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These levels of inspection are imposed on the mechanical contractor; however, in construction they can be increased if the failure rate is high or reduced if there are no or very few weld failures.

8. INSPECTION RECORDS
Inspection records must be retained to guarantee that the inspection levels imposed have been met. These records must include the following:
. . . . .

Type of examination. Name of inspector and radiographer. Equipment used. Welding procedure specication (WPS). Welders performance qualication (WPQ).

9. METALLIC FLANGED JOINTS

A number of ange standards are recognized internationally. The most commonly used are as follows:
ASME B16.5for sizes 1224 in. pressure ratings to 150, 300, 400, 600, 900, 1500, and 2500 lbs. ASME B16.47for sizes 2660 in. and pressure ratings to 150, 300, 400, 600, 900, 1500, and 2500 lbs.

There are also British (BS), German (DIN), French (AFNOR), and various other national standards; however, the ASME codes are recognized worldwide and, for the purpose of clarity and space, they are referenced in this chapter. A very common method of joining two lengths of pipe is by using metallic anged connections. The piping components required to make this connection are as follows:
. . .

Two metal anges (carbon steel, stainless steel, cast iron, Inconel, etc.). One set of bolts (carbon steel, low-alloy steel, stainless steel, etc.). One gasket (rubber, graphite, Teon, spiral wound, metal ring).

This joint requires two mating ange faces, which are pulled together by a set of equally spaced bolts with a gasket generally sandwiched between

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the two faces. In very special circumstances, a gasket is not used; however, this is very rare. The pressure seal is made by a compressive force applied by tightening the bolts against the two anges with the gasket trapped between the two faces. This method of connection allows the bolts to be loosened and the joint disassembled. This, therefore, is not considered a permanent joint, although in practice it could be in place for several years.

Basic Flange Types

Several methods are used to connect the ange to the piping system:
.

Weld neckrequires a full-penetration butt weld to connect the ange to pipe. (see Figure 5.3). Socket weldrequires a socket weld (llet weld) to connect the ange to pipe. (see Figure 5.4). Slip onrequires a minimum of one llet weld, however some clients specify two llet welds to connect the ange to the pipe (see Figure 5.5). Screwedrequires a male/female thread to connect the ange to the pipe (see Figure 5.6). Lap jointrequires two piping components for each side of the joint, one stub end, which is butt welded to the pipe, and a backing ring. The backing ring is drilled to take a set of bolts to make the pressure seal (see Figure 5.7).

Flange Facings
A ange must have a specied facing, which could be one of the following;
Flat face (FF)a at machined face, which requires a full-faced gasket to make the pressure seal. Raised face (RF)a ange with a raised step machined on the face, which requires a spiral wound gasket to make the pressure seal. Ring-type joint (RTJ)a ange with a circumferential groove machined into the ange face, which requires an oval or an octagonal circular ring gasket to make the pressure seal. Tongue and groove (T&G)two dissimilar anges, one having a tongue machined on one face and the other ange having a mating groove machined onto the face.

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The rst three are the most common ange facings used in the process industry; the last type is available but rarely used.

Figure 5.3. Weld Neck Flange, Raised Face.

Figure 5.4. Socket Weld Flange, Raised Face.

Machining of Flange Facing

The machined faces for the at face and the raised face anges are supplied in various machined nishes. The grooves are concentric or

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Figure 5.5. Slip On Flange, Raised Face.

Figure 5.6. Screwed Flange, Raised Face.

phonographic, machined onto the ange face that bites into the gasket, provides an improved pressure seal, and prevents the gasket being squeezed out radially when the bolt loads are applied. These nishes are identied in micro inch (AARH) or micrometer (Ra). For example:
125250 AARH (Ra 3.26.3)suitable for at faced anges with soft cut gaskets 1.5 mm and thinner.

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Figure 5.7. Lap Joint Flange, Raised Face.

125500 AARH (Ra 3.212.5)suitable for at faced anges with soft cut gaskets thicker than 1.5 mm. 125250 AARH (Ra 3.26.3)suitable for raised face anges with spiral wound gaskets.

10. WELD-NECK FLANGE

The dimension and the design of the weld neck ange have been calculated to meet the approval of the relevant code, in this case ASME B16.5 or ASME B16.47 (series A or B). Basically, the weld neck ange comprises a anged blade with standard drilling for bolts, based on the size and pressure rating. One side of the blade is machined to mate with another ange, and the other side has a tapered hub with a weld bevel prepared for mating to a pipe of a matching diameter. One circumferential weld is required to connect the ange to the pipe. A butt weld is a high-integrity weld that can be inspected visually or

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Type

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Characteristics Limiting Factors

Component more expensive than screwed, socket weld, and slip on anges Butt weld more expensive than socket weld Heavier component Socket weld Intermediate-integrity joint Not suitable for high Suitable for low and intermediate pressure and temperatures pressure and temperatures Not available in sizes over Used for smaller sizes, 4 in. <4 in.(usually <2 in.) Low component cost Not suitable for process Screwed Low-integrity joint piping Used for utility piping Not available in sizes systems and ambient over 4 in. temperature and low pressures Used for smaller sizes, <4 in. (usually <112 in.) Slip on Low-integrity joint Suitable for only lower Used for utility piping systems pressures and temperatures and ambient temperature and Generally restricted to low pressures utility piping systems Available in larger sizes Requires two llet welds Low component cost Lap joint Intermediate- to high-integrity Not suitable for smaller joint diameters Suitable for use at high pressures Requires two components and temperatures Available in larger sizes

Weld neck

High-integrity joint Suitable for use at high pressures and temperatures Available at all sizes High component cost

The choice of ange connection should be based on the following considerations. Concerning the process media:
. . .

Hazardous processASME 31.3, Category M. Nonhazardous processASME B31.3, Normal Fluid Service (NFS). Utility serviceASME 31.3, Category D.

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For pressure conditions:

. . .

Low pressureASME Class 150 and 300. Intermediate pressureASME Class 600, 900, 1500, 2500. High pressureabove ASME 2500 as specied in ASME B31.3, Chapter IX, K.

For joint integrity:

. . .

Highbutt weld used for weld neck, lap joint. Mediumllet weld used for socket weld, slip on. Lowthreaded used for screwed joints.

For size:
.

Generally 112 in. and belowa choice between butt weld, socket weld, and screwed. Above 2 in.butt weld is the preferred pipe to pipe weld, which excludes the use of socket weld and screwed anges.

For component cost:

. . . .

Lap jointmost expensive (two components). Weld neckexpensive (one component, one butt weld). Socket weldcheaper (one component, one or two llet welds). Screwed and slip oncheapest (one component, no weld).

For fabrication cost:

. . . .

Lap joint and weld neckmost expensive (one butt weld). Slip onexpensive (two llet welds). Socket weldcheaper (one llet weld). Screwedcheapest (one mechanical joint).

For the ange face:

. . .

Flat face. Raised faced. Ring-type joint.

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Table 7.1.

Piping Materials Guide

Valve Selection Based on the Fluid Phase and Type and the Function the Valve Performs Valve Function Type of Disc

Nature of Fluid

Liquid Phase Neutral (water, oil, etc.) On/off Gate Rotary ball Plug Diaphragm Buttery Plug gate Globe Buttery Plug gate Diaphragm Needle Gate Plug gate Rotary ball Plug Diaphragm Buttery Globe Diaphragm Buttery Plug gate Buttery Diaphragm Buttery Diaphragm Squeeze Pinch Rotary ball Buttery Diaphragm Plug Pinch Squeeze Buttery Diaphragm Squeeze Pinch Gate Gate Diaphragm Squeeze Pinch

Regulating

Corrosive (acid, alkaline)

On/off

Regulating

Hygienic (food, beverages, drugs)

On/Off Regulating

Slurry

On/off

Regulating

Fibrous suspensions

On/off, regulating

Valves Gas Phase Neutral (air, steam) On/off

215

Regulating

Corrosive (acid vapors, chlorine)

On/off

Regulating

Vacuum

On/off

Gate Globe Rotary ball Plug Diaphragm Globe Needle Buttery Diaphragm Gate Buttery Rotary ball Diaphragm Plug Buttery Globe Needle Diaphragm Gate Globe Rotary ball Buttery

Solid (powder) Phase Abrasive powder (silica) Lubricating powder (graphite, talcum) On/off, regulating On/off, regulating Pinch Squeeze Spiral sock Pinch Gate Spiral sock Squeeze

2. VALVE DATA SHEETS

It is common for the project process engineers to dene the function of the valve, and the piping material engineers to specify the valve on a valve data sheet (VDS), which gives complete details on the design codes, design conditions, materials of construction, testing and inspection, coating and painting, and all other requirements for the valve.