L6-TGN-105

PIPE FITTINGS, FLANGES & COUPLING INSPECTION GUIDELINE

Contents
1) PURPOSE ...................................................................................................................................... 1
2) APPLICATION ............................................................................................................................. 1
3) INTRODUCTION......................................................................................................................... 2
4) INTERNATIONAL STANDARDS ........................................................................................... 13
5) PRE-INSPECTION MEETING ................................................................................................ 14
6) FINAL INSPECTION ................................................................................................................ 14
7) PREPARATION FOR SHIPMENT ......................................................................................... 14
8) APPLICABLE DOCUMENTS ................................................................................................... 15
9) GUIDELINE HISTORY ............................................................................................................ 15

1) PURPOSE

The purpose of this guideline is to assist with the Third Party Inspection of Materials or Equipment at manufacturing
locations, in order to determine if the Materials or Equipment meet the Client’s expressed needs, expectations,
Purchase Order, call off, etc. placed on the manufacturer.

This guideline shall be read in conjunction with the specified revisions of applicable national or international Codes and
Standards; the Client’s specifications; the Manufacturers’ procedures; the Quality Plan and/or any other related
documents pertinent to the Order.

This document assists Inspectors in completing the inspection in accordance with the Client’s prescribed scope, it does
not determine the minimum or maximum range or scope of the inspection to be carried out. Hence elements of the
guide may not be applicable in all cases.

It is also intended to ensure that all relevant information is included in the Inspection Report in such a way that all the
issues relating to the Purchase Order, Contract, Manufacturing and Client requirements are correctly addressed and
documented.

Inspection reports will serve as the principle record of information relating to Quality, Status of the Purchase
Order/Contract/Material and Equipment.

2) APPLICATION

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This guideline is applicable to the inspection of new and refurbished equipment. The level of inspection also depends
on the complexity of the equipment involved. Hence, it is the responsibility of the Inspector to check the sections
described herein are relevant to their work.

Inspection during field installation of the fore-going equipment is outside the scope of this Technical Guideline Note.

3) INTRODUCTION

Mandatory Requirement
This procedure has been prepared as a general guide for the inspection of Pipe Fittings and Couplings and must be
used in conjunction with the Industry Standards.

Description of Equipment
Piping Fitting
A fitting is used in pipe and plumbing systems to connect straight pipe or tubing sections, to adapt to different sizes or
shapes, and for other purposes, such as regulating or measuring fluid flow. The term plumbing is generally used to
describe conveyance of water, gas, or liquid waste in ordinary domestic or commercial environments, whereas piping is
often used to describe high-performance (e.g. high pressure, high flow, high temperature, hazardous materials)
conveyance of fluids in specialised applications. The term tubing is sometimes used for lighter-weight piping, especially
types that are flexible enough to be supplied in coiled form.

Fittings (especially uncommon types) require money, time, materials, and tools to install, so they are a non-trivial part
of piping and plumbing systems. Valves are technically fittings, but are usually discussed separately.

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Various Pipe Fittings

Materials
The material with which a pipe is manufactured often forms as the basis for choosing any pipe. Materials that are used
for manufacturing pipes include:
 Carbon Steel (CS)
 Low Temperature Service Carbon Steel (LTCS)
 Stainless Steel (SS)
 Non-Ferrous Metals (Inconel, Incoloy, Copper-nickel etc.)
 Non-Metallic (ABS, GRE, PVC, HDPE, tempered glass, etc.)
 Chrome-Molybdenum Steel (Alloy steel) — generally used for high temperature service

The bodies of fittings for pipe and tubing are most often of the same base material as the pipe or tubing being
connected, for example, copper, steel, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or acrylontrile
butadiene styrene (ABS). However, any material that is allowed by the plumbing, health, or building code (as
applicable) may be used, but must be compatible with the other materials in the system, the fluids being transported,
and the temperatures and pressures inside and outside of the system. For example, brass- or bronze-bodied fittings
are common in otherwise copper piping and plumbing systems. Fire hazards, earthquake resistance, and other factors
also influence choice of fitting materials.

Gaskets
Gaskets are used for sealing of flange joints. In general, gaskets should not be reused. Various types of gaskets are
available depending upon their construction, materials, and features. The following are the type of gaskets commonly
used:

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 Non-Metallic Gaskets (ASME B 16.21)
 Spiral-Wound Gaskets (ASME B 16.20)
 Ring Joint Gaskets (ASME B 16.20)

Non-Metallic Gaskets are used with flat face or raised face flanges. Spiral-wound Gaskets are used with raised face
flanges. They are available with an inner ring and outer ring, which is also known as the cantering ring. Ring Joint
Gaskets are used with Ring Type Joint (RTJ) flanges. They are available in octagonal or oval cross sections.

A very high surface stress is developed between an RTJ gasket and the flange groove when RTJ is bolted up in a
flange. This leads to plastic deformation of the gasket. Thus, the hardness of the gasket is kept less than the hardness
of the groove to achieve coining i.e. bringing two metal surfaces of different hardness so tightly together that the
softer surface deforms to match the harder surface exactly in shape and finish. Hence RTJ gaskets are recommended
for reuse.

Various Gaskets RTJ Gasket Configurations

Gender of Fittings
Piping or tubing is usually (but not always) inserted into fittings to make connections. To avoid confusion, connections
are conventionally assigned a gender of male or female, respectively abbreviated as "M" or "F".

Common Fittings for Both Piping

While there are hundreds of specialised fittings manufactured, some common types of fittings are used widely in piping
and plumbing systems.

Elbow
An elbow is a pipe fitting installed between two lengths of pipe or tubing to allow a change of direction, usually a 90°
or 45° angle, though 22.5° elbows are also made. The ends may be machined for butt welding, threaded (usually
female), or socketed, etc. When the two ends differ in size, the fitting is called a reducing elbow or reducer elbow.

Elbows are categorised based on various design features as below:

• Long Radius (LR) Elbows – radius is 1.5 x the pipe diameter
• Short Radius (SR) Elbows – radius is 1.0 x the pipe diameter
• 90 Degree Elbow – where change in direction required is 90°
• 45 Degree Elbow – where change in direction required is 45°

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A 90 degree elbow is also called a "90 bend" or "90 Ell". It is a fitting which is bent in such a way to produce 90 degree
change in the direction of flow in the pipe. It used to change the direction in piping and is also sometimes called a
"quarter bend". A 90 degree elbow attaches readily to plastic, copper, cast iron, steel and lead. It can also attach to
rubber with stainless steel clamps. It is available in many materials like silicone, rubber compounds, galvanised steel,
etc. The main application of an elbow (90 degree) is to connect hoses to valves, water pressure pumps, and deck
drains. These elbows can be made from tough nylon material or NPT thread.

A 45 degree elbow is also called a "45 bend" or "45 Ell". It is commonly used in water supply facilities, food industrial
pipeline networks, chemical industrial pipeline networks, electronic industrial pipeline networks, air conditioning facility
pipelines, agriculture and garden production transporting systems, pipeline network for solar energy facilities etc.

Most elbows are available in short radius or long radius variants. The short radius elbows have a centre-to-end
distance equal to the Normal Pipe Size (NPS) in inches, while the long radius is 1.5 x the NPS in inches. Short elbows
are widely available, and are typically used in pressurised systems.

Long elbows are typically used in low-pressure gravity-fed systems and other applications where low turbulence and
minimum deposition of entrained solids are of concern. They are readily available in acrylonitrile butadiene styrene
(ABS plastic), polyvinyl chloride (PVC) for DWV, sewage and central vacuums, chlorinated polyvinyl chloride (CPVC) and
copper for 1950s to 1960s houses with copper drains.

Various Elbows

Coupling
A coupling connects two pipes to each other. If the size of the pipe is not the same, the fitting may be called a
reducing coupling or reducer, or an adaptor. By convention, the term "expander" is not generally used for a coupler
that increases pipe size; instead the term "reducer" is used.

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Various Couplings

Union
A union is similar to a coupling, except it is designed to allow quick and convenient disconnection of pipes for
maintenance or fixture replacement. While a coupling would require either solvent welding/soldering or being able to
rotate with all the pipes adjacent as with a threaded coupling, a union provides a simple transition, allowing easy
connection or disconnection at any future time. A standard union pipe is made in three parts consisting of a nut, a
female end, and a male end. When the female and male ends are joined, the nuts then provide the necessary
pressure to seal the joint. Since the mating ends of the union are interchangeable, changing of a valve or other device
can be achieved with a minimum loss of time. Pipe unions are essentially a type of flange connector, as discussed
further below.

In addition to a standard union, there exist dielectric unions which are used to separate dissimilar metals (such as
copper and galvanised steel) to avoid the damaging effects of galvanic corrosion. When two dissimilar metals are in
contact with an electrically conductive solution (even tap water is conductive), they will form a battery and generate a
voltage by electrolysis. When the two metals are in direct contact with each other, the electric current from one metal
to the other will cause a movement of ions from one to the other, dissolving one metal and depositing it on the other.
A dielectric union breaks the electric current path with a plastic liner between two halves of the union, thus limiting
galvanic corrosion.

Various Pipe Couplings

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Reducer
A reducer allows for a change in pipe size to meet hydraulic flow requirements of the system, or to adapt to existing
piping of a different size. Reducers are usually concentric but eccentric reducers are used when required to maintain
the same top- or bottom-of-pipe level.

Reducers Eccentric Reducer

Olets
Whenever branch connections are required in size where reducing tees are not available and/or when the branch
connections are of smaller size as compared to header size, olets are generally used. The following are few
configurations of olet connections:
• Flanged Olet
• Socket-Weld & Threaded Olet
• Lateral & Elbow Olets
• Nipple Olet
• Butt-Weld Olet
• Swage Nipples

Various Pipe Olets

Tee
A tee is the most common pipe fitting. It is available with all female thread sockets, all solvent weld sockets, or with
opposed solvent weld sockets and a side outlet with female threads. It is used to either combine or split a fluid flow. It
is a type of pipe fitting which is T-shaped having two outlets, at 90° to the connection to the main line. It is a short
piece of pipe with a lateral outlet. A tee is used for connecting pipes of different diameters or for changing the

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direction of pipe runs. They are made of various materials and available in various sizes and finishes. They are
extensively used in pipeline networks to transport two-phase fluid mixtures. They are categorised as:
• Equal
• Unequal

When the size of the branch is same as header pipes, an equal tee is used and when the branch size is less than that
of header size, a reduced tee will be used. Most common are tees with the same inlet and outlet sizes. Some of the
industrial tees are Straight Tee, Reducing Tee, Double Branch Tee, Double Branch Reducing Tee, Conical Tee, Double
Branch Conical Tee, Bullhead Tee, Conical Reducing Tee, Double Branch Conical Reducing Tee, Tangential Tee, and
Double Branch Tangential Tee.

The above tees are categorised on the basis of their shapes and structure. They can also be classified on the basis of
the application they are required to perform.

The three outlet sizes should be named in order (e.g. left, middle, right; measuring 15-22-15)]
The three sizes of a tee are end x end x centre. So if you want a tee that is 1" on both ends and 3/4" in the centre it
would be 1" x 1" x 3/4".

Various Tees

Cross
Cross fittings are also called 4-way fittings. If a branch line passes completely through a tee, the fitting becomes a
cross. A cross has one inlet and three outlets, or vice versa. They often have solvent welded socket ends or female
threaded ends.

Cross fittings can generate a huge amount of stress on pipe as temperature changes, because they are at the centre of
four connection points. A tee is steadier than a cross, as a tee behaves like a three-legged stool, while a cross behaves
like a four-legged stool. (Geometrically, "any 3 non-collinear points define a plane" thus 3 legs are inherently stable.)
Crosses are common in fire sprinkler systems, but not in plumbing, due to their extra cost as compared to using two
tees.

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PIPE FITTINGS, FLANGES & COUPLING INSPECTION GUIDELINE

Various Pipe Crosses

Cap
Caps are liquid or gas tight, and cover the end of a pipe. A cap is used like plug, except that the pipe cap screws or
attaches on the male thread of a pipe or a nipple. A cap may have a solvent weld socket end or a female threaded end
and the other end closed off. In plumbing systems that use threads, the cap has female threads. Industrial caps can
be round, square, rectangular, U-shaped, and I-shaped and may have a round hand grip or a flat hand grip.

If a solvent weld cap is used to provide for a future connection point, several inches of pipe must be left before the
cap. This is because when the cap is cut off for the future connection, enough pipe must remain to allow a new fitting
to be glued onto it.

Various Pipe Caps

Plug
A plug closes off the end of a pipe. It is similar to a cap but it fits inside the fitting it is mated to. In a threaded iron
pipe plumbing system, plugs have male threads. Some of the popular types of plugs are:
• Mechanical pipe plug
• Pneumatic disk pipe plug
• Single size pneumatic all rubber pipe plug
• Multi-size pneumatic pipe plug
• Multi-size flow-through pipe plug
• High pressure pipe plug

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PIPE FITTINGS, FLANGES & COUPLING INSPECTION GUIDELINE

Various Pipe Plugs

Nipple
A short stub of pipe usually threaded steel, brass, chlorinated polyvinyl chloride (CPVC) or copper; occasionally just
bare copper. A nipple is defined as being a short stub of pipe which has external male pipe threads at each end, for
connecting two other fittings. Nipples are commonly used for plumbing and hoses, and second as valves for funnels
and pipes.

Equal Nipple Barrel Nipple Reducing nipple

Pipe Flanges
There are many different flange standards to be found worldwide. To allow easy functionality and interchangeability,
these are designed to have standardised dimensions. Common world standards include ASA/ANSI/ASME (USA), PN/DIN
(European), BS10 (British/Australian), and JIS/KS (Japanese/Korean).

In most cases these are not interchangeable (e.g. an ANSI/ASME flange will not mate against a JIS flange). Further,
many of the flanges in each standard are divided into "pressure classes", allowing flanges to be capable of taking
different pressure ratings. Again these are not generally interchangeable (e.g. an ANSI/ASME 150 will not mate with
an ANSI/ASME 300).

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These pressure classes also have differing pressure and temperature ratings for different materials. Unique pressure
classes for piping can also be developed for a process plant or power generating station; these may be specific to the
corporation, engineering procurement and construction (EPC) contractor, or the process plant owner. The ANSI/ASME
pressure classes for Flat-Face flanges are 125# and 250#. The classes for Ring-Joint, Tongue & Groove, and Raised-
Face flanges are 150#, 300#, (400# - unusual), 600#, 900#, 1500#, and 2500#.

The flange faces are also made to standardised dimensions and are typically "flat face", "raised face", "tongue and
groove", or "ring joint" styles, although other obscure styles are possible.

Flange designs are available as "weld neck", "slip-on", "lap joint", "socket weld", "threaded", and also "blind".

ASME Standards (US)

ASME type Flange on a Gas Pipeline

Pipe flanges that are made to standards called out by ASME B16.5 or ASME B16.47 are typically made from forged
materials and have machined surfaces. B16.5 refers to nominal pipe sizes (NPS) from ½" to 24". B16.47 covers NPS
from 26" to 60". Each specification further delineates flanges into pressure classes: 150, 300, 400, 600, 900, 1500 and
2500 psi for B16.5; B16.47 delineates its flanges into pressure classes 75, 150, 300, 400, 600, 900.

The gasket type and bolt type are generally specified by the standard(s). However, sometimes the standards refer to
the ASME Boiler and Pressure Vessel Code (B & PVC) for details (see ASME Code Section VIII Division 1 - Appendix 2).
These flanges are recognised by ASME Pipe Codes such as ASME B31.1 Power Piping, and ASME B31.3 Process Piping.

Materials for flanges are usually under ASME designation: SA-105 (Specification for Carbon Steel Forgings for Piping
Applications), SA-266 (Specification for Carbon Steel Forgings for Pressure Vessel Components), or SA-182
(Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature
Service). In addition, there are many "industry standard" flanges that in some circumstance may be used on ASME
work.

Other Countries
Flanges in other countries also are manufactured according to the standards for materials, pressure ratings etc. Such
standards include DIN, BS, and/or ISO Standards.

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Vacuum Flanges
A vacuum flange is a flange at the end of a tube used to connect vacuum chambers, tubing and vacuum pumps to
each other.

Vacuum Flanges

Various Flanges Weld neck Flange Slip on Flange

Blank Flange Ring Type Joint

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Various Flange Configurations

4) INTERNATIONAL STANDARDS

General
This list of standards is provided for guidance only and is not intended to be comprehensive. It is included to assist the
Inspector in selecting relevant sources of information where a Client’s specific requirements do not exist.

Technical Standards
There are certain standard codes that need to be followed while designing or manufacturing any piping system.
Organisations that promulgate piping standards include:
• ASME - The American Society of Mechanical Engineers
• ASTM – American Society for Testing and Materials
• API – American Petroleum Institute
• AWS – American Welding Society
• AWWA – American Water Works Association
• MSS – Manufacturing Standardisation Society
• ANSI - American National Standards Institute
• NFPA – National Fire Protection Association
• EJMA – Expansion Joint Manufacturing Association

For example pipes need to conform to the dimensional requirements of:

• ASME B36.10M - Welded and Seamless Wrought Steel Pipe
• ASME B36.19M - Stainless Steel Pipe
• ASME B31.3 2008 - Process Piping

The B31.3 code has requirements for piping found in petroleum refineries; chemical, pharmaceutical, textile, paper,
semiconductor, and cryogenic plants; and related processing plants and terminals. This code specifies requirements for
materials and components, design, fabrication, assembly, erection, examination, inspection, and testing of piping. This
Code is applicable to piping for all fluids including:

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(1) Raw, intermediate, and finished chemicals
(2) Petroleum products
(3) Gas, steam, air and water
(4) Fluidised solids
(5) Refrigerants
(6) Cryogenic fluids

5) PRE-INSPECTION MEETING

A Pre-Inspection Meeting may be desirable when an Order is placed for high values or quantities. If the Client has
requested such a meeting, the Area Technical Coordinator/Manager will be responsible for instructing the Inspector as
to whether such a meeting is required. The Applus Velosi reference documents are: L5-FMT-058/060/075.

The Client's Purchase Order and specification requirements must be fully discussed.

6) FINAL INSPECTION

Areas to be checked/inspected (against Purchase Order description):

• Dimensional Measurement
• Flange face (check flange profile, Ring Joint groove etc. for damage).
• Check hole configuration
• Cross check heat number with Materials Certification
• Check mechanical properties on Material Certificates match PO and standard requirements (Tensile’s, Charpy’s,
Hardness, Chemical composition, NACE MR01-75 etc.
• Verify authenticity of materials Certification.
• Packing and marking (if applicable)

Note: Any change against Order requirement is to be rejected until clarification is received from client.

7) PREPARATION FOR SHIPMENT

If required by Purchase Order or specification, the Inspector must ensure that identification of equipment and those
shipping marks, tag numbers etc. are clearly visible to avoid confusion at site. Equipment must be adequately sealed
and protected when overseas shipment is required.

Marking of equipment/packages is to be as per Purchase Order and Client requirements (i.e. address to where
shipment is to be sent).

If overseas shipment is required, the Inspector is to note on his/her report the correct INCOTERMS, carrier’s reference
(Ship’s name, Airway bill etc.), departure and delivery time to Client.

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Packaging and Marking Standards
a) BS 1133 Packaging code
b) BS 2540 Silica gel for use as a desiccant
c) BS 2541 Activated alumina for use as a desiccant
d) BS 3482 Methods of test for desiccants used in dynamic dehumidification equipment
e) BS 3523 Silica gel, cobalt chloride impregnated
f) BS 4672:1/2 Guide to hazards in the transport and storage of packages
g) BS 4826:P1-P14 Methods of test for complete, filled transport packages
h) BS 4853 Tensional steel strapping

8) APPLICABLE DOCUMENTS

Sr. No. Document No. Name of Document Retention Period

1 L5-FMT-008 Stamp Register 6 years
2 L5-FMT-045 IRC 6 years
3 L5-FMT-046 Inspection Report 6 years
4 L5-FMT-049 NCR 6 years
5 L5-FMT-054 Assignment Nomination Form 6 years
6 L5-FMT-058 PIM Report 6 years
7 L5-FMT-060 Flash Report 6 years
8 L5-FMT-062 PIM Checklist 6 years
9 L5-FMT-075 PIM Agenda 6 years
11 L5-FMT-080 AMIS Inspection Assignment 6 years
12 L5-FMT-082 Client Kick-off Meeting Report Form 6 years
13 L6-TGN-102 Types of Certification
14 L6-TGN-106 Steel Types
15 L6-TGN-094 Types of Non-Destructive Testing

9) GUIDELINE HISTORY

Rev. Date Section Outline of Change Generated By Authorisation

00 24-Sep-13 All First Issue C. J. Bandick M. Coles

01 08-Apr-14 8 TGNs added

All Minor grammatical & formatting

changes made only. B. Upton M. Coles

Note: Track changes removed for

legibility.

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Note: The above is for information only.

The Client’s Purchase Order/Procedures/Specifications have precedence over this Procedure.

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