107
Chapter 4 – Fabrication methods 115

Pipe fabrication.............................................................................................................115
Preparing for fabrication...............................................................................................116
Fabrication process......................................................................................................123
Welding process...........................................................................................................129
Appendix 1 – MRC Data Chart 135
© WestOne Services 2013 3

4 ENG2068 © WestOne Services 2013
Chapter 1 – Introduction to pipe
fabrication
About pipe fabrication

Pipelines are used to transport fluids, including vapours, gases, slurries and powders
which flow through pipes at various pressures and temperatures. The transmission of
these materials invariably subjects the pipe to intense stresses and strains and this
demands the highest possible performance from the pipe.
All pipework must be designed and fabricated in a way that ensures the safety of plant
operators, the plant, the public and the environment.
The fabricator is responsible for the quality of the pipework and pipe fabrication must
be carried out in accordance with all relevant standards and specifications. One faulty
weld could lead to damage costing millions of dollars, personal injury and in serious
cases even death. Welded pipe systems demand the highest degree of excellence in
materials and quality of work.
Because high standards are required, the cost of pipework is extremely high. Typical
costs for pipework in a manufacturing plant are shown in Table 1.1.
Field labour costs 47%
Material costs 23%
Design engineering costs 20%
Table 1.1: Fabrication costs
It is essential that pipework is fabricated by suitably trained and competent

tradespersons.
© WestOne Services 2013 ENG2068 5

Codes and standards
To ensure the highest standards of uniformity, safety and work quality, most piping
systems are designed, welded, installed and tested to rigid specifications or codes. The
most commonly used codes for welded pipework in Australia are as follows.
Standards Australia International Limited (SAI)

● AS/NZS 3992:1998/Amdt 1:2000 Pressure equipment – Welding and brazing
qualification
● AS/NZS 4645.2:2008 Gas distribution networks - Steel pipe systems
● AS 2885.4-2010 Pipelines - Gas and liquid petroleum - Submarine pipeline
systems
● AS 1796-2001 Certification of welders and welding supervisors
● AS 1074-1989 Steel tubes and tubulars for ordinary service
● AS 4458-1997 Pressure equipment – Manufacture
● AS 4041-2006 Pressure piping
American Society of Mechanical Engineers (ASME)
● ASME IX Piping systems in connection with power boilers, nuclear vessels and
unfired pressure vessels
American Petroleum Institute (API)
● API Std 1104 (R2010) Welding of Pipelines and Related Facilities – 20th Edition,
includes Errata 1 (2007) and 2 (2008)
American National Standards Institute (ANSI)
● ANSI/ASME B31.3 Chemical plant and petroleum refinery piping
● ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe
Some insurance companies, manufacturers and the military forces set up their own
codes to cover the fabrication and welding of pipeline systems.
All codes are developed to establish uniform minimum standards for:

● piping material
● fabrication and welding procedures
● quality of work
● qualification of personnel
● inspection and testing.
These standards ensure that there is maximum protection against accidents
occurring when the piping is in service.

Approval of piping systems
There must be a high degree of quality control when high-pressure pipe systems are
being fabricated to ensure that they meet the specifications of the relevant codes.
The inspecting authority may be the machinery inspection branch of the state
or territory government, the insurance company underwriting the job or the
representatives of the client for whom the pipework is being fabricated.
The quality control program includes the following steps.
1. Approval of the design of the pipe system.
2. Approval of the fabricator who may have to prove that there is adequate equipment
and expert personnel to successfully meet the requirements of the relevant
code(s).
3. Frequent checks to ensure that the specified material is being used.
4. Approval of welding procedures and regular inspections to ensure that these
procedures are being followed.
5. Qualification of welders who are tested to ensure that they are capable of carrying
out the approved procedures successfully.
6. Non-destructive testing as required by the code(s).
7. Post-weld heat treatment as required by the code(s).
8. Final hydrostatic testing or alternative testing method.
Fabricators are responsible for the quality of the work they perform and for the
coordination of all inspection and testing procedures as required by the relevant
code(s).

Pipe fabrication abbreviations
Abbreviation Definition
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
API American Petroleum Institute
AWS American Welding Society
ASSY assembly
BB bolted bonnet
BC bolt circle
BE bevelled ends (for welding)
BF blind flange
BM bill of material
BOP bottom of pipe
BLDG building
BW butt weld
˚C degrees Celsius
centre-line
CH. OP. chain operated

CI cast iron
CO2 carbon dioxide
COND condensate
CORR corrosion or corrosive
CONC concentric
CPLG coupling
CS carbon steel, cast steel or cold spring
Ø diameter
DIA or D diameter
DF drain funnel
DWG drawing
ECC eccentric
EFW electric fusion welded
EL elevation
ELL elbow

ERW electric resistance welded
FF flat faced or full faced
FFW field fit and weld
FIG figure or figure number
FLG flange
FOB flat on bottom
FW field weld
GA general arrangement
GALV galvanised
GJ ground joint
GR grade
HC hydrocarbon
HDR header
ID inside diameter
IDD inside depth of dish
INS insulate
INV invert (inside bottom of pipe)
LC lock closed
LO lock open
LR long radius
M&F male and female
MFG manufacture or manufacturing
MI malleable iron
MIN minimum
MW mitre weld
NC normally closed
NO normally open
NS nominal size
OD outside diameter
plate
PCD pitch circle diameter

PE plain end (not bevelled)
P&ID Pipe and instrument diagram

PFD Process flow diagram
PI point of intersection
PR pair
RED reducer
REINF reinforce
RF raised face
RTJ ring type joint (sometimes just designated RJ)
SCH schedule
SCRD screwed
SMLS seamless
SO slip on
S.O. steam out
SPEC specification
SQ square
SR short radius
SS stainless steel
STD standard
STL steel
STM steam
SW socket weld
SWG swage
SWP standard working pressure
SC sample connection
TC test connection
TE threaded end
TEMP temperature
T&C thread and coupled
T&G tongue and groove
TOC top of concrete
TOS top of steel
TYP typical
VET vertical
WB welded bonnet

WE weld end
WN weld neck
WT weight
XH extra heavy
XXH double extra heavy
XS extra strong
XXS double extra strong


Chapter 2 – Materials
Piping systems
There are three common methods of joining piping, each with its own advantages and
disadvantages.
Butt welded piping systems are used for most process, utility or service piping. Butt
welding is the most practicable way of obtaining strong, leak-proof joints; especially
on larger piping. The pipe and fitting used have, or are prepared with, standard weld
preparation. They require high levels of workmanship in their assembly and welding.
Detail B
Scale 1/2
Fig 2.1: Butt welded piping system

Socket-welded piping systems are used for lines of small diameter which carry
flammable, toxic or expensive materials where no leakage is permitted. They are easier
to assemble and weld than butt welds and no weld metal can enter the bore. The
pipe end is finished square and fitted into the fittings, usually with a 1.5 mm gap. This
gap sometimes pockets liquids and is not recommended if severe erosion of crevice
corrosion is anticipated.
Detail C
Scale 1/2
Fig 2.2: Socket-welded piping system

Screwed piping systems are used for small lines, usually of 50 mm diameter and are
easily assembled using standard fittings. The removal of metal to create the thread is a
disadvantage and fatigue strength is poor. There is no need for coded welders when a
screwed pipe system is used except where seal welding is undertaken.
Only butt welded and socket welded systems will be dealt with in this text.
Detail A
A Scale 1/2
Fig 2.3: Screwed piping system

Pipe
Pipe is specified by stating its nominal size (NS), which is only approximate. Nominal
size is neither the inside nor the outside diameter and it is necessary to use standard
tables or manufacturers’ tables to ascertain these two dimensions exactly.
Pipe thicknesses are often described as ‘standard’ (STD), ‘extra strong’ (XS) and
‘double extra strong’ (XXS). However, most manufacturers have adopted the American
piping code classification which classifies pipes into a schedule system. The mass
of the pipe is referred to as the schedule of pipe, and may vary from Schedule 10 to
Schedule 160.
As the schedule number increases so does the wall thickness, and as a consequence
the inside diameter reduces. The outside diameters remain constant enabling
standardisation of pipe brackets or threading. The exact wall thickness can be
determined from standard tables.
Pipe nominal size versus actual

outside pipe diameter
Schedule pipe wall thickness

NS 100 pipe
SCH 10 3.05
SCH 40 6.02
NS 100 114.3 (+14.3) SCH 80 8.56
NS 150 168.3 (+18.3)
NS 200 219.1 (+19.1) SCH 160 13.49
NS 250 273.1 (+23.1)
Nominal Pipe wall

pipe size Outside diameter
Fig 2.4: Comparison of nominal size and schedule for 100 NS pipe

Pipes are sometimes referred to as tubes. The primary difference is in how they are
measured, Boiler tubes and tubing are known by their outside diameter and their wall
thickness. Both dimensions are required when ordering.
Carbon steel pipe

Carbon steel (CS) pipe is by far the most common pipe used and it is supplied to
strict specifications.
Straight seam-welded and spiral-welded pipe is made from plate, and seamless pipe
is made by piercing solid billets.
CS pipe is strong, weldable, durable, ductile, machinable and cheaper than most
other materials.
If CS pipe can meet the requirements of pressure, temperature, corrosion, resistance
and hygiene, it is a cost effective choice.
CS pipes in common use are manufactured to the following standards:
●● ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe
●● AS 1074-1989 Steel tubes and tubulars for ordinary service
●● BS 1387:1985 Specification for screwed and socketed steel tubes and tubulars
and for plain end steel tubes suitable for welding or for screwing to BS 21
pipe threads.
Dimensions for pipes covered by these standards are, for practical purposes,
the same.

Pipe fittings
A pipe fitting may be defined as any type of pipe connector that is used to:
●● make a connection
●● change the size or direction of pipes or
●● change the pipe specification from one material to another.
Fittings are classified by the method of end fixing, eg. butt welding, socket-welding,
screwed or flanged and by name, eg. 90° and 45° elbows, reducing elbows, short and
long radius bends, equal and unequal tees, concentric and eccentric reducers and
stub ends.
How are fittings rated?

Fittings are rated by nominal working pressure in cold, non-shock conditions.
Pressure rating Manufacturer’s Schedule no. Pressure rating

weight
PSI kPa
2000 13 790 STD 40
3000 20 670 XS 80
6000 41 340 XXS 160
Table 2.1: Relationship between PSI, kPa and the schedule
Socket weld fittings are not manufactured in 2000 PSI (13 790 kPa).

Butt welded fittings
Butt welded fittings have a 30° truncated edge with a designed weld preparation
consisting of a root gap and landing that is welded. Types in common use are shown in
Figure 2.5.
180o Long radius Weld ELL 180o Short radius Weld ELL Cap
90o Short radius 90o Long radius 90o Reducing long 45o Long radius
Weld ELL Weld ELL radius Weld ELL Weld ELL
Straight Reducing Concentric Eccentric

tee tee reducer reducer
Fig 2.5: Butt welded fittings

Preparation for butt welds
Unless the piping system is of a large enough diameter to permit internal access,
butt welds must possess sound and smooth root penetration when welded from the
outside.
To achieve this, the weld preparation requires careful attention and the root face, root
gap and root alignment are all critical. A single-Vee preparation is most common with
the dimensions as shown in Figure 2.6.
+7½
300
-0
2 - 3 mm 1.5 mm
Fig 2.6: Preparation for butt weld
Butt weld elbows

Elbows are fittings which are used to change the direction of flow. They are available
for changes in direction of 180°, 90° and 45°. The 180° elbow is also referred to as a
‘return bend’. All butt weld elbows are supplied with bevelled ends.
The 90° butt weld elbow is used to make a 90° offset-in any direction. It is available
in short and long radius. The radius of the fitting is important when calculating cutting
sizes as it must be subtracted in order to achieve correct centre line dimensions.
The long radius elbow is most common, and equals one-and-a-half times the nominal
pipe diameter from the face of the weld preparation to the elbow’s centre-line. Unless
otherwise specified long radius elbows will always be supplied.
1½ × NPS 1 × NPS
90o Long radius weld ELL 90o Short radius weld ELL
Fig 2.7: Short and long butt welding elbows

When an offset is required where the angle is not than the standard fitting, it is
customary to use a 90° or a 45° elbow and cut to the desired angle.
Critical dimensions of elbows and other fittings can be obtained from standard tables.
Reducing elbows
Reducing elbows facilitate a change in line size along with a 90° change in direction.
The centre-line radius is one and a half times the nominal size of the larger end.
Fig 2.8: Reducing elbow
Return bends
Return bends are used to change the direction of piping through 180°. Long radius
returns have a radius of 1½ × NS, ie centre to centre distance of 3 × NS.
3 × NS 2 × NS
180o Long radius weld ELL 180o Short radius weld ELL
Fig 2.9: Return bends

Lap joint stub ends
Lap joint stub ends are flared pipes that accommodate slip on flanges. They are
supplied mainly in material other than carbon steel, eg stainless steel.
As an economic measure carbon steel flanges are used as an alternative to stainless
steel flanges. The flanges are allowed to float free and can swivel which is useful when
pipes are being aligned.
Fig 2.10: Lap joint stub end
Reducers
Reducers are used to join a smaller pipe to a larger one. Reducers are available in two
types – eccentric and concentric. Eccentric reducers are used when the top or bottom
of the line needs to be kept level.
Fig 2.11: Concentric and eccentric reducers

Butt welding tees
Butt welding tees are used to make 90° branches from the main run of pipe and may be
either straight or reducing. Reducing tees have a 90° branch smaller than the main line.
Tees with branches larger than the main line are seldom used, as they must be made
to order.
Fig 2.12: Straight and reducing tees
How to specify tees

Equal tees are abbreviated, eg a NS 150 mm straight tee = NS 150 EQ tee.
Reducing tees are specified in the following order:
Run inlet Run outlet Branch

NS 100 NS 100 NS 80
Specified red tee: 100 × 100 × 80
Laterals
Laterals let branches enter at odd angles to the main run and both straight and
reducing laterals are available. 45° straight laterals are the most common and are
available in STD or XS weights.
Reducing laterals and laterals at odd angles usually require special order. Reducing
laterals are ordered in a similar way to ordering reducing tees, except that the branch
angle is also stated.

Fig 2.13: A lateral
Caps
Caps are used to seal off the ends of pipes.
Fig 2.14: A cap
Socket-welded fittings
Socket-welded fittings allow for easy fabrication and fit-up of piping. Square end
preparation of the pipe is all that is required and fillet welds are used, preferably made
in two passes.
Lower levels of operator skill are required to assemble and weld socket joints than are
required for butt joints. The socket-welding system is preferable to the screwed system
as it is simpler to assemble and avoids the possibility of leakage which sometimes
arises in screwed joints.

Elbows
Socket-welding elbows are available to make changes in direction of 90° or 45°.
Fig 2.15: A socket-welding elbow
Tees
Tees make 90° socket-welded branches either as straight or reducing tees.
Fig 2.16: A socket-welding tee
Laterals
Laterals are available to make 45° branches.
Fig 2.17: A socket-welding lateral

Coupling
Full couplings are used to join a pipe to a pipe or to a swage of the same diameter. Half
couplings are also available but are not in common use as Sockolets® are generally
preferred.
Fig 2.18: Couplings
Reducers
Reducers are similar to couplings but are used to join pipes of different diameters.
Fig 2.19: A reducer
Reducer inserts
Reducer inserts are used to connect smaller pipes to larger fittings.
Fig 2.20: Reducer inserts

Swaged nipple or ‘swage’
Swages are used to join socket-welded fittings of different sizes or to weld a socket-
welded fitting to a butt welded fitting of a larger size.
When ordering swages, it is necessary to specify nominal diameter, the weight of the
pipes to be joined and the end preparation.
Fig 2.21: A swaged nipple
It is possible to make custom reducer inserts or tees by boring standard blanks.

Normal specification tolerances call for a 1.6 mm shrinkage gap when assembling
socket weld fittings Figure 2.22). Dimensions of socket weld fittings can be obtained
from standard tables.
Max 2 t
Diametrical
clearance 0.75 mm
c
c-minimum — 1 ¼ t
But not less than 3 mm
t = nominal pipe wall thickness
1.5 mm approximately Not less
than 3 t
Fig 2.22: Section view of swage tolerances

Specialised weld fittings
Specialised weld fittings are designed for making right-angle branch-type outlets such
as tees, crosses and side outlets by welding. They are available in all common types of
material, eg carbon steel, chrome/moly and stainless steel.
Using specialised fittings eliminates the need for parallel line development. No
templates are used and threading, forming or complicated fitting are not necessary.
They are available to make butt welded, socket-welded and welded/screwed joints.
Specialised fittings come in a range of sizes and are fully approved by most design
codes.
Weldolet® Butt-welded Elbolet® Butt-welded Latrolet®
Sweepolet® Nipolet®
Sockolet® Socket-welded Elbolet® Socket-welded Latrolet®
Thredolet® Screwed Elbolet® Screwed Latrolet®
Fig 2.23: Specialised weld fittings

Flanges
Flanges are used primarily as a way of connecting valves and fittings to pipes and they
vary widely in size and type. They enable valves to be removed periodically for repair or
replacement. Like pipe and pipe fittings they are made to strict code specifications.
Flanges, like pipes, are referred to by nominal size and flange type, ie weld-neck
flange, slip-on flange, as well as by class and the type of flange face.
Flange types
Flange types need to match the designed pressure and temperature ratings of piping
systems.
Weld neck flanges

Weld neck flanges are distinguished from other types of flanges by their long tapered
hub and gradual transition of thickness in the region of the butt weld joining them to
the pipe. The hub provides an important reinforcement of the flange itself from the
perspectives of strength and resistance to ‘dishing’.
The smooth transition from flange thickness effected by the taper is extremely
beneficial under repeated conditions of bending caused by pipeline expansion or other
variable forces. It produces an endurance strength of weld neck flanged assembles
equivalent to that of a butt welded joint which, if done properly, is the same as that of a
seamless pipe. This type of flange is preferable for very severe service conditions such
as high-pressure, sub-zero or elevated temperatures.
Fig 2.24: A weld neck flange
Slip-on flanges
Slip-on flanges are used extensively because of their lower initial cost. They are easier
to fix than a weld-neck type as the pipe does not require such accurate cutting and the
ease of alignment to an assembly is simplified.
However, the final installed cost is not much less than that of the weld-neck flange and
their strength under internal pressure is approximately two-thirds that of weld-neck
flanges with life under fatigue approximately one-third.

Fig 2.25: A slip-on flange
Socket-welding flanges
Socket-welding flanges are used fairly extensively in chemical process piping, as
smooth, pocketless bore conditions can be obtained by grinding the internal weld flush.
Their cost is about 10 per cent greater than the slip-on flange. Their static strength is
about equal to welded slip-on flanges but their fatigue strength is 50 per cent greater.
Fig 2.26: A socket-welding flange
Lap joint flanges

Lap joint flanges are used mainly with carbon or low alloy-steel piping systems where
the services necessitate frequent dismantling for cleaning and inspection. They also
simplify erection, as the flange can be swivelled to align bolt holes. They require
lap joint stubs and the combined initial cost of the flange and stub is approximately
one-third higher than a comparable weld-neck flange. Their pressure-holding ability
is no better than slip-on flanges and the fatigue life of the assembly is approximately
one-tenth of a weld-neck flange. They should not be used where severe bending
stress occurs.

Lap joint
Slip on
Fig 2.27: A lap joint flange
Blind flanges
Blind flanges are used to close off the ends of piping, nozzles or valves. Due to internal
pressure acting to bend blind flanges at their centre, they are the most highly stressed
of the flange types. Where severe water-hammer or temperature is a service factor
consideration should be given to the use of closures made from weld-neck flanges and
caps.
Fig 2.28: A blind flange

Orifice flanges
Orifice flanges are used to measure the flow rate of liquids and gases within a pipeline,
thus eliminating the need for hot tapping or pipe modification.
The orifice flange consists of two flanges with an additional tapped hole in each so
that monitoring equipment, an orifice plate and jacking bolts can be attached. These
facilitate the separation of flanges when they need to be inspected.
Orifice flanges come in a range of nominal sizes and types, such as weld neck, slip on
and screwed.
A A
A-A
Fig 2.29: An orifice flange

Flange facings
There are many facings offered but only a handful are in common use. The main
variables in flange facings are the profile of the flange face; the smoothness of the face;
and whether or not the use of a gasket is employed.
Raised face
Raised face is by far the most common type used, accounting for approximately 80%
of all applications. The face is raised 1.6 mm for Class 150 and Class 300 flanges, and
6.5 mm for other classes.
The raised face is machine finished with either concentric or spiral grooves
approximately 0.4 mm deep which bite into and hold the soft, flat gasket normally
employed with this face type.
Fig 2.30: A raised face weld neck
Flat face
The most common use for flat face is for non-steel flanges such as cast iron or plastic.
The gasket used has the same outside diameter as the flange. This reduces the danger
of cracking the flange when tightened.
Fig 2.31: A flat face weld neck

Ring joint
Although expensive, the ring joint facing is the most efficient facing for high-pressure
and high-temperature service. Both flanges of the pair are alike, with a groove
machined into each face. (Flat bottom grooves are standard.) Oval or octagonal ring
type gaskets are fitted into the groove before tightening.
Fig 2.32: A ring joint weld neck
Lap joint
The lap joint flange in combination with the lap joint stub end provides a joint facing
similar to that of a raised face flange.
Slip on
Lap joint
Fig 2.33: A lap joint slip-on

Male and female
Male and female facings come in two standard types – one with a large male–female
contact area and the other with a small male–female contact area. The large
male–female contact area is excessive for use with metal gaskets and the small
male–female contact is not suitable for use with screwed fittings of standard weight.
The male face is usually 6.5 mm high (1/4”) and the female face is approximately
4.7 mm (3/16”) deep. Both faces are usually smooth and the outer diameter of the
female face acts to locate and retain the gasket.
Fig 2.34: Male and female butt welds
Tongue and groove

Tongue and groove fittings are designed to match each other and, although similar to
male and female fittings, the grooves do not extend into the flange base. These types
of flanges are self-aligning which is useful when bore alignment is critical. Tongue and
groove fittings are available in all nominal sizes.

Fig 2.35: A tongue and groove butt weld
Finish
Finish refers to the surface texture of the flange face and may be either ‘serrated’ or
‘smooth’. A serrated finish is produced by machining grooves into the surface. A smooth
finish is usually specially ordered and comes in two qualities – the regular smooth finish
which shows no tool marks to the naked eye or the ‘cold water finish’ which is even
smoother. The cold water finish is normally used without gaskets.
Class rating
Flanges are given a ‘class’ rating which refers to service pressure and temperature.
The class of flange may be: 150, 300, 400, 600, 900, 1500, 2500.
The number of boltholes in a flange varies with the size and class. For example, a
class 150, 80 mm flange has four boltholes, and a class 150, 150 mm flange has eight
boltholes. In a class 300, an 80 mm flange has eight boltholes and a 150 mm has
twelve boltholes.
The diameter of the bolthole also varies with class so that large diameter bolts may be
used for additional strength in the heavier classes.
Dimensions of each class of flange, and the dimensions of the bolts used by these
flanges can be determined from standard tables.

Gaskets
Gaskets are used to provide leak tight joints between matching surfaces. Gasket
materials vary widely and may include:
●● non-metals – such as paper and rubber
●● metals – such as copper, iron or stainless steel
●● combinations of metals and non-metals.
The choice of gasket materials depends on factors such as service pressure, service
temperature, corrosion, bolt loadings and cost.
Gasket types
Gasket types need to match the designed pressure and temperature ratings of piping
systems and the flange type.
Flat ring gaskets

Flat ring gaskets are the most commonly used. They vary in thickness from
approximately 0.2 mm up to approximately 6 mm (the former being the most common),
and in width from approximately 6 mm upwards.
Narrow gaskets are preferred, as they require lower bolt loadings to obtain an effective
seal. However, they must not be too narrow, in case they become crushed or indented
into the flange.
Serrated gaskets
Serrated gaskets are flat metal gaskets which have concentric grooves machined into
their faces. The reduced surface area provided by the grooves allows an efficient seal
at lower bolting loads. They are commonly used with smooth faced flanges where
gaskets of soft material would be unsuitable.
Fig 2.36: A serrated gasket
Laminated gaskets
Laminated gaskets are made up of a skin with a filler material. There are two basic
types of laminated gasket:
●● flat jacketed
●● spiral wound.

Flat jacketed gaskets
Flat jacketed gaskets can be used at higher temperatures than plain flat gaskets and
they require lower bolt loads than flat metal gaskets.
Fig 2.37: A flat jacketed gasket
Spiral wound gaskets

Depending on the type of metal–filler combinations, spiral-wound gaskets are suitable
for raised face, flat faced and lap joint flanges at pressures up to 7000 kPa (1000 PSI)
and temperatures up to 1000°C.
Fig 2.38: Spiral wound gaskets
Ring joint gaskets

Ring joint gaskets are available with either an oval or octagonal cross-section. They
can be used with all classes of flange, especially the 600 – 2500 lb classes. They are
manufactured from soft iron, low-carbon steel, chromium and molybdenum steel and
stainless steels For relatively low-temperature joints, plastic may be used to prevent
corrosion or to provide electrical insulation.
Fig 2.39: A ring joint gasket

Insulating gaskets
Gaskets made of non-conductive material together with insulating sleeves around bolts
are used where it is necessary to provide electrical isolation between parts of a line.
A guide to the suitability of gasket materials is provided in Table 2.2.
Material Maximum Maximum

service pressure at
temperature °C temperature
Synthetic rubber 120 450 kPa (60 PSI)
Synthetic rubber with cloth insert 120 3450 (500)
Teflon 250 2050 (300)
Ring type joint Carbon steel 400 14 200 (2100)
Stainless steel 650 17 250 (2500)
Spiral wound S/S Teflon 250
above 3450 (500)
S/S ceramic 1000
Table 2.2: Material gasket vs temperature and pressure

Valves
The variety of valves available for use in piping systems is extensive. This is due to the
range of functions that valves perform, the diversity of fluids carried, and the varying
conditions under which valves must perform these tasks.
Valves can be examined under the following headings:
●● basic parts
●● functions performed by valves
●● valve types
●● installation of valves
●● specification of valves.
Basic parts of a valve

Despite vast differences in valve design, common parts can be identified.
Bonnet
Stem
Disc
Seat
Body
Fig 2.40: Basic parts of a valve

The body
The body is the main structure of the valve which contains – or to which is attached
– the other parts of the valve. The body must possess sufficient mechanical strength
and sufficient resistance to corrosion, erosion and high temperature to meet service
conditions. The material from which the valve body is made is important in this regard
and common materials in use include carbon steel, low-alloy steel, bronze, brass,
stainless steel and monel.
The disc, seat and port

The disc, seat and port arrangement is the means of controlling the flow of fluids
through the valve. Regardless of shape and arrangement the disc is the moving part
that directly controls the flow. The non-moving part upon which the disc bears is called
the seat, and the port is the maximum internal opening through which the fluids can
pass.
The stem
The stem is used to move the disc. It is usually a screwed rod, although in some cases
fluid under pressure moves the disc. There are two basic stem types.
●● The rising stem – As the valve is operated, the stem rises, lifting the disc with
it. The hand wheel can either rise with the stem, or the stem can rise through the
hand wheel.
Stem Stem
bushing bushing
Stem moves
Stem moves down through
up through valve bonnet
stem bushing
Gate withdrawn and handwheel
from line of flow
Gate seated
to block
line of flow
Fully open Fully closed
Fig 2.41: The rising stem

●● The non-rising stem – The stem remains in the same position whether the
valve is open or closed. The disc moves up the thread on the stem as the valve is
operated. The screw is inside the bonnet and in contact with the fluid carried.
Stem turns with handwheel

but does not move
up or down Gate threads down
off stem and seats
Gate threads up
onto stem
Fully open Fully closed
Fig 2.42: The non-rising stem
The bonnet
The bonnet is the top housing of the valve. It provides a bearing in which the stem can
run. It acts as a means of sealing the stem of the valve against leakage (usually by
means of a gland and packing). There are three basic means of attaching the bonnet to
the valve body.
●● The screwed bonnet is generally used on small, low pressure valves. A problem
which can sometimes occur with the screwed bonnet is that the bonnet can
become unscrewed as the valve is operated. This is caused by a tight or ‘sticky’
stem.
●● The bolted bonnet is the most common type used in refinery applications. It is
suitable for medium/high pressure applications.
●● The breech lock is a heavier more expensive bonnet, normally used for high
pressure work. It employs a seal weld to guard against leakage.

The operator
The operator is the method of actuating the valve. Valves may be operated manually:
by the use of hand wheels, levers and chains, by geared hand wheels on larger valves
or by powered operation employing electric, pneumatic or hydraulic actuators. Powered
actuators are normally used when:
●● rapid opening or closing is required
●● the valve is operated very frequently
●● access to the valve is difficult
●● the operation of the valve requires great effort
●● valve operation present a safety hazard.
Functions performed by valves

Valves perform the following basic functions.
●● They shut off supply in a pipeline or they enable a piece of pipeline to be isolated
so that repairs to piping or equipment can be carried out faulty or damaged items
can be replaced, etc. This is a shut-off or stop valve.
●● They throttle, regulate or restrict the flow passing along a pipeline by partially
closing the area of flow through the valve.
●● They redirect the flow at a branch line by changing the path along which the flow
occurs.
●● They protect a system against excessive pressure or sudden increases in
pressure. These are safety valves or relief valves. When the pressure in a line
reaches a pre-set high pressure, the valve opens and allows the pressure to
escape either to atmosphere or to another part of the system. Safety valves are
generally used for steam, air or other gases. Relief valves are usually used for
liquids.
●● They enable one part of a continuous system of piping to operate at a different
pressure from another part. These are pressure-reducing valves (also known as
pressure regulators) and are often used in air piping to reduce the compressor or
main line pressure down to a low value for operation of low-pressure equipment.
●● They prevent flow in one direction along a pipe or they allow flow in one direction
only. This valve is referred to as a non-return, or check or reflux valve.

Types of valves
The type of valve to be used depends on the function it is to perform and the conditions
under which it is expected to perform.
The following types of valves can be used:
●● gate valve
●● globe valve
●● diaphragm valve
●● ball valve
●● taper plug valve
●● butterfly valve
●● check (non-return) valve
●● relief valve.
Gate valve
Because of the disc and seat design, the gate valve is for on–off use, and not for
throttling applications. If gate valves are used for throttling applications, they may
damage the disc and seat through erosion or vibration.
Fig 2.43: A gate valve

Globe valve
The term ‘globe valve’ is applied loosely to a valve whose body is globeshaped or has
globelike features. Globe valves are generally suitable for throttling applications, with
the design of the valve determining how closely flow can be regulated. The direction of
flow through a globe valve is usually from stem to seat to assist leaktight closure of the
valve.
Fig 2.44: A globe valve

Types of globe valves include:
Angle globe valve

An angle globe valve changes direction through 90°.
Fig 2.45: An angle globe valve
Needle valve
A needle valve is a small valve used for precise flow control.
Fig 2.46: A needle valve

Wye valve
Because of its smooth flow pattern, a wye valve is preferable for use with erosive fluids.
Fig 2.47: A wye valve
Diaphragm valve
The diaphragm valve is generally used where particles or fibres are carried, eg
slurries. The diaphragm is capable of sealing against these particles and it gives full,
unrestricted flow in the fully open position. The disc is usually a rubber diaphragm.
Handwheel
Bonnet Stem
Compressor
Rubberised
diaphragm
Diaphragm
weir seat
Fig 2.48: A diaphragm valve

Ball valve
A spherical ball is used to block the bore of this valve and cut off the flow. The ball,
which has a hole through it, is rotated 90° by a lever and flow is permitted when the
hole through the ball lies along the pipe axis.
Lever handle
Retainer nut
Body
Cartridge
Stem O-ring
O-ring (top)
Stem
Cartridge
O-ring (bottom)
Seat ring Ball Ball retainer
Fig 2.49: A ball valve
Taper plug valve

Similar to a ball valve, a tapered (conically shaped) plug is used to seal the bore of the
valve. A hole through the plug is used to permit flow when this hole is lined up with the
axis of the pipe.
Ball and plug valves are quick and easy to operate and require only a 90° turn of the
lever to open or close the valve. When these valves are closed, they pocket fluid in the
ball or plug, which may create problems when used with corrosive fluids.

Stem
Grounding Adjuster
spring rocker-arm
adjustment
Valve
cap
TFE diaphram
cap seal
Valve
body
TFE sleeve
positive shut-off
plug and body seal
Raised ribs, grooves,

and recesses positively
lock sleeve in body
Tapered
plug
Fig 2.50: A taper plug valve
Butterfly valve
A butterfly valve has a circular disc, which is approximately the size of the pipe bore in
diameter. This disc rotates around its centre, so that when closed, the disc completely
covers and seals the bore of the pipe.
When fully open, the disc thickness lies along the centre of the pipe. The contents of
the pipe then pass down and past both sides of the disc.
The butterfly valve has the advantage of 90° on–off operation and does not pocket
fluids like the ball and plug valve.

Handle
Stem
Packing
Body
Disc
Seat
Closed Open
Fig 2.51: A butterfly valve
Check (non-return) valve

Check valves permit flow in one direction only. The valve closes if flow is reversed.
Swing check Lift check
Fig 2.52: A check valve

Relief valve
Relief valves are used to prevent build-up of excessive pressure of gas or liquid in lines
or vessels. They usually operate against a pre-set spring loading. Relief valves for gas
are designed to permit a large flow; a small flow which will rapidly decrease pressure is
usually all that is required for liquids.
Fig 2.53: A relief valve
Installation of valves
Valves may be attached to lines or vessels by the following methods.
Screwed attachments – Generally used on small diameter, low pressure lines.
Flanged joints –The body of the valve is flanged to make it compatible with flanges of
the same pressure rating. It offers the advantages of easy installation and removal, and
is suitable for medium/high pressure applications.
Butt weld attachments – The valve ends are supplied with standard weld preparation.
Although difficult to fit and remove, this is the preferred method for extreme service
applications. Weld procedures should be designed so as to minimise distortion of the
valve body.

Wafer valves – These have no flanges of their own and are sandwiched between the
flanges on the pipe ends. They are located and held in position by the bolts which pass
between the pipe flanges. Because the pipe flanges are held a distance apart equal to
the thickness of the wafer valve, longer bolts than usual will be required. The valve has
flat faces which contact the flanges. Gaskets or O-rings are used to seal against leaks.
The outer diameter of the body is made to suit the pitch circle diameter (PCD) of the
bolts of the flange. The bolts go around the valve body rather than passing through it.
Fig 2.54: A wafer valve
These guidelines should be followed when valves are being installed.

●● The direction of flow through the valve must be correct. Where this is important,
flow direction will be indicated on the valve body (usually by an arrow).
●● Valves should be placed in horizontal rather than vertical runs to facilitate the
draining of the line when the valves are closed.
●● Heavy valves should be suitably supported. A minimum of 300 mm between flange
and support should be allowed to facilitate installation and removal.
●● For aesthetic reasons, it is important to keep the centre-lines of valves at the same
height and in line on the plan view.
●● There should be no safety hazards for the operator to contend with when
accessing valves.
●● Lines carrying hazardous materials should have valves placed in such a way that
the operator does not have to reach up to open or close them.
●● Valve stems should not point downward at any angle below the horizontal. This
prevents sediment from collecting in the gland packing which may damage the
stem.
●● Valve stems should not be pointed into walkways, etc.

Specification of valves
Manufacturers use identification codes or model numbers to identify their valve; these
are usually cast or stamped into the valve body. There is no standard system and each
manufacturer uses their own so it is necessary to consult manufacturers’ catalogues to
assist in the identification or ordering of valves. The important factors which determine
the suitability of a particular valve for use are:
●● pressure rating
●● valve type (gate, globe, etc)
●● method of attachment
●● type of operator
●● disc and seat material
●● body material.
These same factors are also used to classify the different valve models.

Bolts
Bolts are used to assemble the piping system through the flanges. They are graded
for tensile strength which is affected by temperature and pressure ratings of the piping
system.
Flange bolts
Two types of bolts are available for the assembly and tightening of flanges:
1. the machine bolt, which uses one nut
2. the stud bolt, which uses two nuts.
Fig 2.55: A machine bolt and a stud bolt
Stud bolts have become the preferred method of bolting flanges. They offer the
following advantages.
●● They can be removed easily (especially when corroded).
●● They are not easily confused with other bolts used on site.
●● They can be made from round stock.
●● The bolt sizes required for flanged joints are readily available from manufacturers’
tables.
Procedure for application of bolt torque on flanged

joints
Step 1
Component parts must be aligned and clamped together with the hold down.
Step 2
Stud (or bolt) threads in area of nut (or forged ring) engagement should be lubricated.
The face of nuts (or bolt heads) should also be lubricated using a suitable lubricant.
Step 3
All bolts should be installed so that torqueing requirements can be followed.

Step 4
All bolts should be numbered so that torqueing requirements can be followed.
Step 5
Torque should be applied in 20% (1/5) steps of required final torque, with all bolts
loaded at each step before the next step is undertaken.
Step 6
Bolts should be tightened in sequential order: 0°–180°, 90°–225° and
135°–315° at each step until final torque is reached. (See Figures 2.56 – 2.60.)
Step 7
Rotational tightening should be used until all bolts are stable at final torque level; two
complete times around are usually required.
Bolt torque procedure

1
8 0°
5
315 ° 45 °
4 270 ° 90 ° 3
225 ° 135 °
6
180 ° 7
Sequential order Rotational order

1–2 1
3–4 5
5–6 3
7–8 7
2
6
4
8
Fig 2.56: Eight bolts per flange

Bolt torque procedure Bolt torque procedure
1 1
12 5 16 9
0° 0°
330 ° 30 ° 8 337½ ° 22½ ° 5
8 9 315 ° 45 °
300 ° 60 ° 12 13
292½ ° 67½ °
4 270 ° 90 ° 3 4 270 ° 90 ° 3
247½ ° 112½ °
240 ° 120 ° 14 11
10 7 225 ° 135 °
210 ° 150 ° 6 202½ ° 157½ ° 7
180 ° 180 °
6 11 10 15
2 2
Sequential order Rotational order Sequential order Rotational order

1–2 1 1–2 1 2
3–4 5 3–4 9 10
5–6 9 5–6 5 6
7–8 3 7–8 13 14
9–10 7 9–10 3 4
11–12 11 11–12 11 12
2 13–14 7 8
6 15–16 15 16
10
4
8
12
Fig 2.57: 12 bolts per flange Fig 2.58: 16 bolts per flange

Bolt torque procedure Bolt torque procedure
12 1 13 24 1 9
20 5 16 17
342 ° 0 ° 18 ° 8 345 ° 0 ° 15 °
330 ° 5
30 °
8 324 ° 36 ° 17 315 ° 45 °
20 13
16 306 ° 54 ° 9 300 ° 60 °
288 ° 72 ° 12 285 ° 75 ° 21
4 270 ° 90 ° 3 4 270 ° 90 ° 3
252 ° 108 ° 22
255 ° 105 °
11
10 15 240 ° 120 °
234 ° 126 ° 14 19
225 ° 135 °
18 216 ° 144 ° 7
210 ° 150 °
198 °180 ° 162 ° 6 195 ° 180 ° 165 ° 7
6 19
18 15
14 2 11 10 2 23
Sequential order Rotational order Sequential order Rotational order

1–2 1 2 1–2 13–14 1 2
3–4 13 14 3–4 15–16 9 10
5–6 5 6 5–6 17–18 17 18
7–8 17 18 7–8 19–20 5 6
9–10 9 10 9–10 21–22 13 14
11–12 3 4 11–12 23–24 21 22
13–14 15 16 3 4
15–16 7 8 11 12
17–18 19 20 19 20
19–20 11 12 7 8
15 16
23 24
Fig 2.59: 20 bolts per flange Fig 2.60: 24 bolts per flange

Brackets and hangers (support)
Piping systems may be subjected to a variety of stresses, which means that the
pipework has to be supported. The lifespan of the pipe will be extended if appropriate
supports are used to accommodate expansion and contraction due to environmental
conditions.
Stresses affecting pipe support

The forces acting on pipework are:
●● the mass (weight) of the pipework and fluids carried by it
●● thermal expansion and contraction
●● vibration
●● settlement stresses.
The mass (weight) of the pipework

Piping systems may have considerable mass that needs to be supported; this factor is
a major consideration in the design of pipework. For example, a reduction of mass is a
significant reason for the widespread use of buttwelded piping systems.
Pipework which is not suitably supported will sag, causing pockets of liquid which
cannot drain from the pipe. Small-diameter pipes sag more easily than those of a larger
diameter, and therefore require more support.
Because of the high cost of pipe support, it is sometimes cheaper to simply use a larger
diameter pipe, than to use a small-diameter pipe with support.
Thermal expansion and contraction

Changes in the temperature in piping due to variations in the ambient temperature
or variations in the temperature of the fluids carried cause changes in the length of
pipework. Changes in length depend on the variation in the temperature and the
coefficient of expansion of the piping material.

The expansion of carbon steel pipe can be determined from Table 2.3.
400
300
Temperature 0o C
200
100
75
50
25
0
3 6 9 12 15 18 21 24 27 30 33 36 39 42 45
Expansion – mm per 10 m
Table 2.3: Temperate vs expansion
Piping systems and pipe supports must be designed with thermal expansion in mind.
Piping systems which are too rigid may place excessive expansion and/or contraction
forces on nozzles, flanges, couplings, etc.

Flexibility
Expansion loops built into pipework are used to enable movement. An expansion loop
is usually an offset-in piping made perpendicular to the pipe run by the use of standard
materials – the greater the offset, the greater the amount of movement which can be
absorbed.
The greater the offset, the

greater the amount of movement
which can be absorbed.
Double offset Expansion Expansion
expansion bend square bend ‘U’ bend
Fig 2.61: Expansion loops
Flexibility can be built into piping systems by other design methods

Limited flexibility Greater flexibility
Fig 2.62: Flexibility options

Cold springing
Cold springing involves offsetting branches during fabrication to minimise stresses
placed on the piping when expansion occurs. The branch is pre-stressed to account for
half the movement which would occur with thermal expansion.
Expansion places high

stress on branch pipe.
Cold
position
Hot
position
E
Expansion
By cold springing joint

excessive stress on branch
Cold
pipe is minimised.
position
Hot
position
E
-
2
Fig 2.63: Cold springing
Vibration
Vibration along with other stresses can significantly increase fatigue failure in piping
systems. Where pipework and equipment are subject to load and vibration, the load
carried and the vibration should be minimised.

Gravitational load due to
improperly supported pipe,
combined with vibration
from pump, leads to fatigue
failure of cast iron flange.
The suitably supported pipe

reduces gravitational load
on the cast iron flange,
thereby reducing likelihood
of fatigue failure.
If the problem is considered

significant enough to
warrant it, a flexible
coupling may also be used to
minimise the effect of
vibration.
Flexible coupling
Fig 2.64: Vibration

Settlement stresses
The positional relationship of equipment placed on separate foundations may
change as settlement of the foundations occurs. This may place excessive stress on
interconnecting pipework.
The problem can be overcome by allowing for this in the pipework.
Settlement of foundations
in direction shown may
cause excessive stress on
connecting pipe.
The offset allows

flexibility of the
connecting pipe thereby
minimising stress due to
foundation settlement.
Fig 2.65: Settlement stresses
Types of pipe support

Pipework can be supported by various mechanisms.
Supports
Supports are usually made from steel or concrete and are designed to support the
weight of the pipework, usually from below.

Fig 2.66: Pipe supports

Hangers
Hangers are used to support pipework from above.
Upper supports
Midsections
Pipe attachments
Fig 2.67: Pipe hangers

Guides
Guides enable movement along the pipeline but prevent movement in other directions.
Teflon pad Stainless steel
Fig 2.68: Pipe guides
Pipe-racks
Pipe racks are used to support groups of pipes and are commonly seen only outside,
as piping within buildings is usually supported from structural steelwork.
A pipe rack consists of vertical members (stanchions) and a supporting horizontal
platform on which the pipework rests. Pipe racks may be single or multi-decked
depending on the size, the number of pipes to be carried, and the available space for
the pipe rack. Pipe racks commonly serve secondary functions and generally support
lighting, cable trays or utility stations.

Fig 2.69: Order of pipes
Design guidelines for pipe racks

●● Pipework must be placed in such a way that it provides ease of access to
equipment for operation and maintenance.
●● Pipework must be placed so that it does not constitute a safety hazard.
●● Pipework should be placed so as to comply with recommended minimum
clearances:
○○ above roadways – 6 m
○○ above walkways – 2 m
○○ operating space around equipment – 750 mm.
●● Large diameter pipes may be located 300–450 mm above or below ground
because of their weight. Other piping should be suitably supported above the
ground on pipe racks or supports.
●● Piping should be placed to the side of equipment rather than above it.
●● Large liquid-filled lines should be placed close to the stanchions on a pipe rack in
order to avoid excessive stress on bents.
●● Hotlines that require expansion loops should be grouped together to the side of
pipe racks with the largest lines outermost.

Fig 2.70: Pipes with expansion loops
●● Lines on pipe racks should be spaced with the outer edges of flanges a minimum
of 25 mm apart, with the flanges offset a minimum distance of 300 mm.
25mm
300 minimum
Fig 2.71: Minimum offset of flanges within the pipe rack
●● On pipe racks, a change in the horizontal direction of pipes should be

accompanied by a change in elevation to prevent blocking of other lines on the
pipe rack.
●● When designing pipe racks additional space (20–25%) must be allowed for to
provide for future requirements.
●● The spacing of platforms depends on pipe sizes. However, it is customary to locate
them approximately 8 m apart.
●● Pipe racks should be single deck if space permits. If multi-deck racks are used,
sufficient space should be left between decks to take off branch lines.

Fig 2.72: Multi-deck pipe rack
●● A minimum distance beneath pipe racks should be maintained so that they can be
accessed easily if work needs to be carried out at a later date.
●● Elevations should be set so that lines will drain.
Positioning of pipe supports and hangers

Support of pipework is expensive and piping support specialists are usually employed
for large projects.
Sections of piping should be supported, so that each section is in equilibrium and
removing adjacent sections of piping or valves that need to be replaced will not upset
the balance of the system as a whole.
The weight of the piping should be shared equally among the pipe supports. Heavy
fittings and valves will affect the centre of gravity (balance) of the pipework and
allowances may need to be made for their removal.
Additional supports can reduce balance or sagging problems but these will also
increase costs. The best solution is to use fewer, well-placed supports.
The diagrams that follow show the basic principles that may be applied to support
pipework.
Central support is OK for short or

thick sections of pipe, but for long
or small diameter pipes, ends sag
downwards causing problems of
removal or installation.

Pipe sags in middle, preventing
complete draining.
Pipe is balanced and level, but

necessitates the additional
expense of three supports.
Ends tend to sag and middle

tends to rise due to uneven
distribution of weight.
Placement of supports as shown

to keep each half of the pipe in
equilibrium without sagging and
without the need for additional
hanger or support.
A cantilevered end will increase

the load on support #4 and
1 2 3 4 reduce the load on support #3.
Position supports close to heavy

valves where possible.

Tendency to sag Locate supports at, Use additional
around support. or as close to, riser support.
as possible.
1 2
4 5
The pipeline is supported so that any of the flanged sections may be

unbolted and removed without upsetting the balance of the line. Note
that the support for section 5 is offset to allow for the weight of the valve.

Identification of piping
To eliminate hazards associated with piping that carries hazardous materials,
Standards Australia International (SAI) has released AS 1345-1995 Identification of the
contents of pipes, conduits and ducts.
The code is designed to identify piping, ducts and conduits in general, and in ships
and associated installations for safety purposes. The code does not apply to pipelines
buried in the ground.
The code cannot be expected to cover every particular industrial requirement and
discretion should be used in its application.
Colour codes
The code uses ground colours to indicate the types of fluids carried by the pipelines. It
also uses safety colours and lettering to provide additional information.
Ground colours
Colour Type of fluid

green water
silver steam
brown oil
violet acids and alkalis
light blue air
yellow ochre gases (except air)
light orange electricity
black other fluids
Table 2.4: Ground colours
Safety colours
Colour Type of fluid
red fire-fighting materials (water, foam, etc)
safety yellow (with black stripes) dangerous materials
safety yellow (with black trefoil) ionising radiation
auxiliary blue fresh water (potable)
Table 2.5: Safety colours

Application of colour codes
Colours are applied directly to the pipe or, in the case of small pipes, over an area
immediately behind the pipe. Or, coloured tags can be used, provided that they are
attached securely to the pipe and are clearly visible.
The ground colour is applied over the full length of the pipeline or over a minimum
length of 400 mm, whichever is available.
When used in conjunction with a safety colour, the ground colour is applied for a
minimum length of 150 mm on each side of the safety colour.
The safety colour is applied for a minimum length of 75 mm where it is clearly visible.
The location of identification markings is at intervals of not more than 8 m and
preferably adjacent to branches, junctions, valves, etc.
AS 1345-1995 Identification of the contents of pipes, conduits and ducts should be
applied. Requirements laid down in other standards should also be kept in mind. For
example:
●● AS 2885.4-2010 Pipelines - Gas and liquid petroleum - Submarine pipeline
systems
●● AS/NZS 1596:2008 The storage and handling of LP Gas
●● AS 4041-2006 Pressure piping.

Chapter 3 – Drawing
Types of drawings
The main purpose of a technical drawing is to communicate fabrication requirements
clearly and simply.
To design process piping, five types of drawings are developed in sequence. These
drawings are developed from the schematics and specifications for process piping
prepared by the process engineer
In order of development, the sequence is as follows:
1. general arrangement (GA)
2. process flow diagram (PFD)
3. piping and instrumentation diagram (P&ID)
4. plot plan layout
5. orthographic and isometric drawings.
Pipe fabricators are required to work from drawings that will vary considerably.
Pipework drawings in their presentation and adherence to relevant codes do not follow
as strictly the standards laid down for other engineering drawings. The standards most
applicable to pipework drawings produced in Australia are:
●● AS 1100.101-1992 Technical drawing - General principles
●● AS 1101.1-2007 Graphic symbols for general engineering - Hydraulic and
pneumatic systems.
General arrangement
The piping plan or general arrangement (GA) drawing shows all major equipment to
scale, its north/south and east/west orientation and all piping leading to and from the
equipment. All instrumentation, access ladders and platforms are shown.
The GA will usually show a plan view (top) with elevations (side) and section elevations,
as well as all pipe dimensions and piping details including line numbers, size and
specifications with the direction of flow noted for all lines, so that the draftsperson will
have all necessary information to create the final fabrication drawings or isometrics.

76
1 2 3 4 5 6 7 8
700 700
Line 1 (80NB)
A C A
ENG2068
201
Line 1 (80NB/50NB) N
Line 3 (50NB)
300
Line 1 (80NB/50NB)
300
Line 3 (80NB) B
B
1900 563
1000
C
C RL 1400 BOP
RL 1270
RL 850
RL 707
D D
RL 550
RL 270
RL 000
E Drawing exercise E
300
Complete 3 isometric drawings &
500 785 3 material lists for each line
Unless noted otherwise Drawn CC
tolerances are:
Third angle Traced
Material Title
Checked TB
Linear
STD WT Pipe Approved
Class 150
Piping GA F
F Issued 14-8-13
Angular FLG’s
A 14-8-13 First issue CC TB Record of Issue
Issue Date Zone Change ECN BY CKD Finish Scale Size DWG No SHT
Drawing practice A
Amendments AS 1100 NTS A3 Drawing exercise 24 1
1 2 3 6 7 8
Fig 3.1: General arrangement

Dimensioning
Dimensioning of GA drawings follows conventional drawing practice closely
however, elevation (height) dimensioning needs special consideration.
Before any building or erecting begins in the field, the site is made as flat as possible
and, after levelling, is termed ‘finished grade’. The ‘highest point of finished grade’
becomes the datum from which all plant elevations are taken. This horizontal plane is
given a ‘false’ or nominal elevation, usually 100.
The nominal elevation of 100 ensures that foundations, basements, buried tanks, etc,
will have positive elevations. ‘Minus’ elevations which may cause error and nuisance
are avoided.
Horizontal distances may be expressed as distances N, S, E or W to match
distances on the plot plan. Dimensions may emanate from structural steelwork to
aid in the location of the pipework within the plant. Dimensioning practices will be
discussed in greater detail in this chapter.
Process flow diagram (PFD)

A process flow diagram (PFD) is an unscaled drawing or schematic which describes
the process of transferring material by piping.
It will:
●● state, for example, the materials to be conveyed by the piping
●● specify the rates of flow
●● list the pumps required
●● provide information such as pressure or temperature.
At this point the pipe sizes, types of valves, etc, have not been determined. The PFD
and specifications are then transferred to a piping and instrumentation (P&ID) diagram,
plot plan or isometric drawing.

78
1 2 3 4 5 6 7 8
Rev No Revision note Date Signature Checked
CW A
ENG2068
Condenser Gas
Sweet gas
Makeup water
B
Top tray Lean amine Rich amine Top tray Reflux
CW
Absorber Pump C
regenerator
Bottom Bottom
Sour gas tray tray Vapor Steam
Condensate
Lean amine
Rich amine
E
Pump
File name FSCM NO Sheet Scale
PFD
PFD1 NTS
Size
Drawn 9/9/2013
Check
Approved
F
Process Flow Diagram
Issued
DWG No
Re
Contract No
1 2 3 6 7 8
Fig 3.2: Process flow diagram

Piping and instrumentation diagram (P&ID)
The P&ID is similar to, but more detailed than, a PFD. It is a single-line schematic
drawing that includes all major equipment items, instruments and controls, major valves
and line sizes, It contains all the data necessary for the various design groups involved
in the project to proceed to the next step in the design of the plant.
D
A
F
Signature Checked
8
8
NTS
Scale
Line C-256-2ʺ
Date
P & ID
PID1
DWG No
7
7
Sheet
LGM
FSCM NO
56
Fig 3.3: Piping and instrumentation diagram

6
9/9/2013
A-8975
6
Revision note
AD
25
PID
Contract No
Approved
File name
Check
Drawn
Issued
Size
RO
Re
Rev No
5
4
Line A-256-1ʺ
34-27
3
3
Line B-256-3ʺ
2
2
Note 15
1
1

Plot plan
The draughtsperson produces a site plan which shows the whole site, including
boundaries, roads, buildings, plant areas, etc. This allows the piping engineer to
arrange equipment to optimise process requirements and design.
When the site plan has been created and the GA drawings approved, they are then
developed into ‘plot plans’ by the addition of dimensions and coordinates to locate all
major items of equipment and structures.
Dimensions and coordinates emanate from the plant datum point. Equipment
coordinates are given to the centre-lines and, depending on the company, coordinates
for pumps are given to the centre-lines of the pump discharge port.
Pipeway
Instrument Meters Drover loop

air plant
E 130.220
T 120 A E 140.000
Process unit plot limit E 36

T 20 A E 148.000
N 272.000
E 157.750
E 170A E 60 A E 159.000
N 195.550
N 206.550
E 180.500
Roadway N 110.000
N 122.000
S 120
S 80 W 20
Pipeway
E 200.500
E 170B E 60 B E 219.000
E 227.650
T 120 B E 240.000
T 120 B E 250.000
Piping skid
E 345
Control T 20 B E 260.000
room
Motor E 270.000
control room Pipeway V 220
unit
Hydro
250 KVA E 250 Pipeway

generator
W 21
E 300.000
E 270 V 250
Fig 3.4: Plot plan

Orthographic and isometric drawings
Orthographic and isometric drawings are representations of an object which are
presented in alternative views so that they can be easily understood.
T
Top view vieop
w
Fro e
vie nt Sidw
w
vie
Front view Side view
Pictorial view Orthographic view Isometric view
Fig 3.5: Pictorial, orthographic and isometric representations of a box
These drawings are used extensively in the development of process pipe systems.

Types of projection
An essential factor in piping fabrication is the ability of the tradesperson to read
technical drawings.
The most common types of projection used in piping drawings are as follows.
1. Orthographic projection.
3. Stud bolts used throughout

1. All pipe schedule 80
®
2. All flanges class 300

Sockolet
Note
EL 2290 B.O.P
N
EL 1500
L 20-3
1000 900
1200
900
200
Ø 50 NB
L 20-2
1300
900
900
900
L 20-1
Ø 200 NB

Materials list
L22
0-B
1 16 Item Qty Description Spec
50
0 Pipe
500 N
1 1 150 NB x 330 SCH80

1 2 1 150 NB x 515 “
9 50
0 3 1 150 NB x 372 “
ho 4
rizo 5 o 4 1 150 NB x 420 “
nta
l 2 5 1 90 NB x 560 “
50
0 6 1 150 N.B. x “
2. Isometric projection.
7 1 150 N.B. x “
8 1 150 N.B. x 900 “
50
9 3 0
Fittings
4 9 2 150 45o Weld ELL XS
17 90
0 “
11 10 1 150 90o Weld ELL
12 11 1 150 EQ B.W. Tee “
16
12 1 150 - 90 Conc. Red. “
18 6
L2 13 1 150 Stub end “
16 20
5 -B2
10 7 15
L2 Flanges
20 14 1 150 Lap-Joint # 600LB
-B3
8 0 15 1 90 RF WN “
14 55 16 3 150 RF WN “
F.F
.W Valves
0 17 1 150 Check W600SCO
70
13
18 1 150 Diaphragm
L2
20
-C
1
Spool drawing
Drawing No 6.36 Date 9 /11/2012
ENG2068
Scale NTS Signature
83
Orthographic projection
The views in orthographic projection are drawn as they would appear when the object
is viewed perpendicular to its surface. Visible outlines are drawn as continuous, ‘full
dark’ lines. Hidden detail is drawn as dashed ‘half dark’ lines. Usually more than one
view is required to show the object in sufficient detail to avoid any misunderstandings.
End view
Side view
Pictorial view
End view Side view
Orthographic view
Fig 3.6: Two-line orthographic view
In Figure 3.6, a simple shaft is shown in pictorial view and two views are shown in
orthographic projection. The two views are necessary in this case to completely
delineate the object. Perspective is not taken into account in orthographic views.
There are two types of orthographic projection:
●● first-angle projection
●● third-angle projection.

Third-angle projection is the preferred type while first-angle projection is used rarely in
Australia. However, it is necessary to distinguish between the two types of projection to
avoid confusion and enhance pipe fabricators’ understanding when reading drawings.
First-angle and third-angle orthographic projections are very similar in that the views of
the object do not change. The difference is in the positioning of the views. In first-angle
projection, the projected view is placed behind the object relative to the viewer. In
third-angle projection, the projected view is placed between the viewer and the object.
Fig 3.7: Pictorial view of a tapered pin
Fig 3.8: Projected end view of the pin (first-angle projection)
Fig 3.9: Projected end view of the pin (third-angle projection)
Third angle projection is used for all engineering drawings drawn in orthographic
projection.
This means that:
a) a top view is placed above the viewed object (Figure 3.10 View ‘c’)
b) a bottom view is placed below the viewed object (Figure 3.10 View ‘d’)
c) a view from the left is placed to the left of the object (Figure 3.10 View ‘b’)
d) a view from the right is placed to the right of the object (Figure 3.10 View ‘e’).

c
b a
View ‘c’
c
b e
d
View ‘b’ View ‘a’ view ‘e’
View ‘d’
Fig 3.10: Comparison of orthographic and isometric views

Isometric projection
Isometric projection is a method which enables a three-dimensional picture of an object
in one view to be drawn.
Isometric drawings are made around three principal axes at 120° to each other so
that each of the three faces is inclined equally towards the viewer. This means that
the effect of perspective is equal on all sides, thus eliminating the need for faces to be
drawn at different scales so that they appear in proportion.
1200
1200 1200
Fig 3.11: Isometric projection
The isometric axis may be rotated so that different faces of the object may be viewed
simultaneously.
To
p En
d
Side
Sid
e
om
d
En
tt
Bo
e
d
Si
m
En tto
d Bo
Fig 3.12: Isometric axis

Spool drawings
Isometric views showing details and dimensions of all lines are produced from the GAs.
These are called isometric spool drawings or simply spool drawings.
Spools
A spool is an assembly of fittings, flanges and pipes that are to be prefabricated. It
does not include bolts, gaskets, valves or instruments. Straight mill-run lengths of
pipe over 6 m are usually not included in a spool, as such lengths may be welded into
the system on erection. (On the ISO drawing, this is indicated by noting the length
and stating ‘BY FIELD’.)
A completed spool drawing will show:

●● title block information
●● the piping schedule
●● the orientation symbol
●● a view of the pipe spool
●● dimensions
●● adjoining pipe spools
●● the direction of flow of the conveyed fluid or gas.
Each pipe spool drawing may also list the materials required for fabrication of the spool.

1 2 3 4 5 6 7 8
Item Qty Description Spec
Pipe
N 1
250 BOP
0
A 72 2
A
11
3
10 4

5
6
350 BOP
7
7
8
B B
450 BOP
8
9
4
10
550 BOP
11
1 12
12
5
C 53
7 Fittings C
9 13
53 14
7 0
54 15
6
2
53
1
0
54
D 3 D
72
0 0
54
Fig 3.13: Pipe spool drawing

Note
E E
1. All pipe 80NB schedule 40
2. All flanges class 150
Unless noted otherwise Drawn CC

tolerances are:
Third angle Traced
Material Title
Checked TB
Linear
Approved
80NB Sched 40 pipe spools
F Issued 27-6-13 F
Angular
A 27-6-13 First issue CC TB Record of Issue
ENG2068
Issue Date Zone Change ECN BY CKD Finish Scale Size DWG No SHT
Drawing practice A
Amendments AS 1100 NTS A3 1
1 2 3 6 7 8
89
A pipe run in isometric is schematic in that pipes are shown by a single, bold line drawn
along the pipe’s centre-line axis. Piping components are represented on the drawing by
simple, stylised symbols which are widely accepted and more or less self-explanatory.
The drawings are not to scale, although any details relevant to fabrication and erection
are shown.
Isometric spool drawings show the pipe spool as a pictorial view. This enables the
fabricator to envisage what the finished spool will look like.
The isometric spool drawings are sent to the shop fabricator. The drawings will usually
show the complete line from one piece of equipment to another and give all the
necessary information required for the fabrication and erection of the piping.
The size of the prefabricated spool is limited by the shop fabricator’s means of transport
but a spool is usually contained within a space of dimensions 12 m × 3 m × 2.4 m.

The orientation symbol
N
N
Orthographic Isometric
Fig 3.14: Orientation symbols
The orientation symbol or ‘north arrow’ appears on all piping drawings. The
orientation symbol is of the utmost importance as it shows:
●● the direction of the piping run through the plant
●● the position of pipes relative to others
●● the relationship between pipes and other items of equipment.
The symbol is normally placed in the top right-hand corner of the drawing. On an
orthographic drawing, north is usually orientated towards the top of the page.
On an isometric drawing, north is usually drawn up and to the right. South is opposite
from north and points down and to the left. West is 90° from north however, in the
isometric, it becomes the opposite 120° line – in this case, running up and to the left.
East will be opposite to west and will run down and to the right. Pipelines running
north/south or east/west will run parallel to the ground unless otherwise noted.
Up
W N
Point of intersection
S E
Down
Fig 3.15: Point of intersection
Bisecting the north and west and the south and east reference lines is the up
and down reference line. The point of intersection (PI) is the point from which all
directions start.
Any time the pipe has a turn – north, south, east, west, up and/or down – the pipe
fabricator must imagine being at the PI to determine which way the pipe turns.

Parallel line
Parallel line drawings are used to develop a two-dimensional template of a
three-dimensional shape.
End view
0 1 2 3 4 5 6 7 8 9 10 11 12
12
8 9 10 11
7 10 Side view
11
6 12
0 9
5 1
4 2 8
3 0 1 2 3 4 5 6 7
Parallel line Isometric
Fig 3.16: Cylindrical development
Parallel line development is a method which can be applied to any object whose sides
are parallel to the axis; it is ideally suited to piping fabrication.
Parallel line development process

The parallel line method of development is used to obtain the ‘true shape’ of the object
in a rolled-out form (also called the stretch out). This method of pattern development
uses vertical parallel lines (also called generator lines) to obtain the true lengths. The
true shape is also determined by intersection lines that form in conjunction with the
vertical lines.
Determining the fabrication method

There are two choices when developing the parallel line method and that is either
the construction of a pipe from plate or a template that wraps around the pipe. Both
methods create a stretch out, by either the mean diameter (also known as the ‘neutral
axis’ – an imaginary centre-line through the plate thickness) or outside diameters when
calculating this length.
The plate method requires the mean diameter in its calculation and the pipe
wraparound uses the outside diameter. The correct use of the diameters is paramount
as the stretch out lengths will differ for both.

Construction of a pipe from plate
The pattern is drawn on, or transferred to, the plate using a centre punch, rolled into the
cylindrical shape and then cut to the pattern.
During rolling (or pressing) operations, the inside of the bend will be compressed, and
the outside of the bend will be stretched around the neutral axis.
The neutral axis is the only part of the plate whose dimension is left unchanged by the
forming operation. For this reason, it is necessary to base all calculations on the neutral
axis when the metal is rolled into a circle.
t
Neutral
axis
ter
ndiame
Mea
This side gets
compressed during
rolling.
N
A
ID = MD + t
This side is stretched OD = MD + t
during rolling.
Fig 3.17: Diameter of pipe
Sleeve templates
When working with piping, the most practical method of development is to make a
template which is then used to mark out the pipe.
Fig 3.18: Sleeve template
Calculations for the template can be based on the outside diameter of the pipe.

Drawing steps
The following example shows step by step the method of development of one half of
a simple pipe joint (pipe A). These basic principles can be applied to more complex
development problems.
Step 1
Select the view which
best shows the pipe to
be developed and draw
a ‘layout’ of the pipe
to accurate size and
shape.
Step 2
Divide the pipe
circumference into
an equal number of
spaces (12 spaces
is suitable for most
applications, more
may be required for
large diameter pipes,
or where accuracy is
important). Transfer
these ‘ordinates’ to the
pipe wall.
Step 3
Number the ordinates
in logical sequence
consecutively around
the pipe.
12 Note: Although any
6 0
7 11
10 1
numbers will suffice,
5 8 9
4 3 2 it is customary to
start the numbering
sequence with zero.

Step 4
Determine the
circumference of
the pipe using this
calculation
D×π=C
ie the diameter (D)
is measured and
multiplied by Pi (π). The
circumference is now
12 the stretch out.
6 0
7 11 0 1 2 3 4 5 6 7 8 9 10 11 12 Divide the stretch out
5 8 9 10 1
4 3 2 into 12 or 24 equal
parts. There is an
option to divide the
pattern into 24 parts
which will create a
smoother curve that
eliminates gaps;
however, 12 is usually
sufficient.
Step 5
Produce the points on
the baseline upward,
perpendicular to the
baseline. (These
represent the ordinates
12 on the pipe.)
6 0
7 11 0 1 2 3 4 5 6 7 8 9 10 11 12
5 8 9 10 1
4 3 2
Step 6
6
5, 7 The height of each
4, 8
3, 9 ordinate is the distance
10, 2
11, 1
from the base of the
12, 0 pipe to the line of
intersection. Transfer
12
6
7 11
0
0 1 2 3 4 5 6 7 8 9 10 11 12
the ordinate heights
5 8 9 10 1 horizontally across to
4 3 2 the development.

Step 7
6
As each ordinate
5, 7 height from the pipe
4, 8
3, 9 layout meets its
2, 10
1, 11 corresponding ordinate
0, 12 on the development,
it will form a series
12
6
7 11
0
0 1 2 3 4 5 6 7 8 9 10 11 12 of coordinates: eg
5 8 9 10 1 1,1:2,2:3,3
4 3 2
Locate and number
each coordinate.
Step 8
6
5, 7 Join the coordinates to
4, 8
3, 9 produce the required
2, 10
1, 11 development.
0, 12
12
6 0
7 11 0 1 2 3 4 5 6 7 8 9 10 11 12
5 8 9 10 1
4 3 2
Development of custom branch connections

The parallel line method of fabrication is used to create custom branch connections
which may be required when a standard fitting is not suitable or available.
There are two basic types of branch connection.
●● Set-in branches – where the branch line is set-into the wall of the main piping run.
The hole in the main pipe is cut to the outside diameter of the branch line.
Fig 3.19: A set-in branch

●● Set-on branches – where the branch line sits on the wall of the main piping run,
the hole in the main pipe is cut to the inside diameter of the branch.
Fig 3.20: A set-on branch
The easiest and most practical way of preparing the joint for welding is to cut pipes
with the torch held perpendicular to the surface of the pipe and grind the weld
preparation afterwards.
Acceptable methods of weld preparation are specified in:
●● AS 4458-1997 Pressure equipment – Manufacture
●● AS 4041-2006 Pressure piping.

Piping symbols
Standard symbols are used to represent fittings and equipment on piping drawings.
These symbols are used to show:
●● pipe
●● piping materials
●● direction of the piping run
●● changes of direction of the piping
●● methods of joining the pipe.
To be able to understand and interpret spool drawings, pipe fabricators will have to be
familiar with these symbols.
The draughtsperson may use a certain amount of ‘artistic licence’ to make drawings
cheaper to produce or clearer and easier to read. This means that there may be
variations in the presentation of the symbols.
An example of this may be seen in the representations of a weld-neck flange shown in
Figures 3.21 and 3.22.
Fig 3.21: Representations of a flange depicted with different line thicknesses
Fig 3.22: Representations which show a flange more graphically for clarity
Drawings may also be produced from copies of drawings made overseas where
conventions vary slightly from Australian standard drawing practice.

Symbols
General Symbol
Pipe – general symbol
Pipe – concealed at section
Pipe – in front of or above section
Crossing pipe – not connected
Crossing pipe – connected
Tee – stub in
Flexible hose
Direction of flow
Direction of fall – both types acceptable
Butt weld
Socket weld
Screwed joint
Site weld
Reinforcement – saddle
Reinforcement – wraparound, saddle
Expansion joint
Trap
End cap
Non-fixed support
Anchor point
Anchor block – at tee joint
Joint – general symbol

Pipe equipment Symbol
Apparatus – general symbol: it is preferred that the
circular symbol be used for items in which there are
rotating parts. For other apparatus, the rectangular
symbol is used.
Pump – Use Ø 10 circle
Steam trap
Strainer – general symbol
Strainer – Y type
Valves Symbol
Valve – general symbol – also for shut-off and
regulating valve – two-way
Valve – general symbol – also for shut-off and
regulating valve – angle
Shut-off and regulating valve – three-way
Reducing valve
Diaphragm valve
Safety valve
Gate valve
Globe valve
Butterfly valve
Check, non-return, reflux, one way valve
Ball valve
Needle valve
Relief valve
Plug valve
Sprinkler head – on pipe

Sprinkler head – upright
Sprinkler head – pendant

Control and regulating Symbol
Hand-operated – general symbol
Spring
Weight
Float
Piston
Diaphragm
Electric motor M
Solenoid
Fitting Double line Butt welded Socket-welded

90° elbow
Tee
45° elbow
Lateral
Eccentric reducer

Fitting Double line Butt welded Socket-welded
Concentric reducer
Cap
Specialised Fitting End view Side view End view

Weldolet
Latrolet
Sweepolet
Nipolet
Flange Symbol Mitres

Weld neck
M M M
M M M
Slip-on
Blind
Lap joint
Orifice
Reducing

Symbol guide
As a guide to the application of these symbols, consider the following information.
• The general piping symbol is always shown as the darkest line on the drawing. For
example, a section of piping with a reducer or other fitting would be shown with the
piping drawn darkest and the fitting represented by a lighter line.
• The symbol for a butt weld is shown by a dot at the location of the weld.
• A butt weld made on site would be represented by a cross over the butt weld.
Sometimes the letters FFW will accompany the site weld symbol. This stands
for ‘field fit and weld’ which means that the joint is fitted and welded on site. To
accommodate this FFW, approximately 150 mm of extra pipe is allowed. This 150
mm allowance is known as ‘green’.
• All piping drawings indicate the direction of flow with an arrow.
• Where pipes cross but are not connected, the pipe in the foreground is represented
by a continuous line and the pipe in the background is broken where the lines cross.
• A butt welded 90° elbow can be drawn two different ways.:

• While most fittings are represented by a single line, reducing fittings are drawn to
shape and approximate scale.
Butt-weld elbow Butt-weld reducing elbow
• Where elbow symbols are used, they always represent a long radius elbow unless
otherwise noted.
• Tee connections may be made by the use of a standard fitting (tee) or by fabrication
(known as a ‘stub-in’).
Joint
Symbol
Tee Stub-in
Symbols used to indicate change of direction

Symbols are used to show changes in direction of the piping run. This is one of the
more difficult aspects of pipework drawing to understand. It helps to keep in mind the
way the joint would appear in third-angle projection.
Pipe riser from bend
This symbol shows a pipe which changes direction from horizontal to vertical going
upwards towards the observer.
‘A’
Fig 3.23: Pipe riser from bend

If the pipe terminates and is left open, it is normally shaded to indicate this.
Or
Pipe dropper from bend

This is the opposite of the previous example. In this case, the vertical pipe runs away
from the observer.
’A‘
Fig 3.24: A pipe dropper from bend.
Combinations
The following symbols are used in combination to show a pipe that changes from
horizontal to vertical and back to horizontal.
Fig 3.25: Symbols used in combination

Pipes which change direction at a riser or dropper can be represented by following the
same principle.
Lower pipe runs Upper pipe runs

North/South North/South
Fig 3.26: Symbols used in combination
Pipe riser from tee
Fig 3.27: A pipe riser from tee
Pipe dropper from tee
Fig 3.28: A pipe dropper from tee

Dimensioning and line types
The dimensioning of piping drawings is in principle the same as for any other
engineering drawing. For example, leader lines, dimension lines, arrowheads, line work
and so on are all used in a similar way.
Pipe fabricators need to be aware of the following points and differences when reading
pipe drawings.
General dimensional practice

●● Horizontal dimensions are given to vertical leader lines.
●● Principal dimensions are given to changes of direction.
●● Secondary dimensions are given to items of equipment such as reducers.
●● To aid erection a pair of dimensions locating the pipework to plant or equipment
is usually given.
●● Although isometric drawings are not drawn to scale, valves and fittings are
drawn reasonably proportional, especially where a fitting to fitting arrangement
locates a valve. For example, in Figure 3.29, the valve is clearly at the elbow –
not the tee.
Fig 3.29: Isometric spool
●● Vessels and other equipment items are dimensioned to their centre-lines and
the faces of flanges or nozzles.
●● The centre-line elevation of horizontal nozzles, and the face elevation of vertical
nozzles are given for vessels and equipment.
●● Reducers not located by a fitting-to-fitting arrangement are dimensioned to their
large end.

Single- and double-line comparison
When orthographic projection is used, pipelines may be drawn as either single-line or
double-line drawings. Double-line representation shows the two edges of the pipework
and is usually used for pipes over Ø 350.
Double-line drawings show a more graphic representation of the pipework; however,
these are more difficult and more expensive to produce.
Fig 3.30: Double-line pipe
Single-line orthographic drawings represent the pipe by its centre-line only, which is
drawn as a continuous heavy line (usually the darkest line on the drawing). The size of
the pipe is shown by drawing a representation of the pipe end to scale, either at the end
of the line or some other convenient place.
Pipesize
drawn to scale
Fig 3.31: Single-line pipe
On single-line diagrams, all fittings – except reducing fittings – are drawn single-lined.
Single-line drawings are generally used for pipework under Ø 350.
Single-line drawings with their use of stylised symbols are easier and quicker,
and therefore cheaper to produce. Single-line drawings are easy to read, and this
advantage, coupled with their lower cost, makes them the preferred type.
Fig 3.32: Comparison of double-line drawing and single-line drawing

Running dimensions
Dimensions on piping drawings are not from a common reference point like they are in
structural drawings; they are placed consecutively as running dimensions.
Structural practice
Piping practice
Fig 3.33: Structural and piping practice
Item number identification

On all spool drawings, the line identification number is placed on the pipe. The
adjoining spool piece is shown as a dashed line, and its identification number is given.
The line identification number should be placed above the line representing the pipe,
and elevations should be placed below it.
C2
00 -
L3
C2
Elev 0
atio 0 - L2
n 22
1.65
0
Fig 3.34: Pipe identification

Use of levels and grids
When a plant is designed, a system of levels is used to refer to elevations, and grids
are used to make reference to horizontal dimensions.
Levels are taken from the lowest part of the plant (datum), which is given a positive
elevation, eg 30 m. This positive elevation enables sumps or other below-ground
equipment to be dimensioned without the need for minus elevations.
EL 38.000 EL 37.750
EL 35.000
EL 32.000
datum EL 30.000
EL 29.000
Fig 3.35: Elevations
Grids are normally taken from the south-west corner of the plant. Distances north and
east of this point are referenced. For example, the tower on the plot in Figure 3.36 is
situated at N44.000, E20.000.
60―
N 56.000 Roadway
N 52.000
50―
N 44.000
E 150.000
40―
E 20.000
30―
20―
N
E 30.000
10―
E 100.000
―
10 20 30 40 50 60 70 80 90 100 120 130 140
Fig 3.36: A grid
It is common practice to dimension pipework with reference to levels and grids, and
also to give dimensions from structural steelwork within the plant.

Flanged joints
Dimensions are given to the faces of flanges. Most flanges have gaskets and the
thickness of the gasket is indicated with ‘hash’ marks which show where the gasket is
included in the valve dimension.
The total dimension between the flange faces, including the gasket, should be given.
Fig 3.37: Flange dimensions
Valves
Standard valves (especially butt- or socket-welded valves) are usually dimensioned to
their centres. The valve stem is shown in its proper orientation, and the valve number is
usually shown along the valve centre-line.
V136
150
Fig 3.38: Valve dimensions

Offsets
An offset is a line running in a direction other than along the axes, ie other than up,
down, north, south, east or west. It is sometimes difficult to determine the direction
of an offset and a 45° offset in a horizontal direction may appear the same as a 45°
offset in a vertical direction. If clarification is needed, a simple grid and note are usually
provided.
In this example, the pipe is drawn the same in both cases. It is the grid which
determines the direction of the piping run.
Up
W N
S E
Down
l
ical n ta
ert rizo
o V Ho
45
o
45
Fig 3.39: A simple offset
Offsets and angles are not always what they appear to be when drawn in isometric
projection.
Up
W N
S E
Down
C
Fig 3.40: A simple offset with a change of direction

Angle ‘A’ is actually a right angle. Angle ‘B’ is drawn at 90° and shows a pipe changing
direction from the vertical to run to north-east. Angle ‘C’ represents a horizontal offset
from north.
The basic symbols used to show pipe and changes of direction are used to show
offsets. When interpreting symbols depicting offsets, it is important to keep in mind the
view as it would appear in third-angle projection.
The following figure shows a 45° elbow as it would appear in orthographic projection
and as it would appear when represented symbolically.
45o Elbow – Orthographic
45o Elbow – Isometric
Fig 3.41: 45° elbow – Orthographic and isometric
Laterals or branch lines are shown in the same manner.
Fig 3.42: Laterals or branch lines
When an ellipse appears as it does in the examples above, it is always an indicator of

an offset or a branch other than 90°.

Compound offsets
Whereas an offset changes its orientation in two directions, eg up and to the west, or
to the south and east, a compound offset changes its orientation in three directions at
once.
In Figure 3.43, the pipe runs upward to the west and to the north from the point of
intersection.
Dime
nsion
P.I.
Fig 3.43: A compound offset
A compound offset is indicated by the ‘box’ shown in Figure 3.43. Lines (both the pipe
and the box) are broken to indicate which is in the foreground, and the offset length is
always dimensioned with a dimension line running parallel to the offset.
Offset boxes should not be drawn as squares even when offset dimensions are the
same in two or more directions. It is necessary to draw offset boxes as rectangles or
the projection will appear incorrect with offsets running along the major axes.

Chapter 4 – Fabrication methods
Pipe fabrication
Pipe fabrication involves assembling pieces such as elbows, tees and flanges into
sections which, along with the pipe and all other equipment, can be accurately fitted
together into the plant.
Because of the cost and importance of such lines, pipe fabricators must assemble
and weld pipes together with a high degree of precision. This requires careful thought
and planning, accurate layout of work and control of welding operations as well as the
competent use of jigs, templates and other precision tools.

Preparing for fabrication
In preparation for fabricating, fabricators are required to calculate all the necessary
pipes and fittings according to the drawing specifications. The pipe fabricator will need
to take into consideration welding and tack welding processes along with any distortion
that may arise from welding. The tools required for the fitting-up of pipes and flanges,
such as pipe supports and clamps will also need some thought.
Extracting information from drawings

After careful scrutiny of the drawing, it is the fabricator’s job to check their interpretation
of the drawing by quickly constructing a simple wire model of the pipe spool.
The project design model may also be consulted (if available), especially for complex
pipe spools. Construction of a wire model will help the fabricator with interpretation as
well as with determining the best sequence of fabrication.
Before fabrication starts, workshop sketches or isometric spool drawings are prepared
from either general arrangements (GAs) or isometrics. These drawings contain all the
information the fabricator needs to be able to fabricate pipes. The fabricator will also
be supplied with accurate material take-off lists and a copy of the client’s fabrication
specifications.

Materials list
L22
0-B
1 16 Item Qty Description Spec
50
0 0 N Pipe
50
1 1 150 NB x 330 SCH80

1 2 1 150 NB x 515 “
9 50
0 3 1 150 NB x 372 “
ho 4
rizo 5 o 4 1 150 NB x 420 “
nta
l 2 5 1 90 NB x 560 “
50
0 6 1 150 N.B. x “
7 1 150 N.B. x “
8 1 150 N.B. x 900 “
50
9 3 0
Fittings
4 9 2 150 45o Weld ELL XS
17 90
0 “
11 10 1 150 90o Weld ELL
12 11 1 150 EQ B.W. Tee “
16
12 1 150 - 90 Conc. Red. “
18 6
L2 13 1 150 Stub end “
16 20
5 -B2
10 7 15
L2 Flanges
20
Fig 4.1: Isometric spool drawing

-B3 14 1 150 Lap-Joint # 600LB
8 15 1 90 RF WN “
14 550
16 3 150 RF WN “
F.F
.W Valves
0 17 1 150 Check W600SCO
70
13
18 1 150 Diaphragm
L2
20
-C
1
Spool drawing
Drawing No 6.36 Date 9 /11/2012
ENG2068
Scale NTS Signature
117
Calculations
To fabricate a spool system, the fabricator must be able to calculate the cutting length
of pipes and take into account the sizes of fittings, flanges and weld preparation. The
allowance for fittings and flanges can be gained from standard tables however the weld
preparation may range from 2 mm to 3 mm.
Y(1) Y(2)
C(1) C(2)
Fig 4.2: Weld neck flange
Y(1) C(1) C(2) Y(2)
Fig 4.3: Slip on flange
Allowance for welding gap and weld shrinkage can be calculated in various ways and
the weld gap required may vary. As a general rule the weld will shrink approximately
half the root gap, so this needs to be considered when working out calculations.
The fabricator may also want to confirm the weld shrinkage by completing a weld test
and making adjustments as necessary. All the gaps noted in this text are 3 mm.

400 500
A B
400 500
A B
Fig 4.4: Double-line and single-line orthographic view with dimensions
To calculate pipes A and B, extract information such as the nominal size (NS) and
schedule (SCH) from the drawing.
●● NS = 100 – the average diameter of the pipe
●● SCH = 40 – the thickness of the pipe
●● Class 150
Now we need to identify the lengths of each pipe, remember that the dimension lines
work from the centres of the pipe.
●● Pipe A = 400 – the length of the pipe from the centres
●● Pipe B = 500 – the length of the pipe from the centres
The lengths of the fittings now need to be worked out. (Fittings can measure from the
centre to the face, or face to face; they are all obtained from charts.)

400 500
A B
76 105 105 152
Fig 4.5: Double-line orthographic view with dimensions
●● Raised face weld neck (RFWN) = 76. This information is on the data charts under
flanges to American standards column Y1. Different class options should be noted.
●● Equal tee = 105. This can be found on the data charts in the carbon steel butt
welding fittings column marked ‘C’.
●● 90° long radius elbow 90ELB = 152. This can be found on the data charts in the
carbon steel butt welding fittings column marked ‘A’.
●● The weld preparation gap = 3.
●● The weld shrinkage =1.5.
Once this information has been determined, it can be applied to a simple equation,
such as:
Pipe A = 400 – 152 – 105 – 3 – 3 + 1.5 + 1.5 = 140
Pipe B = 500 – 105 – 76 – 3 – 3 + 1.5 + 1.5 = 316
Piping schedule
The piping schedule is simply a materials list similar to that found on other engineering
drawings. The schedule gives details of all the pipes, valves and fittings used to
fabricate the pipe spool and is usually divided into sections for different materials such
as tubes, fittings, valves, flanges, bolts.
It contains all the materials needed to fabricate the pipe spool shown on the drawing,
with each item clearly numbered. Standard abbreviations are always used in the
piping schedule.

Material list
Description of item Description of item
Nom Nom
size Sch Type or Std Qty size Sch Type or Std Qty
Tubes
Flttings
Flanges
Jolnts
Mlsc
Valves
Bolts
Fig 4.6: A piping schedule
Tools
A pipe fabricator relies on a selection of quality tools to construct and align piping
systems.
These tools usually consist of a large plate square, a pipe square, level(s), a
combination square, a protractor set, flange pins, wraparound tapes and a pipe
alignment device. The only tools that pipe fabricators may not be familiar with are the
wraparound tapes, flange pins and pipe alignment devices, which are specialised to the
pipe fabrication trade.

The wraparound
The wraparound – sometimes referred to as a ‘runaround’ – is a flat strip of flexible
material about 1.5–3 mm thick, 75–100 mm wide and 450 mm or more long. It is
made of any composition gasket material or leather belting. The edges must be
perfectly straight. The length may vary, but the wraparound should be long enough
to go around the pipe one-and-a-half times, so that it may be lined up to make it
possible to obtain a straight line around the pipe.
When laying out a straight line around a pipe, the wraparound should be placed on
the pipe at the location of the centre-line, and the edges should be lined up. A chalk
line should be drawn around the pipe with a piece of engineer’s chalk and using the
edge of the wraparound as a guide.
Fig 4.7: Using a wraparound
Depending on the sizes of the pipes and fittings, lifting tackle may be necessary and
chain blocks, turfers and cranes are often required. Three legged adjustable pipe
stands, adjustable trestles and adjustable pipe rollers are essential for successful pipe
fabrication.
Ratchet line up clamp Pipe claw
Figure 4.8: Typical pipe joint alignment devices
Carelessness must be avoided when tools are being used as this will impair their
accuracy. Levels and squares should be checked periodically, because a level that
does not read correctly or a square that is ‘out of square’ can result in serious errors.

Fabrication process
The fabrication process requires tradespersons to assemble pipes and pipe fittings
according to the spool drawing. Pipe fabricators need to take into consideration the size
of the assembly, as transport may become an issue. Sub-assemblies are an effective
way of transporting large projects.
Assembly methods
Before fabrication starts, the fabrication specifications, the weld procedure for
fabrication tolerances, the dos and don’ts and weld preparations must be consulted.
When the fabrication sequence and sub-assemblies have been identified, the
sub-assemblies are broken into pipe runs and given numbers for easy identification.
Cutting sizes are then calculated and the fabrication specification is checked to
determine the shortest run of straight pipe that can have a welded joint. The fittings
must be checked for size before the calculation of run lengths. Catalogues give nominal
sizes, and actual sizes may vary.
Assembly of sub-assembly
Appropriate equipment such as marking out tables, adjustable pipe stands, levels, etc
is used to set up and tack individual pipe components. Weld preparation root gap is
determined from the welding procedure and by consulting the welding operator. The
welding procedure will in most cases allow slight leeway to accommodate the specific
requirements of the welding operator.
Usually a piece of wire or a welding electrode of the correct diameter bent to a ‘V’
shape will give the required gap. Depending on the diameter of the pipe, four tack
welds, 25 mm long and 90° apart are usually adequate. On large tubulars, it may be
necessary to have tacks 150 mm long with multiple passes.
As fabrication of sub-assemblies continues, the welding operator can be welding the
rolling butts and flanges of the sub-assemblies.
As work progresses, dimensions should be continually checked and shrinkage
dimensions of welds checked and adjustments made, if appropriate. Distortion of
sub-assemblies should also be monitored and corrected before incorporation into final
assembly.
If distortion occurs, the fabrication specification is checked to determine whether
deviation is within acceptable limits. If not, it is rectified by applying spot heating (if
permissible) or other means such as mechanical pressing.
Welded sub-assemblies should be set up to comply with the configuration and
dimensions on the fabrication drawing. Once tacked, the assembly is ready for welding.
It is essential that the assembly is well supported and that all necessary precautions
are taken to reduce distortion.
Two or more sub-assemblies can often be tacked up and welded before incorporation
into the final spool assembly.
After welding, the assembly should be checked for distortion and dimensional accuracy
and rectified if not within acceptable limits.

Cutting the pipe
The process by which pipe is cut is determined by its ferrous or non-ferrous nature.
There are several types of cutting machines available, both hand and mechanical.
Tools such as pipe cutters, joint profile machines, oxy and plasma cutting tools are all
appropriate for cutting pipe.
To ensure accuracy of cut, a scribed line should be centre punched every 10 mm.
Dividing the pipe surface into four equal parts

The pipe fabricator is often required to divide the pipe surface into four equal parts this
will aid in the assembly process.
The four equal parts now become centre-lines from which to take measurements, and
in which to locate fittings.
The fabricator is required to follow these four steps to achieve this.
1. Wrap a strip of paper around the pipe.
2. Double the paper as shown in Figure 4.9 and double it again. This will divide the
paper into four parts. The distance between an end and a crease, and between
each crease, is equal to a quarter of the circumference.
3. Place the paper around the pipe.
4. Mark the pipe with engineer’s chalk at each crease and where the two ends meet.
Fig 4.9: Dividing pipe surface into four equal parts

Bevelling
After cutting, weld preparation bevels should be prepared to weld procedure
specification.
If an oxy-cutting process is used, the pipe edge should be heated slightly to help
produce a smooth cut face.
Slag from the oxy cutting must be removed before bevelling starts.
Excellent results can be produced manually with oxy cutting equipment if the bevel is
made from the root face of the preparation, cutting back to the outer surface. With this
technique, the distance from the top of the flame’s inner cone is slightly increased to
ensure that the root face is not damaged by excessive heat.
When oxy cutting is finished, the slag, oxide and burrs from both the bore and the
external surface of the pipe should be removed. The preparation may be smoothed by
grinding of filing.
It is critical that weld preparations comply completely with the weld procedure
specification, because incorrect weld preparation is often a reason for rejection of
prepared butt joints by inspectors and welding operators.
The following problems are common reasons for rejection:
1. not enough or too much, root face
2. not enough or too much, gap
3. misalignment
4. bevel not adequately prepared, ie inadequate bevel and not enough metal removed
with round bevel surface (see Figure 4.10).
Rounded face bevel

restricts access to root.
Fig 4.10: Unsuitable weld preparation

Lining up the pipe
Correct alignment of the pipe and pipe fittings is one of the most important tasks
performed by the pipe fabricator. The methods of ensuring correct alignment will vary
depending on available equipment and there is no one ‘best system’.
The procedures suggested here are common and will enable pipe to be quickly and
accurately aligned using manual tools.
Setting of flanges
There are no hard and fast rules as to when to set flanges on the assembly; they
may be placed on sub-assemblies to facilitate setting up and welding. However, it is
generally deemed best practice to set up flanges once the pipe assembly has been
completed, as this approach allows for any minor inaccuracies to be rectified as flanges
are placed.
Flanges are more likely to remain accurate and in correct alignment, as their final
position after welding is not going to be influenced by the expansion and contraction
stresses (distortion) of other welds in the assembly which may have to be welded after
the flanges have been placed.
Once the flanges have been placed, it is important to make sure that the assembly
is level and accurately set. This can be done using appropriate tools such as spirit
levels, plumb lines and squares. The pipe should also be checked to see that it is
dimensionally correct to accept the flange.
The flange should be positioned using a level, ensuring that the boltholes straddle the
centre-line (unless otherwise stated). Flanges must be positioned equally around the
pipe diameter. This can be made easier using small wedges which have been created
by tapering the end of welding rod stubs.
Four 25 mm long tacks are usually adequate, but it depends on the diameter of the
flange.
After the flanges have been tacked, it is important to check dimensions and hole
positions. The flange is then ready for welding.
Fitting up the pipes

The two pipes to be welded must be properly and accurately aligned before they are
welded. There must be no misalignment of the internal bore or the external surface
of the pipe and the pipes and pipe fittings must be aligned so that the finished piping
system will be in the correct location and orientation. Considerable skill is required to fit
up two pipes in preparation for welding and this is an essential and fundamental part of
the pipe fabricator’s responsibility.

Tacking the pipe
There are several ways in which pipe joints can be tack welded.
Bridge tacks
A rod or bar of base metal composition is used to bridge the root gap by tack welding
to the groove sides. The bridge rod and tacks are not incorporated into the final joint,
thus ensuring an accurate joint for the welding operator and eliminating the chances of
a defective tack being incorporated into the final weld. Bridge tacks are normally placed
by the pipe fabricator.
Fig 4.11: Bridge tacks
Integral tacks
Integral tacks must be placed with care as they form part of the root run. For this
reason, tacking is not normally done with stainless steel or alloy materials until
pre-purging and purging have been completed.
Both ends of the tack should be carefully ground to a feathered edge to allow the tie-in
of the remainder of the root bead. Integral tacks must be done by a coded welder.
Fig 4.12: Integral tacks

It is highly desirable that tack welds be removed as welding progresses.
Green or run off

The complete assembly shown on a spool drawing is seldom completely welded in the
workshop due to allowances being made for site variation.
Depending on the complexity of the pipe spool, it is often necessary to leave extra
material length on the pipe to allow for site variations. This extra length is often called
‘green’ or ‘run off’.
Usually 150 mm of ‘green’ is left when the drawing indicates a fit and field weld (FFW).
In addition, selected flanges should only be tacked where possible to accommodate
site variations and any inaccuracies of the fabricated spool.

Welding process
Several considerations need to be looked at when pipes are being welded together.
These include the grade of material, the welding process and the thickness of the
material. These factors determine the consumables, type of welding machine and the
design of weld preparation according to standards.
Preparing for welding

Contaminants such as grease, oil, scale or rust will have harmful effects on the quality
of the weld. All traces of the oxide produced by oxygen/fuel cutting must be removed by
filing, grinding or wire brushing.
The pipe fabricator/welder must also make sure that any other contaminants are
removed before starting to weld. This can usually be accomplished by vigorous
application of a wire brush. Stainless steels and other exotic alloys must be degreased
with a suitable solvent immediately before welding. After cleaning, the piping should be
handled with clean hands or clean gloves to ensure that the base metal and filler metal
remain clean.
Butt joints
In butt joint preparation, two important factors emerge:
●● the shape of the groove, which relates to wall thickness
●● the pipe roundness, which affects accuracy. (If the pipe is out of round, the weld
joint may be misaligned.)
A small root face is recommended for good root penetration. Where a feathered edge is
used, there is a tendency to melt away unevenly during welding. This makes it difficult
to control the weld pool and can result in weld defects such as uneven penetration.
A U joint is preferred for heavy wall pipe.
Butt welds are usually single-Vee preparations with the dimensions shown, unless the
piping system is of a large enough diameter that access is permitted.
30 ° + 7½
–0
1.5 - 3 mm 1.5 mm
Fig 4.13: Single-Vee butt

For detailed information on butt weld preparation, refer to:
●● AS/NZS 3992:1998/Amdt 1:2000 Pressure equipment – Welding and brazing
qualification
●● AS 4458-1997 Pressure equipment – Manufacture.
Branch joints
It should be noted that difficulties arise when setting up set-in branches. These joints
should be only used where design conditions do not permit set-on type joints. Typical
examples of the use of set-in joints are branch joints in pressure vessels, high operating
pressures and corrosive media. The applicable codes mentioned previously contain
recommendations.
x x
Y
w
Set-on unequal branch Set-on equal branch
45 ° s
min 45 ° g g
min
g 3 mm
Ledge
Section at X Section at Y Section at W
Fig 4.14: Set-on branches

When the hole in the header is cut by oxygen fuel gas, the ledge illustrated should be
obtained. This can be removed by grinding if required. Alternatively, if the hole in the
header is prepared by machining, this ledge will not be obtained (see section at W).
x x
Y1 Y2
45 °
min
s 45 ° 45 °
s min
min
g
g
60 °
min g
s g
s = 1.5 mm ± 0.8 mm
g = 2.5 mm ± 0.8 mm
Fig 4.15: Set-in branches
Flanges
The clearance between the base of the flange and the outside diameter of the pipe
should not typically exceed 3 mm at any one point, and the sum of the clearance
diametrically opposite should not be more than 5 mm.
The section of flange type and joint to be used will depend on the service requirements.

Weld neck flange
1 See recommended weld

preparation.
2 Where access permits joint

may be background and
back welded.
Fillet welded flange

F2
1 F1 = 1.5t
F1 2 F2 - t min
t t
Hubbed flange
F2
1 F1 - 1.5t but should not
exceed 16 mm.
2 F2 = t min
F1
t t
Fig 4.16: Weld specifications for flanges
Distortion
Distortion is easily controlled in pipe butt joints by ensuring that the heat input is
equalised all around the joint. Fit-up is most important as an uneven root gap means
that, where the gap is wider, more weld metal is required and the uneven shrinkage
forces can cause distortion. Tacks must also be strong enough to hold the root gap
even.
Welders can sometimes be tempted – especially when settled into a comfortable
position – to carry on with the next pass before completing the previous pass all around
the joint. The unequal heat input obtained causes unequal shrinkage which results in
angular distortion.
Where two or more welders are welding the same joint, it is important that the welding
procedure is balanced so that the heat input is even all around the joint.
When pipe branch joints are being welded, it is advisable to tack weld a stay or stays to
maintain the correct alignment.

Fig 4.17: A temporary stay to maintain alignment
Where a number of branch joints are in close proximity to each other as in the branches
from a header pipe, the problem of the header pipe becoming distorted needs to be
avoided.
One way of overcoming this problem is to attach a suitable strong back to the header
pipe on the side opposite the branch welds.
Fig 4.18: Minimising distortion in a header pipe
Further information on welding can be found in the technical notes available for
purchase from Welding Technology Institute of Australia.

MRC Data Chart reproduced with the permission of MRC Global Australia.

Appendix 1 – MRC Data Chart
Data Chart
Pipe | Fittings | Flanges
Face Side of Chart Reverse Side of Chart

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The information contained in this data chart is provided in good faith, and every reasonable effort is made to ensure that it is correct and up to date. However MRC does not warrant the accuracy
and completeness of the information within this data chart. Accordingly, this information is provided 'as is' without warranty of any kind. Any person relying on any of the information contained in this
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To the fullest extent permitted by the applicable law, MRC hereby disclaims any liability and in no event shall MRC be liable for any damage including, without limitation, direct, indirect or consequential
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inaccuracies, omissions or errors.

sTeel PiPes TO ameriCaN sTaNDarD asme B36.10
Dimensions (mm)
Weight (kg/m)
Nominal size
Outside Nominal Wall Thickness & Weight for
Diameter Welded & seamless steel Pipe asme B36.10
eXTra XX sCHeD. sCHeD. sCHeD. sCHeD. sCHeD. sCHeD. sCHeD. sCHeD. sCHeD. sCHeD.
DN NPs mm sTD
sTrONG sTrONG 10 20 30 40 60 80 100 120 140 160
1.73 2.41
6 1/8 10.3 0.37 0.47 – – – – – – – – –
2.24 3.02
8 1/4 13.7 0.63 0.80 – – – – – – – – –
2.31 3.20
10 3/8 17.1 0.84 1.10 – – – – – – – – –
2.77 3.73 7.47 4.78
15 1/2 21.3 1.27 1.62 2.55 – – – – – – – 1.95
2.87 3.91 7.82 5.56
20 3/4 26.7 – – – – – – –
1.69 2.20 3.64 2.90
SAME AS EXTRA STRONG W.T. (X.S.)

3.38 4.55 9.09 6.35
SAME AS STANDARD W.T. (Std. W.T.)

25 1 33.4 – – – – – – –
2.50 3.24 5.45 4.24
3.56 4.85 9.7 6.35
32 1 - 1/4 42.2 – – – – – – –
3.39 4.47 7.77 5.61
3.68 5.08 10.15 7.14
40 1 - 1/2 48.3 – – – – – – –
4.05 5.41 9.56 7.25
3.91 5.54 11.07 8.74
50 2 60.3 – – – – – – –
5.44 7.48 13.44 11.11
5.16 7.01 14.02 9.53
65 2 - 1/2 73.0 – – – – – – –
8.63 11.41 20.39 14.92
5.49 7.62 15.24 11.13
80 3 88.9 11.29 15.27 27.67 – – – – – – – 21.35
5.74 8.08
90 3 - 1/2 101.6 – – – – – – – – –
13.57 18.63
6.02 8.56 17.12 11.13 13.49
100 4 114.3 16.07 22.32 41.03 – – – – – 28.32 – 33.54
6.55 9.53 19.05 12.7 15.88
125 5 141.3 – – – – – –
21.77 30.97 57.43 40.28 49.11
7.11 10.97 21.95 14.27 18.26
150 6 168.3 – – – – – –
28.26 42.56 79.22 54.20 67.56
8.18 12.7 22.23 6.35 7.04 10.31 15.09 18.26 20.62 23.01
200 8 219.1 –
42.55 64.64 107.92 33.31 36.81 53.08 75.92 90.44 100.92 111.27
9.27 12.7 25.4 6.35 7.8 XS 15.09 18.26 21.44 XXS 28.58
250 10 273.1 –
60.31 81.55 155.15 41.77 51.03 81.55 96.01 114.75 133.06 155.15 172.33
9.53 12.7 25.4 6.35 8.38 10.31 14.27 17.48 21.44 XXS 28.58 33.32
300 12 323.9 –
73.88 97.46 186.97 49.73 65.20 79.73 108.96 132.08 159.91 186.97 208.14 238.76
9.53 12.7 6.35 7.92 Std.W.T. 11.13 15.09 19.05 23.83 27.79 31.75 35.71
350 14 355.6 –
81.33 107.10 54.59 67.90 81.33 94.55 126.70 158.10 194.96 224.65 253.56 281.70
9.53 12.7 6.35 7.92 Std.W.T. XS 16.66 21.44 26.19 30.96 36.53 40.49
400 16 406.4 –
93.27 123.30 62.64 77.83 93.27 123.30 160.12 203.53 245.56 286.64 333.19 365.35
9.53 12.7 6.35 7.92 11.13 14.27 19.05 23.83 29.36 34.93 39.67 45.24
450 18 457 –
105.16 139.15 70.57 87.71 122.38 155.80 205.74 254.55 309.62 363.56 408.26 459.37
9.53 12.7 6.35 Std.W.T. XS 15.09 20.62 26.19 32.54 38.1 44.45 50.01
500 20 508 –
117.15 155.12 78.55 117.15 155.12 183.42 247.83 311.17 381.53 441.49 508.11 564.81
9.53 12.7 6.35 Std.W.T. XS 22.23 28.58 34.93 41.28 47.63 53.98
550 22 559 – –
129.13 171.09 86.54 129.13 171.09 294.25 373.83 451.42 527.05 600.63 672.26
9.53 12.7 6.35 Std.W.T. 14.27 17.48 24.61 30.96 38.89 46.02 52.37 59.54
600 24 610 –
141.12 187.06 94.53 141.12 209.64 255.41 355.26 442.08 547.71 640.03 720.15 808.22
9.53 12.7 7.92 XS
650 26 660 – – – – – – – – –
152.87 202.72 127.36 202.72
9.53 12.7 7.92 XS 15.88
700 28 711 164.85 218.69 – 137.32 218.69 271.21 – – – – – – –
9.53 12.7 7.92 XS 15.88
750 30 762 176.84 234.67 – 147.28 234.67 292.18 – – – – – – –
9.53 12.7 7.92 XS 15.88 17.48
800 32 813 188.82 250.64 – 157.24 250.64 312.15 342.91 – – – – – –
9.53 12.7 7.92 XS 15.88 17.48
850 34 864 200.31 266.61 – 167.20 266.61 332.12 364.90 – – – – – –
9.53 12.7 7.92 XS 15.88 19.05
900 36 914 212.56 282.27 – 176.96 282.27 351.7 420.42 – – – – – –
9.53 12.7
1050 42 1067 248.52 330.19 – – – – – – – – – – –
Formula to attain approximate mass in kilograms per metre (kg/m) for steel round Pipe and Tubing
Where: m = mass to the nearest 0.01 kg/m eXamPle: Nominal Size Step 1. 323.9 – 9.53 = 314.37
m = (D – t) t x 0.02466 D = Outside Diameter in millimetres Step 2. 314.37 x 9.53 = 2995.9461
DN300 NPS12
(To nearest 0.1mm for OD up to 406.4mm) OD = 323.9mm Step 3. 2995.9461 x 0.024 66
(To nearest 1.0mm for OD 457mm and above) W.T. = 9.53mm = 73.88kg/m
t = Wall Thickness to nearest 0.01mm
1 1
1 Steel Pipes to ASME B36.10 Stainless Steel Pipes to ASME B36.19 2

2 2
sTaiNless sTeel PiPes TO ameriCaN

sTaNDarD asme B36.19
Nominal Wall Thickness & inside Diameter (mm)
Outside
Nominal schedule 5s schedule 10s schedule 40s schedule 80s
Diameter
size DN Wall inside Wall inside Wall inside Wall inside
(mm)
Thickness Diameter Thickness Diameter Thickness Diameter Thickness Diameter
6 10.29 – – 1.24 7.81 1.73 6.83 2.41 5.47
8 13.72 – – 1.65 10.42 2.24 9.24 3.02 7.68
10 17.15 – – 1.65 13.85 2.31 12.53 3.20 10.75
15 21.34 1.65 18.04 2.11 17.12 2.77 15.80 3.73 13.88
20 26.67 1.65 23.37 2.11 22.45 2.87 20.93 3.91 18.85
25 33.40 1.65 30.10 2.77 27.86 3.38 26.64 4.55 24.30
32 42.16 1.65 38.86 2.77 36.62 3.56 35.04 4.85 32.46
40 48.26 1.65 44.96 2.77 42.72 3.68 40.90 5.08 38.10
50 60.33 1.65 57.03 2.77 54.79 3.91 52.51 5.54 49.25
65 73.03 2.11 68.81 3.05 66.93 5.16 62.71 7.01 59.01
80 88.90 2.11 84.68 3.05 82.80 5.49 77.92 7.62 73.66
100 114.30 2.11 110.08 3.05 108.20 6.02 102.26 8.56 97.18
125 141.30 2.77 135.76 3.40 134.50 6.55 128.19 9.52 122.25
150 168.28 2.77 162.74 3.40 161.47 7.11 154.05 10.97 146.33
200 219.08 2.77 213.54 3.76 211.56 8.18 202.72 12.70 193.68
250 273.05 3.40 266.24 4.19 264.67 9.27 254.51 12.70 247.65
300 323.85 3.96 315.93 4.57 314.71 9.52 304.08 12.70 298.45
350 355.60 3.96 347.68 4.78 346.05 - - - -
400 406.40 4.19 398.02 4.78 396.85 - - - -
450 457.20 4.19 448.82 4.78 447.65 - - - -
500 508.00 4.78 498.45 5.54 496.93 - - - -
600 609.60 5.54 598.53 6.35 596.90 - - - -
750 762.00 6.35 749.30 7.92 746.16 - - - -

CarBON sTeel BUTTWelDiNG FiTTiNGs TO
asme B16.9, B16.28 & Bs.1640
B16.9 B16.28
LONG RADIUS WELDING ELBOWS, RETURN BENDS & CAPS SHORT RADIUS WELDING ELBOWS & RETURN BENDS
B
K
A E D V
B
A A A D D D
90° 45° 180° 90° 180°
Wall Thickness (mm)

Nom. Pipe e. std. Nom.
size OD sch. sch. sch. std. sch. sch. sch. sch. sch. sch. sch. X.X. a B K D V Wt. & size
DN mm X stg. ex. stg. DN
10 20 30 Wt. 40 60 80 100 120 140 160 stg.
15 21.3 — — — 2.77 — 3.73 — — — 4.78 7.47 38 16 47.5 — — 25.4 15
20 26.7 — — — 2.87 — 3.91 — — — 5.56 7.82 38 19 43 19 33 25.4 20
25 33.4 — — — 3.38 — 4.55 — — — 6.35 9.09 38 22 55.5 25.4 41 38.1 25
32 42.2 — — — 3.56 — 4.85 — — — 6.35 9.70 47.5 25.4 70 32 52 38.1 32
SAME AS X. STG.
SAME AS STD. WT.
40 48.3 — — — 3.68 — 5.08 — — — 7.14 10.15 57 29 82.5 38 62 38.1 40

50 60.3 — — — 3.91 — 5.54 — — — 8.74 11.07 76 35 106 51 81 38.1 50
65 73.0 — — — 5.16 — 7.01 — — — 9.53 14.02 95 44.5 132 63.5 100 38.1 65
80 88.9 — — — 5.49 — 7.62 — — — 11.13 15.24 114 51 159 76 121 50.8 80
90 101.6 — — — 5.74 — 8.08 — — — - 16.15 133 57 184 89 140 63.5 90
100 114.3 — — — 6.02 — 8.56 — 11.13 — 13.49 17.12 152 63.5 210 102 159 63.5 100
125 141.3 — — — 6.55 — 9.53 — 12.70 — 15.88 19.05 190 79 262 127 197 76.2 125
150 168.3 — — — 7.11 — 10.97 — 14.27 — 18.26 21.95 229 95 313 152 237 88.9 150
200 219.1 — 6.35 7.04 8.18 10.31 12.70 15.09 18.26 20.62 23.01 22.23 305 127 414 203 313 102 200
250 273.1 — 6.35 7.80 9.27 12.70 12.70 15.09 18.26 21.44 25.40 28.58 25.40 381 159 517 254 390 127 250
300 323.9 — 6.35 8.38 9.53 10.31 14.27 12.70 17.48 21.44 25.40 28.58 33.32 25.40 457 190 619 305 467 152 300
350 355.6 6.35 7.92 9.53 9.53 11.13 15.09 12.70 19.05 23.83 27.79 31.75 35.71 — 533 222 711 356 533 165 350
400 406.4 6.35 7.92 9.53 9.53 12.7 16.66 12.70 21.44 26.19 30.96 36.53 40.49 — 610 254 813 406 610 178 400
450 457 6.35 7.92 11.13 9.53 14.27 19.05 12.70 23.83 29.36 34.93 39.67 45.24 — 686 286 914 457 686 203 450
500 508 6.35 9.53 12.70 9.53 15.09 20.62 12.70 26.19 32.54 38.10 44.45 50.01 — 762 318 1016 508 762 229 500
600 610 6.35 9.53 14.27 9.53 17.48 24.61 12.70 30.96 38.89 46.02 52.37 59.54 — 914 381 1219 610 914 267 600
750 762 7.92 12.70 15.88 9.53 — — 12.70 — — — — - — 1143 470 1524 762 1143 267 750
900 914 7.92 12.70 15.88 9.53 19.05 — 12.70 — — — — - — 1372 565 — 914 1372 267 900
STRAIGHT TEES (B16.9) REDUCING TEES (B16.9) M CONCENTRIC & ECCENTRIC

C REDUCERS (B16.9)
H H
C C C C
Nominal size Nominal size Nominal size

DN C m H DN C m H DN C m H
large large large
small end small end small end
end end end
20 20 28.6 - - 100 105 - - 400 305 - -
15 28.6 28.6 38.1 90 105 102 102 350 305 305 356
25 38.1 - - 100 80 105 98.4 102 400 300 305 295 356
25 20 38.1 38.1 50.8 65 105 95.3 102 250 305 283 356
15 38.1 38.1 50.8 50 105 88.9 102 200 305 273 356
32 47.6 - - 40 105 85.7 102 150 305 264 356
32 25 47.6 47.6 50.8 125 124 - - 450 343 - -
20 47.6 47.6 50.8 100 124 117 127 400 343 330 381
15 47.6 47.6 50.8 125 90 124 114 127 450 350 343 330 381
40 57.2 - - 80 124 111 127 300 343 321 381
32 57.2 57.2 63.5 65 124 108 127 250 343 308 381
40 25 57.2 57.2 63.5 50 124 105 127 200 343 298 381
20 57.2 57.2 63.5 150 143 - - 500 381 - -
15 57.2 57.2 63.5 125 143 137 140 450 381 368 508
50 63.5 - - 150 100 143 130 140 400 381 356 508
40 63.5 60.3 76.2 90 143 127 140 500 350 381 356 508
50 32 63.5 57.2 76.2 80 143 124 140 300 381 346 508
25 63.5 50.8 76.2 65 143 121 140 250 381 333 508
20 63.5 44.5 76.2 200 178 - - 200 381 324 508
65 76.2 - - 150 178 168 152 600 432 - -
50 76.2 69.9 88.9 200 125 178 162 152 500 432 432 508
65 40 76.2 66.7 88.9 100 178 155 152 450 432 419 508
32 76.2 63.5 88.9 80 178 152 152 600 400 432 406 508
25 76.2 57.2 88.9 250 216 - - 350 432 406 508
80 85.7 - - 200 216 203 178 300 432 397 508
65 85.7 82.6 88.9 250 150 216 194 178 250 432 384 508
80 50 85.7 76.2 88.9 125 216 191 178 750 559 - -
40 85.7 73.0 88.9 100 216 184 178 600 559 533 610
32 85.7 69.9 88.9 300 254 - - 750 500 559 508 610
25 85.7 69.9 88.9 250 254 241 203 450 559 495 610
90 95.3 - - 300 200 254 229 203 400 559 483 610
80 95.3 92.1 102 150 254 219 203 900 673 - -
90 65 95.3 88.9 102 100 254 210 203 750 673 635 610
50 95.3 82.6 102 350 279 - - 900 600 673 610 610
40 95.3 79.4 102 300 279 270 330 500 673 584 610
350 250 279 257 330 450 673 572 610
200 279 248 330
150 279 238 330
NOTE: All dimensions are in millimetres (mm)
3 3
3 Dimensions - Buttweld Fittings to ASME B16.9, B16.28 Flanges - Forged Steel to ASME B16.5 4

4 4
FlaNGes TO ameriCaN sTaNDarDs

DN 15 to 600 are to ASME B16.5 (BS 1560). DN 750 & 900 are to BS 3293 for Slip-On & Weldneck only.
Welding Neck Flange Threaded Flange Slip-On Flange Socket Welding (DN 15 - 80) Blind Flanges up to DN600
(Above DN600 see notes below † )
PN20 (Class 150) PN50 (Class 300) PN100 (Class 600)

length Thru Hub length Thru Hub length Thru Hub
Nominal Dia. Nominal
size Dia. of Thickness Thrd. Dia. of Dia. of Thickness Thrd. Dia. of Dia. of Dia. of Thickness Thrd. Dia. of Dia. of size
Weld No. of of Weld Bolt No. of Weld Bolt No. of
DN Fig. of Fig. min. slip-On Bolt Bolt of Fig. min. slip-On Bolt Fig. of Fig. min. slip-On Bolt DN
Neck Circle Bolts Fig. Neck Circle Holes Bolts Neck Circle Holes Bolts
O C(1)* soc/Weld Holes C(1)* soc/Weld O C(2)† soc/Weld
Y(1)* O Y(1)* Y(2)†
Y(1)* Y(1)* Y(2)†
15 90 11.5 16 48 60.5 16 4 95 14.5 22 52 66.5 16 4 95 14.5 22 52 66.5 16 4 15
20 100 13.0 16 52 70.0 16 4 120 16.0 25 57 82.5 20 4 120 16.0 25 57 82.5 20 4 20
25 110 14.5 17 56 79.5 16 4 125 17.5 27 62 89.0 20 4 125 17.5 27 62 89.0 20 4 25
32 120 16.0 21 57 89.0 16 4 135 19.5 27 65 98.5 20 4 135 21.0 29 67 98.5 20 4 32
40 130 17.5 22 62 98.5 16 4 155 21.0 30 68 114.5 22 4 155 22.5 32 70 114.5 22 4 40
50 150 19.5 25 64 120.5 20 4 165 22.5 33 70 127.0 20 8 165 26.5 37 73 127.0 20 8 50
65 180 22.5 29 70 139.5 20 4 190 25.5 38 76 149.0 22 8 190 29.0 41 79 149.0 22 8 65
80 190 24.0 30 70 152.5 20 4 210 29.0 43 79 168.5 22 8 210 32.0 46 83 168.5 22 8 80
90 215 24.0 32 71 178.0 20 8 230 30.5 44 81 184.0 22 8 230 35.0 49 86 184.0 26 8 90
100 230 24.0 33 76 190.5 20 8 255 32.0 48 86 200.0 22 8 275 38.5 54 102 216.0 26 8 100
125 255 24.0 36 89 216.0 22 8 280 35.0 51 98 235.0 22 8 330 44.5 60 114 267.0 30 8 125
150 280 25.5 40 89 241.5 22 8 320 37.0 52 98 270.0 22 12 355 48.0 67 117 292.0 30 12 150
200 345 29.0 44 102 298.5 22 8 380 41.5 62 111 330.0 26 12 420 55.5 76 133 349.0 33 12 200
250 405 30.5 49 102 362.0 26 12 445 48.0 67 117 387.5 30 16 510 63.5 86 152 432.0 36 16 250
300 485 32.0 56 114 432.0 26 12 520 51.0 73 130 451.0 33 16 560 66.5 92 156 489.0 36 20 300
350 535 35.0 57 127 476.0 30 12 585 54.0 76 143 514.5 33 20 605 70.0 94 165 527.0 39 20 350
400 600 37.0 64 127 540.0 30 16 650 57.5 83 146 571.5 36 20 685 76.5 106 178 603.0 42 20 400
450 635 40.0 68 140 578.0 33 16 710 60.5 89 159 628.5 36 24 745 83.0 117 184 654.0 45 20 450
500 700 43.0 73 145 635.0 33 20 775 63.5 95 162 686.0 36 24 815 89.0 127 190 724.0 45 24 500
600 815 48.0 83 152 749.5 36 20 915 70.0 106 168 813.0 42 24 940 102.0 140 203 838.0 52 24 600
750 985 54.0 † 89 130.2 914.0 35 28 1090 92.0 210 210 997.0 48 28 1130 114.0 248 248 1022.0 54 28 750
900 1170 60.3 † 95 136.5 1086.0 41 32 1270 105.0 241 241 1168.0 54 32 1315 124.0 283 283 1194.0 67 28 900
PN150 (Class 900) PN250 (Class 1500) PN420 (Class 2500)
length Thru Hub length Thru Hub length Thru Hub
Nominal Dia. Thickness Dia. Thickness Nominal
size Thrd. Dia. of Dia. of Dia. of Dia. of Dia. of Thickness Thrd. Dia. of Dia. of size
of of Fig. min. Weld Bolt No. of of of Fig. min. Thrd. slip- Weld No. of Weld No. of
DN slip-On Bolt Bolt Bolt Fig. of Fig. min. slip-On Bolt Bolt DN
Fig. Neck Circle Holes Bolts Fig. On soc/ Neck Bolts Neck Bolts
C(2)† soc/Weld C(2)† Circle Holes O C(2)† soc/Weld Circle Holes
O Y(2)† O Weld Y(2)† Y(2)† Y(2)†
Y(2)† Y(2)†
15 120 22.5 32 60 82.5 22 4 135 30.5 40 73 89.0 22 4 15
20 130 25.5 35 70 89.0 22 4 140 32.0 43 79 95.0 22 4 20
25 150 29.0 41 73 101.5 26 4 160 35.0 48 89 108.0 26 4 25
32 USE PN250 DIMENSIONS IN THESE SIZES 160 29.0 41 73 111.0 26 4 185 38.5 52 95 130.0 30 4 32
40 180 32.0 44 83 124.0 30 4 205 44.5 60 111 146.0 33 4 40
50 215 38.5 57 102 165.0 26 8 235 51.0 70 127 171.5 30 8 50
65 245 41.5 64 105 190.5 30 8 270 57.5 79 143 197.0 33 8 65
80 240 38.5 54 102 190.5 26 8 270 48.0 73 118 203.0 33 8 305 67.0 92 168 228.5 36 8 80
100 295 44.5 70 114 235.0 32 8 310 54.0 90 124 241.5 36 8 355 76.5 108 190 273.0 42 8 100
125 350 51.0 79 127 279.5 35 8 375 73.5 105 155 292.0 42 8 420 92.5 130 229 324.0 48 8 125
150 380 56.0 86 140 317.5 32 12 395 83.0 119 171 317.5 39 12 485 108.0 152 273 368.5 56 8 150
200 470 63.5 102 162 393.5 39 12 485 92.0 143 213 393.5 45 12 550 127.0 178 318 438.0 56 12 200
250 545 70.0 108 184 470.0 39 16 585 108.0 159 254 482.5 52 12 675 165.5 229 419 539.5 68 12 250
300 610 79.5 117 200 533.5 39 20 675 124.0 181 283 571.5 56 16 760 184.5 254 464 619.0 76 12 300
350 640 86.0 130 213 559.0 42 20 750 133.5 298 635.0 60 16 350
400 705 89.0 133 216 616.0 45 20 825 146.5 311 705.0 68 16 400
450 785 102.0 152 229 686.0 52 20 915 162.0 327 774.5 76 16 450
All dimensions
500 855 are shown
108.0 in millimetres
159 (mm)
248 749.5 54 20 985 178.0 356 832.0 80 16 500
600 1040 140.0 203 292 901.5 68 20 1170 203.5 406 990.5 94 16 600
raised Face approximate Welding Neck Flange Bores - mm
Nominal O.D.
Diam. of
Pipe
NOTes: all Press. size DN mm sCH. sCH. sCH. sTD. sCH. sCH. eXT. sCH. sCH. sCH. sCH. sCH. X.X
ratings mm 10 20 30 WT. 40 60 sTG. 80 100 120 140 160 sTG
* 1. The 2mm Raised Face is included in thickness C(1) and length
35 15 21.3 15.8 13.9 11.8 6.4
through hub Y(1). This applies to PN20 and PN50 Pressure
43 20 26.7 20.9 18.9 15.5 11.0
Ratings. 51 25 33.4 26.6 24.3 20.7 15.2
64 32 42.2 35.1 32.5 29.5 22.8
Same as EXT. STG.
† 2. The 7mm Raised Face is not included in thickness C(2) and length
Same as STD. WT.
through hub Y(2). PN100, 150, 250 and 420 Pressure Ratings 73 40 48.3 40.9 38.1 34.0 27.9
92 50 60.3 52.5 49.2 42.9 38.2
are regularly furnished with 7mm Raised Face which is additional to
105 65 73.0 62.7 59.0 54.0 45.0
the flange thickness C(2) and Y(2).
127 80 88.9 77.9 73.7 66.7 58.4
3. Always specify bore when ordering weldneck flanges. Bore 140 90 101.6 90.1 85.4 –– ––
dimensions shown opposite also provide inside pipe diameters. 157 100 114.3 102.3 97.2 92.1 87.3 80.1
186 125 141.3 128.2 122.3 115.9 109.6 103.2
larGe DiameTer FlaNGes aBOVe DN 600 216 150 168.3 154.1 146.3 139.7 131.8 124.4
† For Blind Flanges refer to MSS SP44. 270 200 219.1 206.4 205.0 202.7 198.5 193.7 188.9 182.6 177.8 173.1 174.6
BS 3293 covers Slip-On and Weldneck but excludes Blind Flanges. 324 250 273.1 260.3 257.5 254.5 247.7 247.7 242.9 236.5 230.2 222.3 215.9 222.3
MSS SP44 covers Blind and Weldneck but excludes Slip-On Flanges. 381 300 323.9 311.1 307.1 304.8 303.2 295.3 298.5 288.9 281.0 273.1 266.7 257.2 273.1
BS 3293 Weldneck PN20 flange thickness, C(1), is less than MSS 413 350 355.6 342.9 339.8 336.6 336.6 333.3 325.4 330.2 317.5 307.9 300.0 292.1 284.2
470 400 406.4 393.7 390.6 387.4 387.4 381.0 373.1 381.0 363.5 354.0 344.5 333.3 325.4
SP44 equivalents.
533 450 457.0 444.5 441.4 434.9 438.2 428.7 419.1 431.8 409.5 398.5 387.4 377.9 366.7
API - 605 Dimensions for Large Diameter Flanges vary considerably
584 500 508.0 495.3 489.0 482.6 489.0 477.8 466.8 482.6 455.6 442.9 431.8 419.1 408.0
from both BS 3293 and MSS SP44 — Details on request. 692 600 610.0 596.9 590.6 581.1 590.6 574.6 560.4 584.2 547.7 531.8 517.6 504.9 490.5
857 750 762.0 746.2 736.6 730.2 743.0 736.6
1022 900 914.0 898.6 889.0 882.6 895.4 876.3 889.0

BOlTiNG FOr aNsi FlaNGes
BOlTiNG
To suit R.F. Flange sizes DN 15 to 600 to ASME — B16.5 (BS. 1560) and DN 750 & 900 to BS. 3293
L
L* Diameter of Bolts is shown in inches. For nominal diameters 1 inch and smaller, threads
are U.N.C.; nominal diameters 1 - 1/8 inch and larger threads are 8 U.N. (8 T.P.I).
Length of Bolts (L) is shown in millimetres rounded to the nearest 5mm. Stud Bolt
*Point Height
lengths (L*) do not include the height of points. Machine Bolt lengths (L) include the
STUD BOLT WITH NUTS MACHINE BOLT WITH NUT height of point. The length shown includes the height of the Raised Face in all cases.
PN 250 (Class PN 420 (Class

PN 20 (Class 150) PN 50 (Class 300) PN 100 (Class 600) PN 150 (Class 900)
Nom 1500) 2500) Nom
Flge l l l l l l Flge
size Dia. Dia. Dia. Dia. Dia. Dia. size
No. stud mach. No. stud mach. No. stud No. stud No. No.
DN Bolts Bolts Bolts Bolts Bolts stud Bolts stud DN
Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts Bolts
ins. ins. ins. ins. ins. ins.
mm mm mm mm mm mm mm mm
15 4 1/2 60 45 4 1/2 65 55 4 1/2 80 4 3/4 105 4 3/4 125 15
20 4 1/2 65 50 4 5/8 75 60 4 5/8 90 4 3/4 115 4 3/4 125 20
25 4 1/2 65 55 4 5/8 80 65 4 5/8 90 4 7/8 125 4 7/8 140 25
32 4 1/2 70 55 4 5/8 80 65 4 5/8 100 USE PN250 DIMENSIONS 4 7/8 125 4 1 150 32
IN THESE SIZES
40 4 1/2 70 60 4 3/4 90 75 4 3/4 105 4 1 140 4 1 1/8 170 40
50 4 5/8 80 65 8 5/8 90 75 8 5/8 105 8 7/8 145 8 1 175 50
65 4 5/8 90 75 8 3/4 100 85 8 3/4 120 8 1 160 8 1 1/8 195 65
80 4 5/8 90 75 8 3/4 110 90 8 3/4 125 8 7/8 145 8 1 1/8 180 8 1 1/4 220 80
90 8 5/8 90 75 8 3/4 110 95 8 7/8 140 - - - - - - - - - 90
100 8 5/8 90 75 8 3/4 110 95 8 7/8 145 8 1 1/8 170 8 1 1/4 195 8 1 1/2 255 100
125 8 3/4 90 80 8 3/4 120 100 8 1 165 8 1 1/4 190 8 1 1/2 250 8 1 3/4 300 125
150 8 3/4 100 85 12 3/4 125 105 12 1 170 12 1 1/8 195 12 1 3/8 260 8 2 345 150
200 8 3/4 110 90 12 7/8 140 110 12 1 1/8 195 12 1 3/8 220 12 1 5/8 290 12 2 380 200
250 12 7/8 115 95 16 1 155 130 16 1 1/4 215 16 1 3/8 235 12 1 7/8 335 12 2 1/2 485 250
300 12 7/8 120 100 16 1 1/8 170 145 20 1 1/4 220 20 1 3/8 255 16 2 375 12 2 3/4 540 300
350 12 1 130 110 20 1 1/8 175 150 20 1 3/8 235 20 1 1/2 275 16 2 1/4 405 350
400 16 1 135 115 20 1 1/4 190 160 20 1 1/2 255 20 1 5/8 285 16 2 1/2 445 400
450 16 1 1/8 150 125 24 1 1/4 195 170 20 1 5/8 275 20 1 7/8 325 16 2 3/4 495 450
500 20 1 1/8 160 135 24 1 1/4 205 180 24 1 5/8 290 20 2 345 16 3 540 500
600 20 1 1/4 175 145 24 1 1/2 230 195 24 1 7/8 330 20 2 1/2 435 16 3 1/2 615 600
750 28 1 1/4 190 160 28 1 3/4 290 250 28 2 355 750
PN150, 250 & 420 - NOT LISTED IN BS 3293
900 32 1 1/2 215 180 32 2 325 280 28 2 1/2 400 900
Raised Face height of 2 mm for PN20 & 50 and 7 mm for PN100, 150, 250 & 420 is included in dimension L (Bolt Length).
inch/ metric Bolting
interchangeable for asme
B16.5 flanges as below
FOr Use
maTerial sPeCiFiCaTiONs 1/2” M14
5/8” M16
asTm a193 Standard specification for alloy steel and stainless steel bolting materials for high temperature 3/4” M20
Grade B7 service.
7/8” M24
1” M27
asTm a194 Standard specification for carbon and alloy steel nuts for bolts for high pressure and high
Grade 2H temperature service. 1 1/8” M30
1 1/4” M33
1 3/8” M36
asTm Standard specification for alloy steel bolting materials for low temperature service.
Grade L7 covers alloy steel stud bolts. 1 1/2” M39
A320
Grade L4 covers alloy steel nuts to suit Grade L7 stud bolts. 1 5/8” M42
1 3/4” M45
1 7/8” M48
2” M52
2 1/4” M56
2 1/2” M64
2 3/4” M72
5 5
5 Bolts & Studs for use with ASME B16.5 Flanges Mass of Fittings & Flanges to ASME Standards 6

6 6
sTeel PiPe, BUTTWelD FiTTiNGs & FlaNGes TO asme sTaNDarDs

asme B36.10 approximate mass of Popular sizes
steel Pipe Dimensions Pipe Buttweld Fittings a.s.m.e Flanges
identification PN20 PN50 PN100 PN150

(150) (300) (600) (900)
Nominal Outside inside steel 90o l/r Con.
Tees
Pipe size Diam. Diam. Pipe & ecc. sOW/ sOW/
elbows equal
DN mm mm kg/m red. sW W/N Blind sW W/N Blind W/N W/N
std. X.s sch. No. kg/ea kg/ea kg/ea Thrded kg/ea kg/ea Thrded kg/ea kg/ea kg/ea kg/ea
kg/ea kg/ea
15.8 Std. 40 1.27 0.08 0.16 -

15 21.3 0.45 0.79 0.57 0.73 0.91 0.79 0.91 2.00
13.9 XS 80 1.62 0.10 0.21 -
20.9 Std. 40 1.69 0.08 0.21 0.07

20 26.7 0.68 0.86 0.91 1.25 1.41 1.13 1.59 2.72
18.9 XS 80 2.20 0.11 0.27 0.10
26.6 Std. 40 2.50 0.17 0.34 0.14

25 33.4 0.95 1.09 1.09 1.36 1.81 1.77 1.86 3.86
24.3 XS 80 3.24 0.21 0.43 0.18
35.1 Std. 40 3.39 0.28 0.64 0.18

32 42.2 1.13 1.41 1.25 2.04 2.27 2.68 2.72 4.54
32.5 XS 80 4.47 0.39 0.75 0.23
40.9 Std. 40 4.05 0.39 0.95 0.27

40 48.3 1.36 1.81 1.70 2.81 3.06 2.83 3.74 6.35
38.1 XS 80 5.41 0.50 1.13 0.32
52.5 Std. 40 5.44 0.68 1.45 0.41

50 60.3 2.22 2.83 2.77 3.13 3.74 3.52 4.65 10.89
49.2 XS 80 7.48 1.00 1.72 0.54
62.7 Std. 40 8.63 1.39 2.45 0.68

65 73.0 3.82 4.42 4.04 4.54 5.56 5.44 6.44 16.33
59.0 XS 80 11.41 1.82 2.95 0.91
77.9 Std. 40 11.29 2.18 3.45 0.91

80 88.9 4.08 5.22 5.44 6.12 7.37 7.26 8.50 14.51
73.7 XS 80 15.27 2.86 4.30 1.27
90.1 Std. 40 13.57 3.05 4.5 1.36

90 101.6 4.99 5.44 6.35 7.71 9.53 9.98 12.25 ––
85.4 XS 80 18.63 4.1 5.9 1.81
102.3 Std. 40 16.07 4.2 5.7 1.59

100 114.3 5.94 7.48 7.37 9.53 11.79 11.79 17.24 23.13
97.2 XS 80 22.32 5.7 7.3 2.18
128.2 Std. 40 21.77 6.8 9.1 2.7

125 141.3 6.12 9.53 9.07 12.70 15.42 15.88 30.84 39.01
122.3 XS 80 30.97 10.0 11.8 3.8
154.1 Std. 40 28.26 10.9 13.6 3.9

150 168.3 8.16 11.34 12.70 16.33 19.96 20.87 34.02 49.90
146.3 XS 80 42.56 16.3 19.0 5.4
202.7 Std. 40 42.55 21.8 25 5.9

200 219.1 12.70 19.05 21.77 25.40 32.21 38.10 52.16 84.82
193.7 XS 80 64.64 33.1 33.5 8.6
254.5 Std. 40 60.31 38.6 41 10

250 273.1 17.24 25.40 31.75 35.38 44.00 53.34 90.36 121.56
247.7 XS 60 81.55 52 54 14
304.8 Std. - 73.88 57 57 15

300 323.9 27.22 38.10 45.36 50.80 64.41 86.18 101.60 168.74
298.5 XS - 97.46 75 77 20
336.6 Std. 30 81.33 73 73 28

350 355.6 35.38 51.26 58.97 74.39 84.37 107.05 157.40 254.92
330.2 XS - 107.39 97 93 37
387.4 Std. 30 93.27 98 91 35

400 406.4 42.18 63.50 77.11 101.60 111.58 145.15 209.11 310.71
381.0 XS 40 123.30 130 120 46
438.2 Std. - 105.16 120 135 40

450 457 52.62 68.04 102.51 126.10 138.35 181.89 217.27 419.12
431.8 XS - 139.15 165 190 53
489.0 Std. 20 117.15 150 168 61

500 508 65.32 81.65 123.38 149.69 174.63 231.33 312.98 527.98
482.6 XS 30 155.12 200 245 82
590.6 Std. 20 141.12 220 240 77

600 610 91.63 118.84 203.21 222.26 247.21 342.92 443.16 680.39
584.2 XS - 187.06 280 350 95
743.0 Std. - 176.84 332 388 107

750 762 142.88 163.29 326.59 367.41 421.84 680.39 589.67 975.22
736.6 XS 20 234.67 440 484 143
895.4 Std. - 212.56 481 588 129

900 914 217.72 235.87 510.29 544.31 589.67 1031.92 793.79 1564.89
889.0 XS 20 282.27 638 731 172
DIMENSIONS MASS IN KILOGRAMS (kg)
APPROXIMATE MASS PER UNIT FOR AUSTENITIC STAINLESS STEEL PIPE AND FITTINGS CAN BE OBTAINED BY APPLYING A FACTOR OF 1.015

meDiUm & HeaVY PiPe TO aUsTraliaN sTaNDarDs
sPeCiFiCaTiON WOrKiNG PressUres – WelDeD eND PrOCessiNG OPTiONs

C250 pipe is manufactured and tested JOiNTs • Plain End • Shouldered
to meet the requirement of the following Where AS 1074 pipe is used in pressure • Roll Grooved • Threaded
specifications: piping covered by AS 4041, the maximum
• AS 1074 Steel tubes and tubulars for pressure shall not exceed 1210 kPa for AS THreaDeD PiPe
ordinary service. 1074 pipe up to and including DN 100 and
Screwed on one or both ends in accordance
1030 kPa for AS 1074 pipe exceeding DN
• AS 1163 Structural steel hollow with AS 1074. The tapered Whitworth thread
100.
sections (Grade C250, C250L0). used complies with the requirements of AS
1722, Part 1 and is suitable for both parallel
and taper threaded sockets.
WOrKiNG PressUres – THreaDeD JOiNTs TaPer/Parallel THreaD

meCHaNiCal PrOPerTies
Type of service
Minimum Yield Strength 250MPa
Nom. Water & inert lPG Fuel Oil Other applications (including
Minimum Tensile Strength 320MPa size Oil steam & Compressed air)
DN
med. Heavy med. & medium Heavy medium Heavy
Minimum Elongation in 5.65 √So 20% Heavy Press Temp Press Temp Press Temp Press Temp
(mm) kPa kPa kPa kPa o
C kPa o
C kPa o
C kPa o
C
sUPPlY CONDiTiONs 25 2070 2410 140 1030 100 1210 192 1210 100 1210 192
32 1720 2070 140 1030 100 1030 192 1030 100 1030 192
Surface Finish Black/Painted/Galvanized/ILG 40 1720 2070 140 1030 100 1030 192 1030 100 1030 192
Straightness 50 1380 1720 140 860 100 860 192 860 100 860 192
Refer to
Thickness Tolerance Australian 65 1380 1720 – 860 100 860 192 860 100 860 192
Standards 80 1380 1720 – 860 100 860 192 860 100 860 192
Dimension Tolerance
100 1030 1380 – 690 100 850 192 690 100 690 192
Standard Length 6.5m 125 1030 1380 – – – – – – – – –
Length Tolerance +50mm/-0mm 150 860 1030 – – – – – – – – –
CHs Grade C250 mass and Bundling Data - Calculated in accordance with as 1163
Dimensions Bundling mass
Bundle Nominal mass mass per Bundle
Designation Nominal size Dimenions lengths Per metres Per
do t DN mm Bundle Bundle kg/m m/tonne tonnes
(mm) (mm) (mm) WxH 6.5m m Black Galv. Black Galv. Black Galv.
26.9 x 2.6 CHS 20 M 350 306 127 825.5 1.56 1.62 642 613 1.29 1.32
3.2 CHS 20 H 350 306 127 825.5 1.87 1.93 535 522 1.54 1.59
33.7 x 3.2 CHS 25 M 372 327 91 591.5 2.41 2.49 415 406 1.43 1.47
4.0 CHS 25 H 372 327 91 591.5 2.94 3.02 340 330 1.74 1.78
42.4 x 3.2 CHS 32 M 383 337 61 396.5 3.10 3.20 322 310 1.23 1.27
4.0 CHS 32 H 383 337 61 396.5 3.80 3.90 263 255 1.51 1.54
48.3 x 3.2 CHS 40 M 436 384 61 396.5 3.57 3.68 280 270 1.41 1.46
4.0 CHS 40 H 436 384 61 396.5 4.38 4.49 228 221 1.74 1.78
60.3 x 3.6 CHS 50 M 422 374 37 240.5 5.03 5.18 199 192 1.21 1.25
4.5 CHS 50 H 422 374 37 240.5 6.19 6.33 161 157 1.49 1.52
76.1 x 3.6 CHS 65 M 533 472 37 240.5 6.43 6.61 156 150 1.55 1.59
4.5 CHS 65 H 533 472 37 240.5 7.93 8.12 126 123 1.91 1.95
88.9 x 4 CHS 80 M 445 397 19 123.5 8.37 8.58 120 116 1.03 1.06
4.9 CHS 80 H 445 397 19 123.5 10.3 10.5 96.8 94.4 1.28 1.30
101.6 x 4.0 CHS 90 M 508 454 19 123.5 9.63 9.88 104 100 1.19 1.22
4.9 CHS 90 H 508 454 19 123.5 11.9 12.2 84 81.7 1.47 1.5
114.3 x 4.5 CHS 100 M 571 509 19 123.5 12.2 12.4 82.2 79.8 1.5 1.54
5.4 CHS 100 H 571 509 19 123.5 14.5 14.3 69.1 67.4 1.79 1.82
139.7 x 5.0 CHS 125 M 698 382 13 84.5 16.6 16.9 60.2 58.6 1.4 1.43
5.4 CHS 125 H 698 382 13 84.5 17.9 18.2 55.9 54.6 1.51 1.54
165.1 x 5.0 CHS 150 M 660 451 10 65 19.7 20.1 50.7 49.3 1.28 1.31
5.4 CHS 150 H 660 451 10 65 21.7 21.57 45.9 46 1.38 1.41
m = medium, H = Heavy
7 7
7 Pipes to Australian Standards Medium/Heavy Pipes to Australian

Pipes Standards
to Australian StandardsLight/Extra
Light/Extra Light
Light 8

8 8
liGHT/eXTra liGHT PiPe TO aUsTraliaN sTaNDarDs
sPeCiFiCaTiON GalVaNiZiNG
Grade C350 pipe is a lightweight, Grade C350 pipe is manufactured and tested Grade C350 pipe is manufactured and tested to
high strength pipe for general to meet the requirement of the following meet the requirement of AS 4792 Galvanized
mechanical and structural specifications: Coatings.
applications.
• AS 1163 Structural Steel Hollow Sections Min. Ave Coating Mass 300g/m2
C350 is manufactured by cold- (Grade C350, C350L0). The coating adherence of the galvanizing is
forming and high frequency
• AS/NZ 4792 Hot dip galvanized (zinc) coatings satisfactory for the pipe to be bent to a radius 6
electric resistance welding.
on ferrous hollow sections by a continuous or a times the diameter of the pipe.
C350 is available in black, ILG and specialised process.
galvanized finishes.
Also available with one or both meCHaNiCal PrOPerTies WelDiNG
ends swaged as follows: Minimum Yield Strength 350MPa The following consumables are recommended by
AS 1554.1 when welding C350 sections.
Minimum Tensile Strength 450MPa
Minimum Elongation in 5.65 √So 20% Manual metal-arc (MMAW) E41XX, E48XX
NB Xl l
Gas metal-arc (MIG) (GMAW) W50X
20 a X sUPPlY CONDiTiONs
25 a a Surface Finish Black/ILG/Galvanized
32 a a Straightness Refer to
Thickness Tolerance Australian
40 a a Standards
Dimension Tolerance
50 a X
Standard Length 6.5m
Length Tolerance +50mm/-0mm
mass and Bundling Data - Calculated in accordance with as 1163

Dimensions Bundling mass
Bundle Nominal mass mass per Bundle
Designation Nominal lengths metres
Dimenions
do t size DN Per Bundle Per Bundle kg/m m/tonne tonnes
mm
(mm) (mm) (mm) WxH 6.5m m Black Galv. Black Galv. Black Galv.
26.9 x 2.0 CHS 20 XL 350 306 127 825.5 1.23 1.29 814 767 1.010 1.070
2.3 CHS 20 LT 350 306 127 825.5 1.40 1.46 717 680 1.150 1.200
33.7 x 2.0 CHS 25 XL 372 327 91 591.5 1.56 1.64 640 602 0.920 0.970
2.6 CHS 25 LT 372 327 91 591.5 1.99 2.07 501 497 1.180 1.230
42.4 x 2.0 CHS 32 XL 383 337 61 396.5 1.99 2.10 502 473 0.790 0.830
2.6 CHS 32 LT 383 337 61 396.5 2.55 2.65 392 374 1.010 1.050
48.3 x 2.3 CHS 40 XL 436 384 61 396.5 2.61 2.73 383 364 1.030 1.080
2.9 CHS 40 LT 436 384 61 396.5 3.25 3.36 308 295 1.290 1.330
60.3 x 2.3 CHS 50 XL 422 374 37 240.5 3.29 3.44 304 288 0.790 0.830
2.9 CHS 50 LT 422 374 37 240.5 4.11 4.25 244 234 0.990 1.020
76.1 x 2.3 CHS 65 XL 533 472 37 240.5 4.19 4.33 239 231 1.007 1.040
3.2 CHS 65 LT 533 472 37 240.5 5.75 5.94 174 167 1.380 1.430
88.9 x 2.6 CHS 80 XL 445 397 19 123.5 5.53 5.75 181 174 0.683 0.710
3.2 CHS 80 LT 445 397 19 123.5 6.76 6.98 148 143 0.840 0.860
101.6 x 2.6 CHS 90 XL 508 454 19 123.5 6.35 6.60 158 152 0.784 0.815
3.2 CHS 90 LT 508 454 19 123.5 7.70 8.04 129 124 0.960 0.990
114.3 x 3.2 CHS 100 XL 572 510 19 123.5 8.77 9.05 114 110 1.083 1.118
3.6 CHS 100 LT 572 510 19 123.5 9.83 10.11 102 98.6 1.214 1.249
139.7 x 3.0 CHS 125 XL 698 382 13 84.5 10.11 10.50 98.9 95.2 0.855 0.887
3.5 CHS 125 LT 698 382 13 84.5 11.76 12.10 85.1 82.4 0.993 1.022
165.1 x 3.5 CHS
150 LT 660 451 10 65 13.95 14.40 71.7 69.4 0.907 0.936
150 LT
NOTes:
LT = Light, XL = Extra Light
The term “tube” is synonymous with the term “pipe”.

FlaNGes TO aUsTraliaN sTaNDarDs
DIMENSIONS
FOR LOOSE FLANGES
DIAM. 1.6mm FLAT FACE FLAT FACE
RAISED FACE DIAM. 1.6mm
RAISED FACE
PLATE FLANGE
BLANK OR BLIND FLANGE WELD NECK FLANGE
SLIP ON WELD
COPPer allOY FOrGeD Or PlaTe sTeel
DIAM. 1.6mm FLAT FACE
T.3 – Plate or Boss or Blank RAISED FACE T.6 – Plate or Boss or Blank, or Weldneck (except for valves)
T.10 – Plate or Boss BOSS FLANGE – SLIP ON WELD OR SCR. B.S.P. T.18– Plate or Blank or Weldneck (except for valves)
T.11 – Blank
Table D Table e Table F
Flange Drilling Flange Drilling Flange Drilling
Nominal Thickness Bolt Thickness Bolt Thickness Bolt Nominal
size DN OD Dia. of Dia. of Dia. of size DN
** Circle No. of OD ** Circle No. of OD ** Circle No. of
T3 Bolts T10 T11 Bolts T10 T11 Bolts
mm T6 Dia. Bolts mm T6 Dia. Bolts mm T6 Dia. Bolts
mm mm mm mm mm mm
15 95 6 5 67 4 M12 95 6 6 6 67 4 M12 95 8 8 10 67 4 M12 15
20 100 6 5 73 4 M12 100 6 6 6 73 4 M12 100 8 8 10 73 4 M12 20
25 115 8 5 83 4 M12 115 8 8 7 83 4 M12 120 10 10 10 87 4 M16 25
32 120 8 6 87 4 M12 120 8 8 8 87 4 M12 135 10 10 13 98 4 M16 32
40 135 10 6 98 4 M12 135 10 10 9 98 4 M12 140 11 11 13 105 4 M16 40
50 150 10 8 114 4 M16 150 10 10 10 114 4 M16 165 11 12 16 127 4 M16 50
65 165 11 8 127 4 M16 165 11 11 10 127 4 M16 185 13 13 16 146 8 M16 65
80 185 13 10 146 4 M16 185 13 13 11 146 4 M16 205 14 15 16 165 8 M16 80
100 215 16 10 178 4 M16 215 16 16 13 178 8 M16 230 17 17 19 191 8 M16 100
125 255 17 13 210 8 M16 255 17 17 14 210 8 M16 280 19 20 22 235 8 M20 125
150 280 17 13 235 8 M16 280 17 17 17 235 8 M20 305 22 23 22 260 12 M20 150
200 335 19 13 292 8 M16 335 19 20 19 292 8 M20 370 25 28 25 324 12 M20 200
250 405 19 16 356 8 M20 405 22 25 22 356 12 M20 430 25 32 29 381 12 M24 250
300 455 22 19 406 12 M20 455 25 28 25 406 12 M24 490 29 37 32 438 16 M24 300
350 525 25 22 470 12 M24 525 25 32 29 470 12 M24 550 32 42 35 495 16 M27 350
400 580 25 22 521 12 M24 580 25 36 32 521 12 M24 610 32 47 41 552 20 M27 400
450 640 29 25 584 12 M24 640 29 41 35 584 16 M24 675 35 52 44 610 20 M30 450
500 705 32 29 641 16 M24 705 32 46 38 641 16 M24 735 38 57 51 673 24 M30 500
600 825 35 32 756 16 M27 825 38 – 48 756 16 M30 850 41 68 57 781 24 M33 600
700 910 – 35 845 20 M27 910 – – 51 845 20 M30 935 – – 60 857 24 M33 700
750 995 – 41 927 20 M30 995 – – 54 927 20 M33 1015 – – 67 940 28 M33 750
800 1060 – 41 984 20 M33 1060 – – 54 984 20 M33 1060 – – 68 984 28 M33 800
900 1175 – 48 1092 24 M33 1175 – – 64 1092 24 M33 1185 – – 76 1105 32 M36 900
1000 1255 – 51 1175 24 M33 1255 – – 67 1175 24 M36 1275 – – 83 1194 36 M36 1000
1200 1490 – 60 1410 32 M33 1490 – – 79 1410 32 M36 1530 – – 95 1441 40 M39 1200
Table H Table J Table r
Flange Drilling Flange Drilling Flange Drilling
Nominal Nominal
size DN Thickness Bolt Thickness Bolt of OD Thickness Dia. Bolt No. Dia. of size DN
† Dia. Circle of Dia. of OD
Dia.
OD Circle No. of Dia.
r/F Dia. No.
Circle of
Bolts Bolts
r/F Dia. Bolts Bolts r/F Bolts
mm T10 T11 * T6 mm mm * T6 mm * T18 Dia. Bolts mm
mm mm mm mm
15 115 10 11 13 57 83 4 M16 115 16 57 83 4 M16 115 19 64 83 4 M16 15
20 115 10 11 13 57 83 4 M16 115 16 57 83 4 M16 115 19 64 83 4 M16 20
25 120 11 12 14 64 87 4 M16 120 19 64 87 4 M16 125 22 76 95 4 M16 25
32 135 11 13 17 76 98 4 M16 135 19 76 98 4 M16 135 22 76 98 4 M16 32
40 140 13 14 17 83 105 4 M16 140 22 83 105 4 M16 150 25 89 114 4 M20 40
50 165 13 16 19 102 127 4 M16 165 25 102 127 4 M20 165 25 102 127 8 M16 50
65 185 14 17 19 114 146 8 M16 185 25 114 146 8 M20 185 29 114 146 8 M20 65
80 205 16 19 22 127 165 8 M16 205 32 127 165 8 M20 205 32 127 165 8 M20 80
100 230 19 23 25 152 191 8 M16 230 35 152 191 8 M20 240 35 152 197 8 M24 100
125 280 22 27 29 178 235 8 M20 280 38 178 235 8 M24 280 41 178 235 12 M24 125
150 305 25 30 29 210 260 12 M20 305 38 210 260 12 M24 305 44 210 260 12 M24 150
200 370 32 39 32 260 324 12 M20 370 41 260 324 12 M24 370 51 260 324 12 M27 200
250 430 35 45 35 311 381 12 M24 430 48 311 381 12 M27 430 60 311 387 16 M27 250
300 490 38 52 41 362 438 16 M24 490 51 362 438 16 M27 510 70 362 457 16 M30 300
350 550 41 58 48 419 495 16 M27 550 57 419 495 16 M30 585 79 419 527 16 M33 350
400 610 44 64 54 483 552 20 M27 610 64 483 552 20 M30 640 89 483 584 20 M33 400
450 675 48 71 60 533 610 20 M30 675 70 533 610 20 M33 735 98 572 673 20 M36 450
500 735 51 78 67 597 673 24 M30 735 79 597 673 24 M33 805 105 622 730 20 M39 500
600 850 57 92 76 699 781 24 M33 850 92 699 781 24 M36 – – – – – – –
NOTes:
1. All dimensions are in millimetres (mm). † 5. The Raised Face is non-preferred for Table “H”.
2. Only metric preferred sizes listed, except for DN 750 which is a Non- 6. It is normal practice to supply Steel Flanges to Tables A, D, C, E, F
preferred size. and H. — Flat Faced.
** 3. It is impractical to use flange thickness less than 12mm for Steel Plate 7. All copper alloy flanges shall be Flat Faced.
Flanges.
8. All flanges shall be drilled to Standard Tables unless otherwise
* 4. Thickness includes 1.6mm height for the Raised Face. specified. (For Bolt dimensions see separate page).
imPOrTaNT: For DN 150 and DN 200 Flanges, the O.D. of pipe being used must be specified. Dimensions for Flange Tables A, C, K, S and T on application.
9 9
9 Flanges to AS.2129 Metric Bolts for use with AS.2129 Flanges 10


10 10
i.s.O. meTriC HeXaGON sTeel BOlTs FOr Use

WiTH as.2129 FlaNGes
o o
Steel hexagon Bolts and Nuts (XOX) are recommended for use within a temperature range of –50 C to +300 C. Outside of this temperature range,
Stud Bolts should be used as recommended in AS.2528.
A quick reference chart for sizing bolts and nuts for a range of regularly used standard flanges is given below:
APPLICABLE TO PLATE & FORGED STEEL LOOSE FLANGES ONLY
NOTe: Integral valve flanges quite often differ in thickness to equivalent loose flanges. When integral flanges are involved due allowance should be
made to bolt lengths.
Length
Table D Table e Table F Table H
Nominal No. No. No. No.
Flange size XOX XOX XOX XOX Bolt
Bolts Bolts Bolts Bolts Diam.
DN Bolt & Nut Bolt & Nut Bolt & Nut Bolt & Nut
Per Per Per Per
dia. x lgth dia. x lgth dia. x lgth dia. x lgth
Flange Flange Flange Flange
M12 x M12 x
15 4 4 4 M12 X 40mm* 4 M16 x 45mm*
40mm* 40mm* Flat faced joint illustrated
M12 x M12 x
20 4 4 4 M12 X 40mm* 4 M16 x 45mm* Bolt lengths listed apply to flat-faced or
40mm* 40mm*
M12 x M12 x 1.6mm raised face flanges with allowance
25 4 4 4 M16 X 45mm* 4 M16 x 50mm* for 1.6mm gasket thickness.
40mm* 40mm*
M12 x M12 x *For approximate Stud Bolt Lengths take
32 4 4 4 M16 X 45mm* 4 M16 x 55mm*
40mm* 40mm* the XOX Bolt Length and add the metric
M12 x M12 x diameter in mm rounded to the nearest
40 4 4 4 M16 X 45mm* 4 M16 x 55mm*
40mm* 40mm* 5mm increment up.
M16 x M16 x
50 4 4 4 M16 X 50mm* 4 M16 x 60mm* Note: (This does not include length of
45mm* 45mm*
M16 x M16 x point)
65 4 4 8 M16 X 50mm* 8 M16 x 60mm*
45mm* 45mm* This chart shows bolt diameters as
80 4
M16 x
4
M16 x
8 M16 X 50mm* 8 M16 x 65mm* recommended in AS.2129. Some of
45mm* 45mm* these are Non-preferred sizes e.g. (M27),
100 4
M16 x
8
M16 x
8 M16 X 60mm* 8 M16 x 70mm* (M33) and (M39) which are not readily
45mm* 45mm* available in Australia.
M16 x M16 x
125 8
45mm*
8
50mm*
8 M20 X 70mm* 8 M20 x 80mm* Stud Bolts should be used as alternatives
to bolts where the size is greater than
M16 x M20 x
150 8
45mm*
8
60mm*
12 M20 X 70mm* 12 M20 x 80mm* M24 and it is therefore suggested that
Stud Bolts as specified in AS.2528 or
M16 x M20 x
200 8
45mm*
8
60mm*
12 M20 X 75mm* 12 M20 x 90mm* BS.4882 should be used.
M20 x M20 x M24 x Inch series bolts interchangeable as
250 8 12 12 M24 X 85mm* 12
55mm* 70mm* 100mm* follows:
M20 x M24 x M24 X M24 x
300 12 12 16 16 FOr Use FOr Use
60mm* 80mm* 100mm* 110mm*
M24 x M24 x M27 X M27 x
350 12 12 16 16
75mm* 85mm* 100mm* 130mm*
1/4 “ M6 7/8” M24
M24 x M24 x M27 X M27 x
400 12 12 20 20 5/16”
75mm* 100mm* 120mm* 140mm* M8 1” (M27)
M24 x M24 x M30 X M30 x 3/8” M10 1 1/8” M30
450 12 16 20 20
80mm* 100mm* 130mm* 160mm*
1/2” M12 1 1/4” (M33)
M24 x M24 x M30 X M30 x
500 16 16 24 24 5/8” M16 1 3/8” M36
85mm* 110mm* 140mm* 170mm*
M27 x M30 x M33 X M33 x 3/4” M20 1 1/2” (M39)
600 16 16 24 24
100mm* 130mm* 150mm* 190mm*
700 20 M27 x 20 M30 x 24 M33 X
100mm* 140mm* 160mm* BOlT HOle DiameTers
750 20 M30 x 20 M33 x 28 M33 X
For bolts to M24, clearance hole 2mm
120mm* 150mm* 170mm*
larger.
800 20 M33 x 20 M33 x 28 M33 X
120mm* 150mm* 180mm* Above M24, clearance hole 3mm larger.
900 24 M33 x 24 M33 x 32 M36 X
140mm* 170mm* 200mm* XOX BOlTs & NUTs
1000 24 M33 x 24 M36 x 36 M36 X XOX is the trade term used for H.R.H.
140mm* 180mm* 220mm* commercial steel bolts and nuts.
1200 32 M33 x 32 M36 x 40 M39 X
160mm* 200mm* 240mm* H.R.H. denotes Hexagon Head x Round
Shank x Hexagon Nut.
Temperature / Pressure ratings for Carbon steel Flanges
Temp in 0C maximum allowable Pressure in kPa by Flange Tables
(For approximate Psi divide by 7) XOX Bolting
D e F H Temp. Range: -50oC to +3000C
-50 to 232 700 1400 2100 3500
250 650 1300 2000 3300 Flange Specifications
275 600 1200 1800 3100 Table Bolts Nuts
300 570 1100 1700 2900 D, E, F AS 1110 AS 1112
325 550 1000 1600 2600 Gr.4.6 Gr.5
350 500 950 1400 2400 or AS 1111
375 450 900 1300 2200 Gr.4.6
400 400 800 1200 2000 H AS 1110 AS 1112
425 350 700 1000 1700 Gr8.8 Gr.8
450 1300
475 900
Max. Hydrostatic Test
1050 2100 3150 5250
Pressure kPa

mass CONVersiON CHarT
The si unit of mass is the KilOGram – symbol kg
The mass of an object is the quantity of matter it contains and is constant irrespective of the location or altitude.
The weight of an object is the force exerted on it by gravity and thus varies from place to place and according to height above sea level or the distance
from the Earth’s centre. (Hence weightlessness of astronauts in outer space).
mass CONVersiON CHarT
(A) To use, locate “given mass” in “given mass” column (coloured grey) whether lbs. or kg.
(B) If “given mass” is in pounds (lbs.), read kilograms (kg) in right hand column.
(C) If “given mass” is in kilograms (kg), read pounds (lbs.) in left hand column.
(D) Example: (i) Given mass is 70 lbs = 31.75 kg from right hand column
(ii) Given mass is 70 kg = 154.32 lbs. from left hand column
1 to 65 66 to 130 131 to 375 380 to 700 705 to 1500

Given Given Given Given Given
lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg
mass mass mass mass mass
2.20 1 0.45 145.50 66 29.94 288.80 131 59.42 838 380 172.37 1554 705 319.79
4.41 2 0.91 147.71 67 30.39 291.01 132 59.88 849 385 174.64 1565 710 322.06
6.61 3 1.36 149.91 68 30.84 293.21 133 60.33 860 390 176.90 1576 715 324.32
8.82 4 1.81 152.12 69 31.30 295.42 134 60.78 871 395 179.17 1587 720 326.59
11.02 5 2.27 154.32 70 31.75 297.62 135 61.24 882 400 181.44 1598 725 328.86
13.23 6 2.72 156.53 71 32.21 299.83 136 61.69 893 405 183.71 1609 730 331.13
15.43 7 3.18 158.73 72 32.66 302.03 137 62.14 904 410 185.98 1620 735 333.40
17.64 8 3.63 160.94 73 33.11 304.24 138 62.60 915 415 188.24 1631 740 335.66
19.84 9 4.08 163.35 74 33.57 306.44 139 63.05 926 420 190.51 1642 745 337.93
22.05 10 4.54 165.35 75 34.02 308.64 140 63.50 937 425 192.78 1653 750 340.20
24.25 11 4.99 167.55 76 34.47 310.85 141 63.96 948 430 195.05 1664 755 342.47
26.46 12 5.44 169.75 77 34.93 313.05 142 64.41 959 435 197.32 1676 760 344.74
28.66 13 5.90 171.96 78 35.38 315.26 143 64.87 970 440 199.58 1687 765 347.00
30.86 14 6.35 174.16 79 35.83 317.46 144 65.32 981 445 201.85 1698 770 349.27
33.07 15 6.80 176.37 80 36.29 319.67 145 65.77 992 450 204.12 1709 775 351.54
35.27 16 7.26 178.57 81 36.74 321.87 146 66.23 1003 455 206.39 1720 780 353.81
37.48 17 7.71 180.78 82 37.20 324.08 147 66.68 1014 460 208.66 1731 785 356.08
39.68 18 8.16 182.98 83 37.65 326.28 148 67.13 1025 465 210.92 1742 790 358.34
41.89 19 8.62 185.19 84 38.10 328.49 149 67.59 1036 470 213.19 1753 795 360.61
44.09 20 9.07 187.39 85 38.56 330.69 150 68.04 1047 475 215.46 1764 800 362.88
46.30 21 9.53 189.60 86 39.01 341.71 155 70.31 1058 480 217.73 1775 805 365.15
48.50 22 9.98 191.80 87 39.46 352.74 160 72.58 1069 485 220.00 1786 810 367.42
50.71 23 10.43 194.0 88 39.92 363.76 165 74.84 1080 490 222.26 1797 815 369.68
52.91 24 10.89 196.21 89 40.37 374.78 170 77.11 1091 495 224.53 1808 820 371.95
55.12 25 11.34 198.41 90 40.82 385.80 175 79.38 1102 500 226.80 1819 825 374.22
57.32 26 11.79 200.62 91 41.28 396.83 180 81.65 1113 505 229.07 1830 830 376.49
59.52 27 12.25 202.82 92 41.73 407.85 185 83.92 1124 510 231.34 1841 835 378.76
61.73 28 12.70 205.03 93 42.18 418.87 190 86.18 1135 515 233.60 1852 840 381.02
63.93 29 13.15 207.23 94 42.64 429.90 195 88.45 1146 520 235.87 1863 845 383.29
66.14 30 13.61 209.44 95 43.09 440.92 200 90.72 1157 525 238.14 1874 850 385.56
68.34 31 14.06 211.64 96 43.55 451.94 205 92.99 1168 530 240.41 1885 855 387.83
70.55 32 14.52 213.85 97 44.00 462.97 210 95.26 1179 535 242.68 1896 860 390.10
72.75 33 14.97 216.05 98 44.45 473.99 215 97.52 1190 540 244.94 1907 865 392.36
74.96 34 15.42 218.26 99 44.91 485.01 220 99.79 1202 545 247.21 1918 870 394.63
77.16 35 15.88 220.46 100 45.36 496.04 225 102.06 1213 550 249.48 1929 875 396.90
79.37 36 16.33 222.67 101 45.81 507.06 230 104.33 1224 555 251.75 1940 880 399.17
81.57 37 16.78 224.87 102 46.28 518.08 235 106.60 1235 560 254.02 1951 885 401.44
83.77 38 17.24 227.07 103 46.72 529.10 240 108.86 1246 565 256.28 1962 890 403.70
85.98 39 17.69 229.28 104 47.17 540.13 245 111.13 1257 570 258.55 1973 895 405.97
88.18 40 18.14 231.48 105 47.63 551.15 250 113.40 1268 575 260.82 1984 900 408.24
90.39 41 18.60 233.69 106 48.08 562.17 255 115.67 1279 580 263.09 1995 905 410.51
92.59 42 19.05 235.89 107 48.54 573.20 260 117.94 1290 585 265.36 2006 910 412.78
94.80 43 19.50 238.10 108 48.99 584.22 265 120.20 1301 590 267.62 2017 915 415.04
97.00 44 19.96 240.30 109 49.44 595.24 270 122.47 1312 595 269.89 2028 920 417.31
99.21 45 20.41 242.51 110 49.90 606.27 275 124.74 1323 600 272.16 2039 925 419.58
101.41 46 20.87 244.71 111 50.35 617.30 280 127.01 1334 605 274.43 2050 930 421.85
103.62 47 21.32 246.92 112 50.80 628.31 285 129.28 1345 610 276.70 2061 935 424.12
105.82 48 21.77 249.12 113 51.26 639.33 290 131.54 1356 615 278.96 2072 940 426.38
108.03 49 22.23 251.32 114 51.71 650.36 295 133.81 1367 620 281.23 2083 945 428.65
110.23 50 22.68 253.53 115 52.16 661.38 300 136.08 1378 625 283.50 2094 950 430.92
112.43 51 23.13 255.73 116 52.62 672.40 305 138.35 1389 630 285.77 2105 955 433.19
114.64 52 23.59 257.94 117 53.07 683.43 310 140.62 1400 635 288.04 2116 960 435.46
116.84 53 24.04 260.14 118 53.53 694.45 315 142.88 1411 640 290.30 2127 965 437.72
119.05 54 24.49 262.35 119 53.98 705.47 320 145.15 1422 645 292.57 2138 970 439.99
121.25 55 24.95 264.55 120 54.43 716.50 325 147.42 1433 650 294.84 2149 975 442.26
123.46 56 25.40 266.76 121 54.89 727.52 330 149.69 1444 655 297.11 2161 980 444.53
125.66 57 25.86 268.96 122 55.34 738.54 335 151.96 1455 660 299.38 2172 985 446.80
127.87 58 26.31 271.17 123 55.79 749.56 340 154.22 1466 665 301.64 2183 990 449.06
130.07 59 26.76 273.37 124 56.25 760.59 345 156.49 1477 670 303.91 2194 995 451.33
132.28 60 27.22 275.58 125 56.70 771.61 350 158.76 1488 675 306.18 2205 1000 453.60
134.48 61 27.67 277.78 126 57.15 782.63 355 161.03 1499 680 308.45 2425 1100 498.96
136.69 62 28.12 279.98 127 57.61 793.66 360 163.30 1510 685 310.72 2646 1200 544.32
138.89 63 28.58 282.19 128 58.06 804.68 365 165.56 1521 690 312.98 2866 1300 589.68
141.09 64 29.03 284.39 129 58.51 815.70 370 167.83 1532 695 315.25 3086 1400 635.04
143.30 65 29.48 286.60 130 58.97 826.73 375 170.10 1543 700 317.52 3307 1500 680.40
CONVersiON FaCTOrs
1 Pound (lb.) x 0.4536 = kilograms (kg) 1 kilogram (kg) x 2.2046 = pounds (lbs.)
11 11
11 Mass Conversion Chart Flange Identification 12
12 12
FlaNGe iDeNTiFiCaTiON CHarT

A guide to the key dimensions of popular steel flange types
Diam. / length Flange

Bolt Circle
size (mm) Table / Class Diam. of Flange No. of Bolts Bolts / studs Diam. Holes Thickness Cast
Diam. steel Flanges / Forged steel
Table D 95 67 4 M12 x 45 14 5*
Table E 95 67 4 M12 x 45 14 6*
Table H 115 83 4 M16 x 60 18 13
15 ANSI 150 89 60.3 4 1/2 x 60 16 11.5
ANSI 300 95 66.7 4 1/2 x 65 16 14.5
ANSI 600 95 66.7 4 1/2 x 80 16 14.5
PN 16 95 65 4 –– 14 ––
Table D 100 73 4 M12 x 45 14 5*
Table E 100 73 4 M12 x 45 14 6*
Table H 115 83 4 M16 x 60 18 13
20 ANSI 150 98 69.8 4 1/2 x 65 16 14
ANSI 300 117 82.5 4 5/8 x 75 20 16
ANSI 600 117 82.5 4 5/8 x 90 20 16
PN 16 105 75 4 –– 14 ––
Table D 115 83 4 M12 x 45 14 5*
Table E 115 83 4 M12 x 45 14 7*
Table H 120 87 4 M16 x 60 18 14
25 ANSI 150 108 79.4 4 1/2 x 65 16 14
ANSI 300 124 88.9 4 5/8 x 80 20 18
ANSI 600 124 88.9 4 5/8 x 105 20 18
PN 16 115 85 4 –– 14 ––
Table D 120 87 4 M12 x 50 14 6*
Table E 120 87 4 M12 x 50 14 8*
Table H 135 98 4 M16 x 65 18 17
32 ANSI 150 117 88.9 4 1/2 x 70 16 16
ANSI 300 133 98.4 4 5/8 x 80 20 22
ANSI 600 133 98.4 4 5/8 x 100 20 22
PN 16 140 100 4 –– 18 ––
Table D 135 98 4 M12 x 50 14 6*
Table E 135 98 4 M12 x 50 14 9*
Table H 140 105 4 M16 x 65 18 17
40 ANSI 150 127 98.4 4 1/2 x 70 16 17
ANSI 300 156 114.3 4 3/4 x 90 23 22
ANSI 600 156 114.3 4 3/4 x 105 23 22
PN 16 150 110 4 –– 18 ––
Table D 150 114 4 M16 x 60 18 8*
Table E 150 114 4 M16 x 60 18 10*
Table H 165 127 4 M16 x 75 18 19
50 ANSI 150 152 120.6 4 5/8 x 80 20 20
ANSI 300 165 127 8 5/8 x 90 20 22
ANSI 600 165 127 8 5/8 x 105 20 26
PN 16 165 125 4 –– 16 ––
Table D 165 127 4 M16 x 60 18 8*
Table E 165 127 4 M16 x 60 18 10*
Table H 185 146 8 M16 x 75 18 19
65 ANSI 150 178 139.7 4 5/8 x 90 20 23
ANSI 300 191 149.2 8 3/4 x 100 23 26
ANSI 600 191 149.2 8 3/4 x 120 23 30
PN 16 185 145 4 –– 18 ––
Table D 185 146 4 M16 x 60 18 10*
Table E 185 146 4 M16 x 60 18 11*
Table H 205 165 8 M16 x 75 18 22
80 ANSI 150 191 152.4 4 5/8 x 90 20 24
ANSI 300 210 168.3 8 3/4 x 110 23 32
ANSI 600 210 168.3 8 3/4 x 125 23 32
PN 16 200 160 8 –– 18 ––
Table D 215 178 4 M16 x 65 18 10*
Table E 215 178 8 M16 x 65 18 13
Table H 230 191 8 M16 x 85 18 25
100 ANSI 150 229 190.5 8 5/8 x 90 20 24
ANSI 300 254 200 8 3/4 x 110 23 32
ANSI 600 273 215.9 8 7/8 x 145 26 38
PN 16 220 180 8 –– 18 ––
*It is impractical to use thickness less than 12.00mm for plate flanges.
Dimensions AS 2129 – ANSI/ASME B16.5

FlaNGe iDeNTiFiCaTiON CHarT
Diam. / length Flange

Bolt Circle
size (mm) Table / Class Diam. of Flange No. of Bolts Bolts / studs Diam. Holes Thickness Cast
Diam.
steel Flanges / Forged steel
Table D 255 210 8 M16 x 65 18 22
Table E 255 210 8 M16 x 65 18 14
Table H 280 235 8 M20 x 95 22 29
125 ANSI 150 254 215.9 8 3/4 x 90 23 24
ANSI 300 279 234.9 8 3/4 x 120 23 35
ANSI 600 330 266.7 8 1 x 165 29 45
PN 16 250 210 8 –– 18 ––
Table D 280 235 8 M16 x 65 18 13
Table E 280 235 8 M20x 65 22 17
Table H 305 260 12 M20 x 95 22 29
150 ANSI 150 279 241.3 8 3/4 x 100 23 26
ANSI 300 318 269.9 12 3/4 x 125 23 37
ANSI 600 356 292.1 12 1 x 170 29 48
PN 16 285 240 8 –– 22 ––
Table D 335 292 8 M16 x 65 18 13
Table E 335 292 8 M20 x 65 22 19
Table H 370 324 12 M20 x 100 22 32
ANSI 150 343 298.4 8 3/4 x 110 23 29
200 7/8 x 140
ANSI 300 381 330.2 12 26 41
ANSI 600 419 349.2 12 1 1/8 x 195 32 56
PN 10 340 295 8 –– 22 ––
PN 16 340 280 12 –– 22 ––
Table D 405 356 8 M20 x 75 22 ––
Table E 405 356 12 M20 x 75 22 22
Table H 430 381 12 M24 x 120 26 35
250 ANSI 150 406 361.9 12 7/8 x 115 29 30
ANSI 600 510 431.8 16 1 1/4 x 215 35 64
PN 10 395 350 8 –– 22 ––
PN 16 405 350 12 –– 22 ––
Table D 455 406 12 M20 x 85 22 22
Table E 455 406 12 M24 x 85 26 25
Table H 490 438 16 M24 x 110 26 41
300 ANSI 150 483 431.8 12 7/8 x 120 26 32
ANSI 300 520 450.8 16 1 1/8 x 170 32 51
PN 10 445 400 12 –– 22 ––
PN 16 450 410 12 –– 25 ––
Table D 525 470 12 M24 x 95 26 25
Table E 525 470 12 M24 x 95 26 29
350 Table H 550 495 16 M27 x 130 30 48
ANSI 150 535 476.2 12 1 x 130 29 35
ANSI 300 585 514.3 20 1 1/8 x 175 32 54
Table D 550 495 12 M24 x 95 26 22
375
Table E 550 495 12 M24 x 95 26 32
Table D 580 521 12 M24 x 95 26 22
Table E 580 521 12 M24 x 100 26 32
400 Table H 610 552 20 M27 x 140 30 54
ANSI 150 597 539.7 16 1 x 130 29 37
ANSI 300 650 571.5 20 1 1/4 x 190 35 57
Table D 640 584 12 M24 x 95 26 25
Table E 640 584 16 M24 x 120 26 35
450 Table H 675 610 20 M30 x 160 33 60
ANSI 150 635 577.8 16 1 1/8 x 150 32 40
ANSI 300 710 628.6 24 1 1/4 x 195 35 60
Table D 705 641 16 M24 x 110 26 29
Table E 705 641 16 M24 x 110 26 38
500 Table H 735 673 24 M30 x 170 33 67
ANSI 150 700 635 20 1 1/8 x 160 32 43
ANSI 300 775 685.8 24 1 1/4 x 205 35 64
Table D 825 756 16 M27 x 120 30 32
Table E 825 756 16 M30 x 140 33 48
600 Table H 850 781 24 M33 x 200 36 76
ANSI 150 815 749.3 20 1 1/4 x 175 35 48
ANSI 300 915 812.8 24 1 1/2 x 230 42 70
*It is impractical to use thickness less than 12.00mm for plate flanges.
Dimensions AS 2129 – ANSI/ASME B16.5
13 13
13
© WestOne Services
Flange 2013
Identification ENG2068
Pressure - Stress Conversion Charts 14149
14 14
PressUre - sTress CONVersiON CHarT

The SI unit of pressure and stress is the NEWTON PER SQUARE METRE which has been given the special name PASCAL – Symbol Pa.
The pascal is too small for most normal uses and suitable multiple units preferred for Australia are:
kilopascal: Symbol – kPa (= 1000 Pa) megapascal: Symbol – MPa (= 1,000,000 Pa)
(1 N/m2 = 0.000145 lbf/in2 = 1Pa) (1 N/mm2 = 145 lbf/in2 = 1MPa)
PSI (lbf/in2) to kPa • PRESSURE – STRESS CONVERSION CHART

(A) To use, locate “given pressure” in “given pressure” column (coloured grey) whether lbf/in2 or kPa.
(B) If “given pressure” is in pounds force per square inch (lbf/in2), read kilopascals (kPa) in right hand column.
(C) If “given pressure” is in kilopascals (kPa), read pounds force per square inch (lbf/in2) in left hand column.
(D) Example: (i) Given pressure is 100 lbf/in2 = 689 kPa from right hand column
(ii) Given pressure is 100kPa = 14.50 lbf/in2 from left hand column
1 to 35 36 to 70 71 to 125 130 to 80,000

Given Given Given Given
lbf/in2 Pressure kPa lbf/in2 Pressure kPa lbf/in2 Pressure kPa lbf/in2 Pressure kPa = mPa
0.15 1 6.89 5.22 36 248.21 10.30 71 490 18.85 130 896 = 0.90
0.29 2 13.79 5.37 37 255.11 10.44 72 496 19.58 135 931 = 0.93
0.44 3 20.68 5.51 38 262.00 10.59 73 503 20.31 140 965 = 0.97
0.58 4 27.58 5.66 39 268.9 10.73 74 510 21.03 145 1000 = 1.00
0.73 5 34.47 5.80 40 275.79 10.88 75 517 21.76 150 1034 = 1.03
0.87 6 41.37 5.95 41 282.69 11.02 76 524 22.48 155 1069 = 1.07
1.02 7 48.26 6.09 42 289.58 11.17 77 531 23.21 160 1103 = 1.10
1.16 8 55.16 6.24 43 296.48 11.31 78 538 23.93 165 1138 = 1.14
1.31 9 62.05 6.38 44 303.37 11.46 79 545 24.61 170 1172 = 1.17
1.45 10 68.95 6.53 45 310.26 11.60 80 552 25.38 175 1207 = 1.21
1.60 11 75.84 6.67 46 317.16 11.75 81 558 26.11 180 1241 = 1.24
1.74 12 82.74 6.82 47 324.05 11.89 82 565 26.83 185 1276 = 1.28
1.89 13 89.63 6.96 48 330.95 12.04 83 572 27.56 190 1310 = 1.31
2.03 14 96.53 7.11 49 337.84 12.18 84 579 28.28 195 1344 = 1.34
2.18 15 103.42 7.25 50 344.74 12.33 85 586 29.01 200 1379 = 1.38
2.32 16 110.32 7.40 51 351.63 12.47 86 593 36.26 250 1724 = 1.73
2.47 17 117.21 7.54 52 358.53 12.62 87 600 43.51 300 2068 = 2.07
2.61 18 124.11 7.69 53 365.42 12.70 88 607 58.02 400 2758 = 2.76
2.76 19 131.00 7.83 54 372.32 12.91 89 614 72.52 500 3447 = 3.45
2.90 20 137.90 7.98 55 379.21 13.05 90 621 108.78 750 5171 = 5.17
3.05 21 144.79 8.12 56 386.11 13.20 91 627 145.04 1000 6894 = 6.89
3.19 22 151.69 8.27 57 393.00 13.34 92 634 217.56 1500 10,342 = 10.34
3.34 23 158.58 8.41 58 399.90 13.49 93 641 290.08 2000 13,790 = 13.79
3.48 24 165.47 8.56 59 406.79 13.63 94 648 435.11 3000 20,684 = 20.68
3.63 25 172.37 8.70 60 413.69 13.78 95 655 580.15 4000 27,579 = 27.58
3.77 26 179.26 8.85 61 420.58 13.92 96 662 725.19 5000 34,473 = 34.47
3.92 27 186.16 8.99 62 427.48 14.07 97 669 1,450.38 10,000 68,948 = 68.95
4.06 28 193.05 9.14 63 434.37 14.21 98 676 2,175.57 15,000 103,421 = 103.4
4.21 29 199.95 9.28 64 441.26 14.34 99 683 2,900.76 20,000 137,895 = 137.9
4.35 30 206.84 9.43 65 448.16 14.50 100 689 4,351.14 30,000 206,843 = 206.8
4.50 31 213.74 9.57 66 455.05 15.23 105 724 5,801.52 40,000 275,790 = 275.8
4.64 32 220.63 9.72 67 461.95 15.95 110 758 7,251.90 50,000 344,738 = 344.7
4.79 33 227.53 9.86 68 468.84 16.68 115 793 8,702.28 60,000 413.686 = 413.7
4.93 34 234.42 10.01 69 475.74 17.40 120 827 10,152.70 70,000 482,633 = 482.6
5.08 35 241.32 10.15 70 482.63 18.13 125 862 11,603.00 80,000 551,581 = 551.6
NOTe: iT is UsUal FOr PressUres iN eXCess OF 1000 kPa TO Be eXPresseD iN meGaPasCals – mPa
1 megapascal (mPa) = 1000 kilopascals (kPa) = 1 newton per mm2 (N/mm2) = 145 lbf/in2
UseFUl CONVersiON FaCTOrs – aPPrOXimaTe

mUlTiPlY BY TO OBTaiN mUlTiPlY BY TO OBTaiN aPPrOXimaTe eQUiValeNTs
TO OBTaiN BY DiViDe TO OBTaiN BY DiViDe 1 Atmosphere (atm) = 14.696 lbf/in2
1.0197 kg f/cm2 6.895 kPa 1 bar = 14.50 lbf/in2
lb f/in2 (PSI)
100.0 kPa 0.00689 MPa 1 kg f/cm2 = 14.22 lbf/in2
Bars
14.504 lbf/in2 ton f/in2 15.444 MPa 100 kPa (1 bar) = 14.50 lbf/in2
0.1 MPa
NOTE: lbf/in2 (pounds force per square inch) is
14.223 lbf/in2
often expressed as PSI (pounds per square inch)
kg f/cm2 98.07 kPa
0.09807 MPa
1422.33 lbf/in2
kg f / mm2 9.807 MPa
0.635 ton f/in2

TemPeraTUre - CONVersiON CHarT
The SI Unit of thermodynamic temperature is the KELVIN – Symbol K. For most practical purposes of temperature measurement and
most calculations involving temperatures, DEGREE CELSIUS, symbol oC will be used. The name CELSIUS was adopted internationally in
1948 instead of Centigrade, to avoid possible confusion with the identically named unit of angle used in some European countries.
TEMPERATURE CONVERSION CHART

(A) To use, locate “given temperature” in “given temperature” column (coloured grey) whether oC or oF.
(B) If “given temperature” is in degrees Celsius (oC), read degrees Fahrenheit (oF) in right hand column.
(C) If “given temperature” is in degrees Fahrenheit (oF), read degrees Celsius (oC) in left hand column.
(D) Example: (i) Given temperature is 35oC = 95oF from right hand column
(ii) Given temperature is 35oF = 1.7oC from left hand column
–320 to 27 28 to 77 78 to 235 240 to 485 490 to 2400

Given Given Given Given Given
o
C F
o o
C o
F C
o o
F C
o o
F C
o
F
o
Temp. Temp. Temp. Temp. Temp.
–196 –320 –– – 2.2 28 82.4 25.6 78 172.4 116 240 464 254 490 914
–184 –300 –– – 1.7 29 84.2 26.1 79 174.2 118 245 473 257 495 923
–173 –280 –– – 1.1 30 86.0 26.7 80 176.0 121 250 482 260 500 932
–162 –260 –436 – 0.6 31 87.8 27.2 81 177.8 124 255 491 266 510 950
–151 –240 –400 0.0 32 89.6 27.8 82 179.6 127 260 500 271 520 968
–140 –220 –364 0.6 33 91.4 28.3 83 181.4 129 265 509 277 530 986
–129 –200 –328 1.1 34 93.2 28.9 84 183.2 132 270 518 282 540 1004
–115 –175 –283 1.7 35 95.0 29.4 85 185.0 135 275 527 288 550 1022
–101 –150 –238 2.2 36 96.8 30.0 86 186.8 138 280 536 293 560 1040
– 90 –130 –202 2.8 37 98.6 30.6 87 188.6 141 285 545 299 570 1058
– 84 –120 –184 3.3 38 100.4 31.1 88 190.4 143 290 554 304 580 1076
– 79 –110 –166 3.9 39 102.2 31.7 89 192.2 146 295 563 310 590 1094
– 73 –100 –148 4.4 40 104.0 32.2 90 194.0 149 300 572 316 600 1112
– 68 – 90 –130 5.0 41 105.8 32.8 91 195.8 152 305 581 321 610 1130
– 62 – 80 –112 5.6 42 107.6 33.3 92 197.6 154 310 590 327 620 1148
– 57 – 70 – 94 6.1 43 109.4 33.9 93 199.4 157 315 599 332 630 1166
– 51 – 60 – 76 6.7 44 111.2 34.4 94 201.2 160 320 608 338 640 1184
– 46 – 50 – 58 7.2 45 113.0 35.0 95 203.0 163 325 617 343 650 1202
– 40 – 40 – 40 7.8 46 114.8 35.6 96 204.8 166 330 626 349 660 1220
– 34 – 30 – 22 8.3 47 116.6 36.1 97 206.6 168 335 635 354 670 1238
– 29 – 20 – 4 8.9 48 118.4 36.7 98 208.4 171 340 644 360 680 1256
– 23 – 10 14 9.4 49 120.2 37.2 99 210.2 174 345 653 366 690 1274
– 17.8 0 32 10.0 50 122.0 37.8 100 212.0 177 350 662 371 700 1292
– 17.2 1 33.8 10.6 51 123.8 41 105 221 179 355 671 377 710 1310
– 16.7 2 35.6 11.1 52 125.6 43 110 230 182 360 680 382 720 1328
– 16.1 3 37.4 11.7 53 127.4 46 115 239 185 365 689 388 730 1346
– 15.6 4 39.2 12.2 54 129.2 49 120 248 188 370 698 393 740 1364
– 15.0 5 41.0 12.8 55 131.0 52 125 257 191 375 707 399 750 1382
– 14.4 6 42.8 13.3 56 132.8 54 130 266 193 380 716 404 760 1400
– 13.9 7 44.6 13.9 57 134.6 57 135 275 196 385 725 410 770 1418
– 13.3 8 46.4 14.4 58 136.4 60 140 284 199 390 734 416 780 1436
– 12.8 9 48.2 15.0 59 138.2 63 145 293 202 395 743 421 790 1454
– 12.2 10 50.0 15.6 60 140.0 66 150 302 204 400 752 427 800 1472
– 11.7 11 51.8 16.1 61 141.8 68 155 311 207 405 761 432 810 1490
– 11.1 12 53.6 16.7 62 143.6 71 160 320 210 410 770 438 820 1508
– 10.6 13 55.4 17.2 63 145.4 74 165 329 213 415 779 443 830 1526
– 10.0 14 57.2 17.8 64 147.2 77 170 338 216 420 788 454 850 1562
– 9.4 15 59.0 18.3 65 149.0 79 175 347 218 425 797 468 875 1607
– 8.9 16 60.8 18.9 66 150.8 82 180 356 221 430 806 482 900 1652
– 8.3 17 62.6 19.4 67 152.6 85 185 365 224 435 815 510 950 1742
– 7.8 18 64.4 20.0 68 154.4 88 190 374 227 440 824 538 1000 1832
– 7.2 19 66.2 20.6 69 156.2 91 195 383 229 445 833 566 1050 1922
– 6.7 20 68.0 21.1 70 158.0 93 200 392 232 450 842 593 1100 2012
– 6.1 21 69.8 21.7 71 159.8 96 205 401 235 455 851 621 1150 2102
– 5.6 22 71.6 22.2 72 161.6 99 210 410 238 460 860 649 1200 2192
– 5.0 23 73.4 22.8 73 163.4 102 215 419 241 465 869 704 1300 2372
– 4.4 24 75.2 23.3 74 165.2 104 220 428 243 470 878 760 1400 2552
– 3.9 25 77.0 23.9 75 167.0 107 225 437 246 475 887 816 1500 2732
– 3.3 26 78.8 24.4 76 168.8 110 230 446 249 480 896 1093 2000 3632
– 2.8 27 80.6 25.0 77 170.6 113 235 455 252 485 905 1316 2400 4352
CONVersiON FaCTOrs
DeGrees FaHreNHeiT TO CelsiUs
(oF – 32) x 5/9 = oC
DeGrees CelsiUs TO FaHreNHeiT

(oC x 9/5) + 32 = oF
15
© WestOne Services 2013 ENG2068 15 151
15
15 Temperature Conversion
Temperature Conversion Chart
Chart American
AmericanStandard
StandardFlanges
Flanges 16
16
16 16
ameriCaN sTaNDarD FlaNGes TemPeraTUre / PressUre raTiNGs

Temperature / Pressure ratings
Carbon steel Pipe Flanges to aNsi / asme 16.5 - 1988 (Bs 1560) Forgings to asTm a105 and a350 - lF2 Forgings to asTm a181 Grade
ii for Class 150 and 300 Only
Temperature maximum Working Pressure in kPa by Classes (for approximate Psi divide by 7)
(oC)
Class 150 Class 300 Class 600 Class 900 Class 1500 Class 2500
(PN20) (PN50) (PN100) (PN150) (PN250) (PN420)
-29 to 38 1960 5110 10210 15320 25530 42550
50 1920 5010 10020 15020 25040 41730
100 1770 4640 9280 13910 23190 38650
150 1580 4520 9050 13570 22610 37690
200 1400 4380 8760 13150 21910 36520
250 1210 4170 8340 12520 20860 34770
300 1020 3870 7750 11620 19370 32280
350 840 3700 7390 11090 18480 30800
375 740 3650 7290 10940 18230 30390
400 650 3450 6900 10350 17250 28750
425 560 2880 5750 8630 14380 23960
450 470 2000 4010 6010 10020 16690
475 370 1350 2710 4060 6770 11290
500 280 880 1760 2640 4400 7330
525 190 520 1040 1550 2590 4320
540 130 330 650 980 1630 2720
NOTe: Flanges above 600 NPA are not included in ANSI B16.5 and the class designations in these large diameters
do not imply specific temperature / pressure ratings.

aPi - Valve standards
An Overview of the American Petroleum Institute - API - Valve Standards
standard Description
Specification for Pipeline Valves. API Specification 6D is an adoption of IO 14313: 1999, Petroleum & Natural Gas
Industries-Pipeline Transportation Systems-Pipeline Valves. This International Standard specifies requirements and gives
aPi sPeC 6D
recommendations for the design, manufacturing, testing and documentation of ball, check, gate and plug valves for application
in pipeline systems.
Flanged Steel Pressure Relief Valves. The standard is a purchase specification for flanged steel pressure relief valves. Basic
requirements are given for direct spring-loaded pressure relief valves and pilot-operated pressure relief valves as follows: orifice
aPi 526
designation and area / valve size and pressure rating, inlet and outlet; materials; pressure-temperature limits; and centre-to-
face dimensions, inlet and outlet.
Seat Tightness of Pressure Relief Valves R(2002). Describes methods of determining the seat tightness of metal and soft-
aPi 527
seated pressure relief valves, including those of conventional, bellows and pilot-operated designs.
aNsi / aPi sTD Check Valves: Flanged, Lug, Wafer and Butt-Welding. API Standard 594 covers design, material, face-to-face dimensions,
594 pressure-temperature ratings and examination, inspection and test requirements for two types of check valves.
Valve Inspection & Testing. The standard covers inspection, supplementary examination and pressure test requirements for
aPi 598 both resilient-seated and metal-to-metal seated gate, globe, plug, ball, check and butterfly valves. Pertains to inspection by the
purchaser and to any supplementary examinations the purchaser may require at the valve manufacturer’s plant.
Metal Plug Valves - Flanged, Threaded & Welding Ends. A purchase specification that covers requirements for metal plug
valves with flanged or butt-welding ends, and ductile iron plug valves with flanged ends, in sizes NPS 1 through to NPS 24,
which correspond to nominal pipe sizes in ASME B36.10M. Valve bodies conforming to ASME B16.34 may have flanged end
aNsi / aPi 599
and one butt-welding end. It also covers both lubricated and non-lubricated valves that have two-way coaxial ports, and includes
requirements for valves fitted with internal body, plug or port linings or applied hard facings on the body, body ports, plug or plug
port.
aNsi / aPi 600 Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries - Modified National Adoption of ISO 10434: 1998.
Compact Steel Gate Valves - Flanged, Threaded, Welding and Extended-Body Ends. The standard covers threaded-end, socket-
aPi 602
welding-end, butt-welding-end and flanged-end compact carbon steel gate valves in sizes NPS4 and smaller.
Corrosion-Resistant, Bolted Bonnet Gate Valves - Flanged and Butt-Welding ends. The standard covers corrosion-resistant
aNsi / aPi 603 bolted bonnet gate valves with flanged or butt weld ends in sizes NPS 1/2 through 24, corresponding to nominal pipe sizes in
ASME B36.10M, and Classes 150, 300 and 600, as specified in ASME B16.34.
Fire Test for Soft-Seated Quarter Turn Valves. The standard covers the requirements for testing and evaluating the
performance of straightway, soft-seated quarter turn valves when the valves are exposed to certain fire conditions defined
aNsi / aPi 607
in this standard. The procedures described in this standard apply to all classes and sizes of such valves that are made of
materials listed in ASME B16.34.
Butterfly Valves: Double Flanged, Lug and Wafer-Type. The standard covers design, materials, face-to-face dimensions, pressure-
aPi 609 temeprature ratings and examination, inspection and test requirements for gray iron, ductile iron, bronze, steel, nickel-base
alloy, or special alloy butterfly valves that provide tight shutoff in the closed position and are suitable for flow regulation.
Specification for Fire Test for Valves. The standard covers the requirements for testing and evaluating the performance of API
aPi 6Fa
Spec 6A and Spec 6D valves with automatic backseats when exposed to specifically defined fire conditions.
aPi 6rs References Standards for Committee 6, Standardisation of Valves and Wellhead Equipment.
Design of Continuous Flow Gas Lift Installation Using Injection Pressure Operated Valves. The standard sets guidelines for
aPi 11V6
continuous flow gas lift installation designs using injection pressure operated valves.
aNsi / aPi rP Recommended Practice for Repair, Testing and Setting Gas Lift Valves. The standard applies to repair, testing and setting gas
11V7 lift valves and reverse flow (check) valves.
Sizing, Selection and Insallation of Pressure-Relieving Devices in Refineries: Part I - Sizing and Selection. The recommended
aPi 520-1 practice applies to the sizing and selection of pressure relief devices used in refineries and related industries for equipment that
has a maximum allowable working pressure of 15 psig (1.03 bar g or 103 kPa g) or greater.
Recommended Practice 520: Sizing, Selection and Installation of Pressure-Relieving Devices in Refineries: Part II - Installation.
The recommended practice covers methods of installation for pressure-relief devices for equipment that has a maximum
aPi 520-2
allowable working pressure of 15 psig (1.03 bar g or 103 kPa g) or greater. It covers gas, vapor, steam, two-phase and
incompressible fluid service.
Inspection Practices for Piping System Components. The standard covers the inspection of piping, tubing, valves (other than
aNsi / aPi 574
control valves) and fittings used in petroleum refineries.
Inspection of Pressure-Relieving Devices. The recommended practice describes the inspection and repair practices for
aNsi / aPi 576
automatic pressure-relieving devices commonly used in the oil and petrochemical industries.
Metal Ball Valves - Flanged and Butt-Welding Ends. The standard covers Class 150 and Class 300 metal ball valves that have
aNsi / aPi 608
either butt-welding or flanged ends and are for use in on-off service.
17 17
17
© WestOne
APIServices
API -- Valve 2013
ValveStandards
Standards Useful ENG2068
UsefulConversion
Conversion Factors
Factors 18
18153
18 18
UseFUl CONVersiON FaCTOrs – imPerial TO meTriC (approx.)

“SI” denotes the International System of Metric Units adopted in Australia
This table may be used in two ways: (1) Multiply Column A by Column B to obtain Column C; or (2) Divide Column C by Column B to obtain Column A.
remarks a B C remarks a B C
multiply By To Obtain multiply By To Obtain
Square Inches 645.16 mm 2
lbf/in2 6.895 kPa
area: symbol m2
Square Feet 0.929 m2 kip/in2 (1000 psi) 6.895 MPa
Square Yards 0.836 m2 PressUre: symbol Pa
The SI unit of AREA is the lbf/ft2 47.88 Pa
Acre 4047 m2
SQUARE METRE. The SI unit of PRESSURE kgf/cm2 98.07 kPa
Hectare (ha) 10000 m2
or stress is the NEWTON bar 100 kPa
DeNsiTY: symbol kg/m3 PER SQUARE METRE which
lb/in3 27.68 t/m3 Vertical column
The SI unit of DENSITY is the lb/ft3 has been given the name
16.02 kg/m3 (head) of water.
kilogram per cubic metre. PASCAL.
lb/yd3 0.5933 kg/m3 (H20 at 20oC)
1 N/m2 = 1Pa = 9.79 kPa
metres of water
1.eleCTriCal eNerGY 0.000145lbf/in2 2.984 kPa
eNerGY: symbol J kilowatt hour (kW.h) 3.6 MJ feet of water
A pascal is the pressure or
torr (vacuum) 0.1333 kPa
The SI unit of ENERGY is the 2.HeaT eNerGY stress which arises when
JOULE. a force of one newton is 1mm Hg. (mercury) 0.1333 kPa
British thermal unit (Btu) 1.055 kJ
applied uniformly over an 1in. Hg. (mercury) 3.386 kPa
Btu/gal 0.2321 kJ/L †† area of one square metre.
1 J = 1 N.m
Btu/ft3 37.26 kJ/m3 atmosphere (atm) 101.325 kPa
A joule is the energy microns 0.133 Pa
expended or the work 3.meCHaNiCal eNerGY
TOrQUe: symbol N.m Poundal-foot
done when a force of one foot poundal (ft.pdl) .04214 J pdl.ft 0.04214 N.m
(moment of force)
newton moves the point of inch pound-force (in.lbf) 0.1130 J pound-force inch
application a distance of one foot pound-force (ft.lbf) 1.356 J lbf.inch 0.1130 N.m
The SI unit of TORQUE is
metre in the direction of foot ton force (ft.tonf) 3.037 kJ lbf.inch 1.152 kgf.cm
the NEWTON METRE. The
that force. Metre kilogram force (m.kgf) 9.807 J pound-force feet
newton metre is the work
done when a force of one lbf.ft 1.356 N.m
FOrCe: symbol N lbf.ft 13.83 kgf.cm
newton moves the point of
(NeWTON)
application a distance of one ton-force feet
metre in the direction of tonf.ft 3.037 kN.m
The SI unit of FORCE (kg.m/ Poundal (pdl) kilogram-force
that force.
s2) has been given the 0.1383 N kgf.m 9.807 N.m
special name – NEWTON. 1 N.m = 1 J kgf.cm 0.09807 N.m
Pound-force (lbf)
The newton is the force 4.448 N
VelOCiTY: symbol m/s ft. per second (ft/s) 0.3048 m/s
which when applied to a ton-force (tonf)
ft. per minute (ft/min) 0.00508 m/s
body having a mass of 9.964 kN
The SI unit of VELOCITY is miles per hour 0.4470 m/s
one kilogram, causes an *kilogram-force (kgf)
the METRE PER SECOND. miles per hour 1.609 km/h
acceleration of one metre 9.807 N
per second in the direction *also known as kilopond (kp) DrY:
of application of the force. cubic inch (in3) 16387 mm3
pounds-force per inch cubic foot (ft3) 0.02832 m3
FOrCe Per UNiT leNGTH:
lbf/in 175.1 N/m VOlUme: CaPaCiTY: cubic yard (yd3) 0.7646 m3
pounds-force per foot symbol m3 litre (L) †† 1 000 000 mm3
The SI unit is NEWTON PER lbf/ft 14.59 N/m litre (L) †† 0.001 m3
METRE: symbol N/m The SI unit of VOLUME is m3
ton-force per foot gallons (lmp.) 0.004546
the CUBIC METRE.
ton/ft 32.69 kN/m
imPerial liQUiD
inches 25.4 millimetres (mm) NOTE: †† fluid ounce 28.41 millilitre (ml)
leNGTH: symbol m feet 0.3048 metres (m) Capital “L” is now the legal
pint (20 fl. oz) 568.3 millilitre (ml)
preferred symbol for litre in
yards 0.9144 metres (m) quart (2 pints) 1.137 litre (L) ††
The SI unit of LENGTH is the Australia.
chain 20.12 metres (m) gallon (lmp.) 4.546 litre (L) ††
METRE.
mile 1609 metres (m) gallon (US) 3.785 litre (L) ††
mile 1.609 kilometres (km) litre (water 4oC) 1.000 kilogram (kg)
Imp. gallons (water 20oC) 4.536 kilogram (kg)
ounce 28.35 grams (g)
pound 0.4536 kilograms (kg) m3/s
Imp. gal. per minute (gal/ 0.0000758
mass: symbol kg slug 14.59 kg min)
ton (2240 lb) 1016.05 kg VOlUme: raTe OF FlOW m3/hr
Imp. gal. per minute 0.272765
The SI unit of MASS is the short ton (2000 lb) 907.2 kg symbol m3/s litre per second
ton (2240 lb) 1.016 tonne (t) Imp. gal. per minute 0.0758
KILOGRAM.
(L/s)
The SI unit of VOLUME RATE
pounds per foot (lb/ft) 1.488 kg/m
OF FLOW is the CUBIC
pounds per yard (lb/yd) 0.4961 kg/m
0.000472 m3/s
METRE PER SECOND. cubic ft. per minute
0.472 litre per second

cubic ft. per minute
(L/s) 1 m3 = 1 kL
POWer: symbol W Btu per hour (Btu/hr) 0.2931 W
The SI unit of POWER is the horsepower (hp) 0.7457 kW
WATT. ton of refrigeration 3.517 kW miles per gallon 0.3540 km per litre
sUNDrY iTems:
gallons per mile 2.825 litres per km
TemPeraTUre
The SI unit of TEMPERATURE is the KELVIN – Symbol K
For most practical purposes of temperature measurement and most calculations involving temperatures,
degrees Celsius, symbol oC will be used.
DeGrees FaHreNHeiT TO CelsiUs: (oF – 32) x 5/9 = oC
DeGrees CelsiUs TO FaHreNHeiT: (oC x 9/5) + 32 = oF

PIPE FABRICATION
MATERIALS, DRAWING AND FABRICATION METHODS
DESCRIPTION
This resource covers content relating to units from the MEM training package in relation to the
pipe fabrication context. It supports the units MEM09003B and MEM09211A, and partially
supports MEM09217A, MEM05010C, MEM04011D, and MEM04045B.
Topics include:
• safety, plant and equipment
• codes and standards
• abbreviations and symbols
• materials, systems and fittings
• drawing and dimensioning
• fabrication methods and processes.
The book includes many technical drawings to support learning.
EDITION
Edition 1, 2013
TRAINING PACKAGE
• METALS AND ENGINEERING
COURSE / QUALIFICATION
• MEM40412 Certificate IV in Engineering (Drafting)
• MEM50212 Diploma of Engineering – Technical
• MEM40105 Certificate IV in Engineering
• MEM50105 Diploma of Engineering – Advanced Trade
UNITS OF COMPETENCY
This resource supports the unit:
• MEM09211A Producre drawings or models for industrial piping
It also partially supports:

• MEM09217A Prepare plans for pipe and duct fabrication
• MEM05011D Assemble fabricated components
ENG2068
PIPE FABRICATION
ISBN 978-1-74205-902-0
ORDERING INFORMATION:
Contact WestOne Services on Tel: (08) 9229 5200 Fax: (08) 9227 8393 Email: sales@westone.wa.gov.au
Orders can also be placed through the website: www.westone.wa.gov.au 9 781742 059020

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PIPE FABRICATION

MATERIALS, DRAWING AND FABRICATION METHODS

METALS AND ENGINEERING

Materials, drawing and fabrication methods

© Department of Training and Workforce Development 2016 (unless indicated

Copyright material available on this website is licensed under a Creative Commons

Except in relation to Excluded Material this license allows you to:

 Share — copy and redistribute the material in any medium or format

Excluded Material not available under a Creative Commons license:

Training Sector Services

© WestOne Services 2013

Published by and available from

1 Prospect Place West Perth WA 6005

Chapter 4 – Fabrication methods 115

Appendix 1 – MRC Data Chart 135

© WestOne Services 2013 3

About pipe fabrication

Field labour costs 47%

Material costs 23%

Design engineering costs 20%

Table 1.1: Fabrication costs

It is essential that pipework is fabricated by suitably trained and competent

© WestOne Services 2013 ENG2068 5

Standards Australia International Limited (SAI)

All codes are developed to establish uniform minimum standards for:

6 ENG2068 © WestOne Services 2013

© WestOne Services 2013 ENG2068 7

CH. OP. chain operated

8 ENG2068 © WestOne Services 2013

PCD pitch circle diameter

© WestOne Services 2013 ENG2068 9

10 ENG2068 © WestOne Services 2013

© WestOne Services 2013 ENG2068 11

Fig 2.1: Butt welded piping system

© WestOne Services 2013 ENG2068 13

Fig 2.2: Socket-welded piping system

14 ENG2068 © WestOne Services 2013

Fig 2.3: Screwed piping system

© WestOne Services 2013 ENG2068 15

Pipe nominal size versus actual

Schedule pipe wall thickness

NS 100 114.3 (+14.3) SCH 80 8.56

NS 150 168.3 (+18.3)

NS 200 219.1 (+19.1) SCH 160 13.49

NS 250 273.1 (+23.1)

Nominal Pipe wall

16 ENG2068 © WestOne Services 2013

Carbon steel pipe

© WestOne Services 2013 ENG2068 17

How are fittings rated?

Pressure rating Manufacturer’s Schedule no. Pressure rating

Table 2.1: Relationship between PSI, kPa and the schedule

18 ENG2068 © WestOne Services 2013

Straight Reducing Concentric Eccentric

Fig 2.5: Butt welded fittings

© WestOne Services 2013 ENG2068 19

Fig 2.6: Preparation for butt weld

Butt weld elbows

Fig 2.7: Short and long butt welding elbows

20 ENG2068 © WestOne Services 2013

Fig 2.8: Reducing elbow

Fig 2.9: Return bends

© WestOne Services 2013 ENG2068 21