YELLOW BOX...ASTM D2310 Standard Classification for Machine-Made Fiberglass Pipe ASTM D1599 Standard...

HIGH PRESSURE PIPELINE SYSTEMYELLOW BOX

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YELLOW BOX® High Pressure Pipeline System Page 1 of 50

Table of Contents

Section I : Pipeline

1 General ....................................................................................................................... 2

2 Applicable Codes / Standards ...................................................................................... 2

3 Classification and Pressure Range ................................................................................. 2

4 Jointing System ............................................................................................................ 4

5 Fittings ........................................................................................................................ 4

6 Applications ................................................................................................................ 4

7 Advantages ................................................................................................................. 4

8 Mechanical and Physical Properties ............................................................................... 5

9 Manufacturing ............................................................................................................. 5

10 Markting and Identification ........................................................................................... 7

11 Packing and Shipping .................................................................................................. 8

Section II : Field Installation Procedure

1 General ....................................................................................................................... 10

2 Trench Preparation ....................................................................................................... 10

3 Sand bedding .............................................................................................................. 11

4 Pipe stringing ............................................................................................................... 11

5 Pipe assembly .............................................................................................................. 12

6 Road Crossing ............................................................................................................. 15

7 Tie-Inn Connection ....................................................................................................... 16

8 Backfilling ................................................................................................................... 18

Section III: Field Hydrotesting Procedure

1 General ....................................................................................................................... 19

2 Inspection .................................................................................................................... 19

3 Section to be tested ...................................................................................................... 19

4 Preparation ................................................................................................................. 19

5 System Flushing ........................................................................................................... 20

6 Pressurizing ................................................................................................................. 20

7 Depressurization .......................................................................................................... 21

8 Safety Precautions ........................................................................................................ 21

Section IV: Field Repair Procedure

1 General ....................................................................................................................... 22

2 Large size coupled joint repair ...................................................................................... 22

3 Integral joint repair ...................................................................................................... 25

Appendix A: Yellow Box STD design – Product Data ................................................................. 27

Appendix B: Yellow Box API 15HR design – Product Data ......................................................... 34

Appendix C: Fittings Dimensions .............................................................................................. 40

Appendix I: Conversion Tables ................................................................................................ 46

Appendix II: Conversion Graph PSI vs Bar ................................................................................ 49

Appendix III: Conversion Graph OC vs OF .................................................................................. 50

YELLOW BOX® High Pressure Pipeline SystemPage 2 of 50

Section I : Pipeline

1. GeneralYELLOW BOX® line pipe is a machine-made composite material produced by filament winding high strength continuous glass fiber filaments and corrosion resistant epoxy resin on to a steel mandrel. The material is especially formulated to result in a structurally and chemically optimum product. The epoxy resin is an aromatic amine, heat cured system that has the highest mechanical strength, thermal resistance and best corrosion resistance of all commercially available resin systems used in the fabrication of fiberglass piping.

YELLOW BOX piping can be supplied with API 15HR certification. The Future Pipe Industries Quality Management System is certified to be in compliance with ISO-9001:2000 and ANSI-RAB.

2. Applicable Codes / StandardsThe latest edition of the following references should be considered.

API 15 HR Specification for High Pressure Fiberglass Line Pipe

API 5 B Specification for Threading, gauging and thread inspection of casing, tubing, and line pipe threads

API RP 5A3 Recommended Practice on Thread Compounds for Casing, Tubing, and Line Pipe

ASTM D3567 Standard Practice for Determining Dimensions of Fiberglass Pipe and Fittings

ASTM D2992 Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for Pipe and Fittings

ASTM D2996 Standard Specification for Filament Wound Fiberglass Pipe

ASTM D2310 Standard Classification for Machine-Made Fiberglass Pipe

ASTM D1599 Standard Test Method for resistance to Short-Time Hydraulic Pressure of Pipe and Fittings

3. Classification and Pressure RangeYELLOW BOX® pipe conforms to ASTM D2996 ( classification RTRP-11AX-2324 ) and ASTM D2310 ( classification RTRP-11AX ).

Product ranges for both Standard series & API 15HR series are mentioned in table I-3.1 and Table I-3.2 respectively.


Pressure Rating – Standard Yellow Box PipelinePipe Size 500 800 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500

2” A A A A A A A A A A A A A

2-1/2” A A A A A A A A A A A A

3” A A A A A A A A A A A A

3-1/2” A A A A A A A A A A A A

4” A A A A A A A A A A A


6” A A A A A A A A A A

6”-L A A A A A A A A A

8” A A A A A A A A A


10”-L A A A A A A

12” A A A A A A

14-1/2” A A A A A A

16-1/2” A A A A A A

18” A A A A A A

A : available Table I-3.1

For dimensional specifications & Performance of Standard product, please refer to Appendix A.

Pressure Rating – API 15 HR rated Yellow Box PipelinePipe Size 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000


2-1/2” A A A A A A A A A A A


3-1/2” A A A A A A A A A A A




6”-L A A A A A A A A A

8” A A A A A A A A

10” A A A A A A A A

10”-L A A A A A A

12” A A A A A A

14-1/2” A A A A A A

16-1/2” A A A A A A

18” A A A A A A

A : available Table I-3.2

For dimensional specifications & Performance of API product, please refer to Appendix B.


4. Jointing SystemYELLOW BOX® pipe products are connected with the reliable, time proven integral joint API 8 round external upset end (EUE) long threaded connections up to 4” size, and with casing long & casing short threaded connections for larger sizes and higher pressure classes. Depending upon pipe size or pressure class, filament wound integral joint female ends or couplings are utilized in the connection.

5. Fittings YELLOW BOX® pipe is offered with a complete line of fittings including elbows, tees, couplings, flanges, nipples, field threads, reducer bushings, reducer couplings and swages.

For Fitting dimensions please refer to Appendix C.

6. ApplicationsYELLOW BOX® pipe system is recommended for use in :- Salt Water injection and water floods lines- Medium to High pressure transmission lines- CO2 injection and recovery lines- Crude Oil and Gas flow lines as well as gathering systems- Chemical effluent and waste disposal lines- Water distribution systems

7. Advantages 1. Manufactured from Aromatic-amine, heat-cured epoxy resin which provides the

highest combination of mechanical and chemical resistance for GRE pipe systems. 2. Suitable for operating temperatures up to 210°F (98°C) 3. No external corrosion from aggressive soils and ground water 4. No internal corrosion from saline or brackish flood water or high-water cuts 5. No maintenance, painting, or cathodic protection is required 6. 20 Year design life 7. Low friction losses ( “C” factor * = 150 ) and low life cycle costs 8. Light weight, easy and fast installation 9. Water and gas tight threaded joints.

* C is the Hazen-Williams coefficient.

Fig. I-4

Fig. I-5


8. Mechanical and Physical PropertiesTypical mechanical properties of the YELLOW BOX® pipe structural wall are listed in Table I-8:

Properties Test Method US Metric

Axial Tensile Modulus ASTM D 2105 1.74 x 10 +06 psi 12,000 MPa

Axial Tensile Strength ASTM D 2105 9,000 psi 62 MPa

Hoop Tensile Strength ASTM D 1599 36,000 psi 220 MPa

Lower Confidence Limit (LCL) at 20 years ASTM D 2992 B 18,351 psi 127 MPa

Specific Gravity ASTM D792 1.93 1.93

Laminate Density ASTM D792 0.07 Lbs/in3 1938 kg/m3

Flow Factor Hazen Williams 150 150

Table I-8

9. ManufacturingThe machine as used by Future Pipe Industries (FPI) is representative of modern state-of-the-art filament winding technology for use in the manufacturing of glass fiber (composite) pipes.

Some main stages of pipe production are described below:

• Structural wall winding stageThe CNC winding program ensuring accurate control is selected from the control panel. This program sets and controls the rotation speed of the mandrel and the speed at which the carriage (which transports the impregnated filament windings) travels across the mandrel. Both the winding angle and the number of layers in the pipe are accurately controlled by the CNC program.

A rack containing the roving bobbins is set facing the rotating mandrels at a distance, and the roving ends of each bobbin are drawn through a ceramic ‘eye’ to the impregnation unit on the carriage. An Automatic dozing machine produces the exact mix of resin and curing agent.

The structural wall of the pipe consists of filament wound glass rovings. These rovings pass through a resin tank positioned above the mandrel & tension bars as shown in the figure below. Each roving is completely submerged & saturated in resin prior to encountering the steel mandrel, with a uniform distribution and under uniform tension.

Fig. I-9.1


• Pipe curing stageThe oven is heated with infrared ray heaters. Inside the oven the pipe and mandrel rotate slowly during the curing process to insure a uniform thickness and even curing temperature. Epoxy pipes are also post-cured after de-molding until to achieve the required level of curing of the epoxy resin.

• Mandrel extraction stagePipes are manufactured on solid mandrels having a length of 35 ft (10.6 m). A separate de-molding station removes the steel mandrel using a hydraulic winch with a steel ring that retains the pipe, while the pipe is pushed against the mandrel. The finished pipe has a laying length of 30 ft (9.14 m).

• Cutting and calibrating stage The unit is equipped with a CNC controlled diamond tipped cutting tool to machine threads on the spigot end of the pipe. For diameters from 2” up to and including 4” the threaded bell is integrated or molded with the pipe. For diameter sizes of 5” and above, the pipe will be supplied with either a threaded coupler or a molded integral joint depending upon the pressure class. As a special case, the 3000 psi API rated YB pipe of sizes 2 ½”, 3” and 3 ½” are supplied with threaded couplers. For more details, refer to the YB data sheets in Appendix A and Appendix B.

• Hydrostatic Testing After cutting and calibration, every pipe is transported to the hydrotest machine to be tested as part of Future Pipe quality control procedure.

As per specification API 15HR, the hydrotest pressure for API rated pipe is 1.5 times the nominal pressure rating. This “mill test pressure “ for both STD & API rated pipe are given in Appendix A & Appendix B respectively.

Fig. I-9.2

Fig. I-9.3

Fig. I-9.4


10. Marking and IdentificationEach pipe section, coupler and fitting shall be marked with the following information:1. Company Name2. Manufacturing standard3. Pipe diameter4. Pressure class5. Item serial number6. Manufacturing Date7. Color Coding Specific marking requirement by customers could be arranged.

10.1 Series Identification A typical YB label is shown below:

The series identification comprises of six parts:1. Pipe Number 2. Nominal Size: 2” – 18” 3. Pipeline Type: YB – YELLOW BOX

Other Types: BB – Blue Box RB – Red Box 4. Pressure Class: 500 – 3500 psi5. Pipe Specification: 0 – Standard API 15 HR6. Job Order Number

10.2 Color Coding Scheme A Color coding scheme has been introduced for easy recognition.

There are two or three lines painted near the both ends of the pipe. These signify the pipeline type and the pressure class of the pipe.

For example (as shown in Figure I-10.2) YELLOW BOX pipe with a pressure rating of 1000psi is painted yellow and black.

FUTURE PIPE INDUSTRIESHOUSTON TX 781-847-2987

MARCH 2008

25 25

8” YB 2500

API 15 HRJOB # 1000003

Pipeline Type

Nominal Size

Specification

Pipe Number

Pressure ClassJob Order Number

Fig. I-10.2 : 1000 psi rated Yellow Box Pipe

Fig. I-10.1: Pipe Label

Pressure ClassPipeline Type


Each pressure class is given color identification. This means that the black color as in Fig. I-10.2 may be replaced by other color (s) as shown in table I-10.

Pressure Class (psi) Equivalent Color Code

500 Gold

800 Orange

1000 Black

1250 Silver

1500 White

1750 Silver + Gold

2000 Blue

2250 Silver + Black

2500 Green

2750 White + Silver

3000 Brown

3250 Blue + Silver

3500 Brown + Gold

Table I-10 : Color Coding Scheme

11. Packing and ShippingNominal Size No. of pipe per crate No. of feet per crate

[inch] [pcs] [ft]

2 110 3,300

2-1/2 82 2,460

3 56 1,680

3-1/2 46 1,380

4 34 1,020

5 22 660

6 12 360

Table I-11 : Crate Frame Quantities

Pipe up to 6” diameter, is packed in open side steel band reinforced wooden crate frames as per table I-11. The weight of individual crates will vary from 3,500 to 5,000 lbs depending on the wall thickness of the shipped pipe.


Pipe sizes larger than 6” are unsuitable for crate frames and are loaded in rows and columns on flatbed trailers with wood tonnage between rows and side frames at each tonnage cross slat.

The standard crate’ outside dimensions are 48 inches wide by 21 inches tall and approximately 32 feet long. Typically, eight crates can be loaded on a standard flatbed trailer. The crates can be easily handled with either a crane or a forklift. Always use nylon straps on crane lifts and some form of padding on forklift forks.

Fig. I-11


Section II : Field Installation

1. General This procedure shall be considered as a guideline for site supervisors and field engineers to avoid mistakes and solve problems during installation. Basis for these installation instructions is the YELLOW BOX Installation Manual.

The objective is to ensure that the installed piping system will meet the specified performance requirements. Thus, this method statement is as complete as possible, as it is not feasible to describe all circumstances one might encounter in the field.

Therefore an experienced supervisor from FPI may vary the described procedure in order to achieve an optimum solution using the latest installation techniques.

2. Trench Preparation The trench excavation shall not be too far ahead of the pipe-laying team to ensure a control of the trench and to ensure safe working conditions. The excavated soil shall be placed on one side of the trench leaving the other side clear for equipment and pipe handling. If the trench consists of various layers of soils, these must be placed separately in order to use the stone-free granular material for backfill.

The trench width must be maintained within certain limits. A very wide trench will increase the volume of backfill material required, and compaction labor and effort. A very narrow trench will render laying, handling and jointing of pipes, as well as compaction of side backfill difficult. The minimum recommended trench width is given in the below figure.

If the water table is high, precautions shall be taken to avoid the trench collapsing and arrangements shall be made for de-watering to keep the trench dry and clean.The trench bottom and sides shall be free from all rubbish, skids, rocks, projecting rocks, wood or any other objects. The trench bottom shall be clean and dry until it is back-filled.The trench width shall be uniform for a distance of 1ft above the crown of the pipe, the width can vary after that. The final burial depth should be within 2 to 10 ft above the crown of the pipe.

Fig. II-2


3. Sand Bedding During trench excavation, a pipe bedding thickness of at least 0.5 ft must be provided. In case of poor native soils (silt, clay or mud) an additional 0.5 ft thick foundation layer must be provided below the bedding. Selected backfill material should be placed at the foundation and bedding levels and thoroughly compacted by plate vibrators or by hand tamping. Wetting of sand bedding / foundation material prior to compaction will improve and facilitate the achievement of the degree of compaction required.

Pipe laying shall always take place in dry trenches. It is not acceptable to lay pipes in flooded trenches. The contractor must provide the necessary dewatering equipment to proceed in a dry trench.

Dewatering equipment must be removed and pumps turned off after completion of backfilling the pipe embedment zone. Sufficient backfill shall be provided to prevent pipes from floating if the normal ground water level is above the pipe invert.

The embedment zone shall be of full sand with less than 12% fines compacted to 90% standard proctor density or with gravel compacted to 70% relative density.

4. Pipe stringing Precautions that shall be taken while stringing the pipes might be described but are not limited to, the following :a- Pipe shall not be strung before the trench is

fully excavated to the required depth and the bedding work is completed.

b- Pipe shall not be placed directly on the ground; proper skids shall be provided with wedges on both sides of each pipe to avoid rolling.

c- Stringing of pipe may be done from a frame trailer or a regular truck bed provided that each joint is handled individually. Pipe shall be set, as opposed to dropped, on the ground.

d- The thread protectors must remain in place throughout the stringing operation.

e- Pipe shall be kept away from the edge of the trench leaving a reasonable working area between the trench and the pipe.

f- To avoid damage to the pipe due to movement of construction equipment, it is advisable to string the pipes based on the requirement of the day-to-day work progress.

g- Pipe shall be strung based on a clear plan taking into consideration the direction of installation. It must be ensured that all the pin rotations must have the same orientation. The preferred direction of pipe installation is such that the liquid will flow out of the pin and into the following box. To achieve this, pipe must be strung with the pin end in the direction of flow and the box end towards the pressure source. Flange connections are considered as a free point, which means that the installation can always start there.

Fig. I-9.4


5. Pipe Assembly Required precautions while stringing the pipes can be described, but are not limited to, the following:5-1. Making up the joint inside the trench is the preferred way of installation. In some cases, however, this might not be possible for practical reasons. In such cases the pipe may be assembled outside, and subsequently lowered into, the trench.

5-2. The thread protector shall remain in place until the make up procedure of the pipe joint is started. Always use a dry hard bristle brush to remove any sand or dirt from the box and pin threads.

5-3. Once clean, the Teflon tape can be applied. The tape roll should be rolled under tension around the pin threads in a clockwise direction starting from the last thread of the pin end, to the vanish point and go back to the pin end. The tape should be applied with enough overlap to ensure full coverage on every application revolution. Table II-5.1 shows typical thread compound and tape usage rates.

Pipe Diameter No. of Connection per Roll

No. of Connections per US Gallon of thread compound

[inch] [pcs] [pcs]

2 8 107

2-1/2 7 93

3 5 83

4 4 60

5 3 47

6 2 43

6-L 2 37

8 1 20

10 0.8 17

10-L 0.75 15

12 0.67 13

Table II-5.1

For diameters above 12”, please contact FPI engineers

Fig. II-5.1


5-4. After application of the tape, both the box (female end) and the pin (male end) should be covered thoroughly, but not excessively, with thread compound. There are many types of compounds selected according the type of application. For example, TFC #15 is used for Oil & Gas as well as Water injection application, APT is used for chemical application, ..etc. Consult FPI for specific application. Quantity of compound required per connection is given in Table II-5.1.

5-5. Thread makeup shall be started by hand. Proper alignment of the connection is essential to avoid cross-threading and shall be constantly monitored.

The position of the far end of the single joint shall be constantly monitored and adjusted during the initial make-up process. Furthermore, it is essential to maintain a smooth constant rotation by steadily increasing the applied torque. For pipe diameters of 4” and smaller, the connection can be made-up until hand-tight and then tightened with a strap wrench.

The strap wrench must be fixed on the thick-walled part of the pipe, also known as the “upset” area of the pipe. If the joint is not assembling properly due to misalignment, or an improper make-up: • Immediately back the joint out.• Clean the threads.• Inspect the threads carefully for damage.• If no damage is visible, re-apply the Teflon tape and sealing compound then remake

the joint. • In case of damaged threads, follow the repair procedure for field thread repair.

5-6. For 5” pipe and larger, 36” chain wrenches have to be used for tightening after the hand tight makeup described before. One wrench must serve as a backup on the existing line while the other wrench, equipped with a four-foot cheater bar, is used to tighten the single joint. In case of manual torque application, the back-up wrench can be locked against the earth. For power torque application, the back-up wrench is connected to the back-up of the power tong, optionally through a load cell. The chain wrench shall be used only on the thick-walled

Fig. II-5.2

Fig. II-5.3

Fig. II-5.4


upset area of the pipe (a few inches back from the threads). Pipe wrenches shall not be used as they apply an unevenly distributed load over the circumference of the pipe, and may cause pipe damage. The recommended torque values are presented in Table II-5.2. This torque shall be applied without “bouncing” on the wrench.

Pipe Diameter Torque Value Pipe Diameter Torque Value

[ inch ] [ ft.lbs ] [ inch ] [ ft.lbs ]

2 110 - 140 8 1400 - 1600

2-1/2 175 - 200 10 1500 - 1700

3 275 - 325 10-L 1600 - 1800

4 350 - 400 12 1700 - 1900

5 475 - 525 Table II-5.2 : (Threaded & Coupled Pipe) For larger sizes, torque should be applied until a 2-thread stand-off is achieved.

6 700 - 750

6-L 950 - 1000

8 1200 - 1300

10 1400 - 1500

Table II-5.2 : (Integral Joint)

5-7. Whenever the required torque value cannot be achieved by hand, power tongs designed to apply controlled torque shall be used for all sizes.

5-8. For operating pressures in excess of 1500 psi, concrete thrust blocks are recommended at every change of direction, or cross-sectional diameter change.

Fig. II-5.6


6. Road Crossing Road crossings shall be carried out strictly as per detailed drawings supplied for each project.

Typically, this requires running the YELLOW BOX pipe through a casing pipe, utilizing spacers to keep the YELLOW BOX pipe separated from the casing. A typical example of a Road Crossing detailed drawing is presented in Fig II-6.

Prior to installation, the pipe section shall be assembled and tested. Prior to insertion into the casing pipe the spacers shall be installed to the required distances. The assembled pipe section shall be a minimum of one pipe length longer than the casing pipe on both sides. The end-sealing sleeve shall be fixed to the casing pipe.

Adequate end-protection shall be provided to the connected pipe section to avoid accumulation of debris and/or sand inside the pipe. Use of the protective end-caps, or by wrapping the pipe ends with polyethylene sheets, is generally sufficient. Always keep the pipe end closed when no jointing activities are carried out.

Prior to installation of the Yellow Box pipe through sleeve, the pipe section shall be tested outside at 1.1 x Pressure Rating of the pipe for one hour.

Fig. II-5.6


7. Tie-Inn Connection Tie-Inn connections of YELLOW BOX® with steel pipe can be made through the following ways:

7-1. Threaded Connection Nominal Pipe

Diameter No. of Cut off threads Length of threads to cut off

[inch] [threads] [inch]

2 5 5/8

2-1/2 6 3/4

3 6 3/4

4 7 7/8

larger than 4” No adjustment necessary

Table II-7.1

YELLOW BOX pipes up to and including 4” nominal diameter are manufactured with a thread profile according to API 8Rd EUE long form threads. This design allows the Yellow Box pin (male end) to be connected directly to the steel box (female) 8Rd threads with the same flexibility as connecting to Yellow Box pipe. A number of excess threads must be cut off from the YELLOW BOX pin end to suit the short profile of the steel pipe for the same diameters. Table II-7.1 gives an indication of the number of threads to be cut off.

When making up a threaded steel pin into a YELLOW BOX box end, no adjustments are necessary. The connections on pipe sizes larger than 4” are API 8Rd Casing long form, which typically is equivalent to the thread type used on the same diameter steel pipe.

Excess threads can be cut using a regular hacksaw. When making up a YELLOW BOX to steel threaded connection always use the fiberglass torque values as detailed in Table II-5.2.

Fig. II-7.1


7-2. Flanged ConnectionYELLOW BOX® flanges are flat face configuration flanges and shall be connected to flat-face flange configurations only. If a raised-face flange configuration is be used, a spacer ring is required to present a flat surface to the fiberglass flange face.

GasketsGasket to be used with YELLOW BOX® flanges shall have adequate flexibility and recovery to maintain a seal whilst subjected to pressure and/or temperature fluctuations. From many years of field experience in the oilfield applications, Spiral Wound (SW) gaskets are considered the preferred gasket for the use with Yellow Box flanges.

Gasket Profile:Specification: Depending on medium & temperatureStandard: ASME B16.2 to suit flange ASME B16.5Manufacturer: Flexitallic , Kroll & ZillerType: Style CGIApplication: All diameters & pressure class.

TorquesPrior to applying the torque value, it is necessary to lubricate the bolt with, for example, molykote.

When assembling Yellow Box flanges, the bolt shall be tightened by hand up to 30% of the maximum torque value as presented in table II-7.2. The bolt tightening sequence as per figure II-7.4 shall be followed.

Pipe Diameter Torque Value( based on spiral wound Gasket-style CGI )

[inch] [ft.lbs]

ANSI 150 ANSI 300 ANSI 600 ANSI 900 ANSI 1500

2 96 48 54 77 77

2-1/2 130 65 79 114 114

3 164 82 101 132 138

4 152 156 209 251 259

5 202 233 316 379 396

6 262 197 264 317 325

6-L 262 197 264 317 325

8 448 366 485 545 570

10 574 383 518 572 808

Fig. II-7.2

Fig. II-7.3


The following figure shows the flange torque sequence:

8. Back Filling Before starting the back filling activity, the pipe trench shall be thoroughly cleaned. Furthermore, all the materials used for supporting shall be removed.

The backfilling materials shall be similar to the materials used for the bedding. The backfill material shall be compacted in 0.5 ft layers and this can be done manually or mechanically. Adequate care shall be taken on using mechanical equipment for compacting. The compaction shall be a minimum of 90 % standard proctor density. The trench side shall be adequately compacted to get full native soil support for the backfill zone. Continue the process until the backfill reaches 1 ft above the pipe crown. Continue the backfilling process with the excavated soil. Do not use heavy equipment until the backfill area reaches a minimum of 2 ft above the crown of the pipe. To prevent damage to the pipe, equipment capable of producing in excess of 20 KN impact force shall not be used.

Fig. II-7.4


Section III : Field Hydrostatic Testing Procedure

1. General In this section general guidelines for the hydrostatic test procedure have been compiled. Hydrostatic pressure testing is normally required to ensure that the assembled pipeline can withstand the required operating pressure and that there is no leakage due to the incorrect joint installation in the field.

This procedure is as complete as possible; it is not feasible to describe all circumstances that could be encountered in the field. Therefore, an experienced FPI Supervisor may vary the described procedure in order to achieve an optimum solution using the latest installation techniques.

2. Inspection It is important to conduct a thorough visual inspection of the pipe system prior to starting the testing process. Any external damage (that may have occurred during the installation / handling process of the pipe) should be identified and assessed. If required, the damage should be repaired as per the FPI repair procedure for high pressure pipeline (section IV).

Prior to testing, the underground line should be padded and back-filled over the area between the connections to secure the line and minimize the movement caused by the testing pressure. At this stage thrust blocks, if required, should be in place and cured. Connections should be left open to allow for inspection during the test.

As for the above ground line, the resting guides or anchors (if any) should be in place and be tightened prior to testing.

3. Section to be tested It is preferred to conduct sectional testing to facilitate the process of inspection. Usually for big projects, 500 meters is a logical selection to be tested.

4. Preparation A formal risk assessment should be carried out prior to the hydrostatic pressure test. All supports, guides and anchors shall be in place prior to testing. Temporary supports and restraints shall be added if required. Unless stated otherwise, all valves shall be through-body tested and shall be kept fully open. Piping containing check valves shall have the source of test pressure located on the downstream side, otherwise those valves shall be removed from the system. Threaded connections and the bolts of flanged joints shall be made up to the correct torque prior to pressure testing.

Fig. III-2


Arrange for all necessary equipment (i.e. filling pump with break tank, pressure pump etc) to available and in good working order. Ensure that the blind flanges have been tightened as per the flange assembly procedure in section II. Also ensure that the required connection for air venting, which has to be closed upon completion of the water filling process, is in good working order prior to testing.

5. System Flushing On completion of installation, GRP piping systems shall be flushed prior to the hydrostatic testing. The medium used for flushing shall be seawater or fresh water. The flushing of the system shall be carried out from the highest point of the pipeline.

Flushing shall take place by pressurizing the system, as described in the clause #6, to a pressure of 50 psi (3.4 barg). Then the line is drained in safe manner to flush away any contamination.

6. Pressurizing Once filled and free of air, the line should be closed off. Pressurization of the pipeline requires the following to be taken into account:

6.1- Increase the pressure up to 15% of the targeted test pressure and hold the pressure for 5 minutes.

6.2- Repeat the same operation to reach 30 % then 75% then the total targeted test pressure. The pressure shall be maintained for at least half hour at each of the mentioned steps (30%, 75%, 100 %) to allow the system to stabilize. The pressure might fluctuate due to the change in the environment’s temperature. Record the pressure within a tolerance of ± 50 psi (3.5 barg).

6.3- If the pressure drop is more than 50 psi, reset the pressure to its related level and hold it for additional half hour provided there is no leakage in the pipeline.

6.4- In case of leakage, depressurize the line as described below, repair the line as per FPI repair procedure (section IV), then repeat the pressurizing sequence from step 6.1.

6.5- Once stabilization time is completed without any leakage the pressure should be reduced by 10 % of maximum test pressure for 5 minutes each until 1.1 x design pressure. Hold the line on that pressure for 24 hours for the tightness test.

6.6- Do not pressurize the system at lowest temperature (earlier morning) to avoid the increase in pressure at the highest temperature (at noon).

Fig. III-4

Fig. III-5


After reaching test pressure, the pump apparatus shall be isolated from the pipeline by the valve on the test header. The pump line should be removed keeping the pressure recorder exposed to facilitate the reading. The entire pipeline shall be carefully inspected for any leakage from the joints or the pipe body.

6.7- Potential Causes for Pressure DropsThe following reasons may be the cause of a pressure drop:a- Temperature variation between day and night.b- Leakage of accessories connected to the system.c- Leakage from the gaskets.d- Dirt at sealing area of the gaskets ( area of the spirals ).e- Leaking test equipment.f- Stabilizing time too short.g- Leaking thread joint.h- Leakage of pipe as a result of impact damage (cracks).i- Unexpected or unforeseen settlement of the pipeline system.

If any leak is observed from the flange connections, it is not permitted to torque the flange under pressure. The line should be depressurized as described below and then the flanges tightened. If the flange or gasket is found to be damaged, it shall be replaced with a new one. If a leakage is observed on the pipe body or the thread joint, the test shall be terminated and the leaking joint / pipe shall be repaired as per the repair procedure (section IV). If no leakage or weeping is observed during the inspection, the hydrostatic test is successfully completed and the system is ready for use. The pipeline shall then be depressurized as described below.

7. Depressurization The depressurization of the system shall be carried out carefully to avoid any negative pressure (vacuum) in the system. All the vents shall be kept open to allow adequate air into the system while draining the pipeline.

The pressure should be decreased progressively at a rate of 100 psi / minute ( 7 barg / minute ) in safe direction. Depressurizing might be implemented through a synchronized valve that can control the pressure as a function of time, or by slowly opening a manual gate valve whilst monitoring the pressure gauge.

8. Safety Precautions a- Barricade the test area.b- Place warning signs at all adjacent areas.c- Ensure that only experienced & authorized personnel operate test equipment.d- Ensure that only authorized personnel shall be involved in the test or inspection

operation.e- Appoint one individual to be in-charge during the test procedure.f- Do not work on the pipeline when it is under pressure.g- Do not test the pipe when it is partially out the ditch.h- Ensure that the testing equipment is installed at a sufficiently safe distance from the

pipeline.i- Ensure that the trench is backfilled and the thrust blocks are in place (see section IV).


Section IV: Field Repair Procedure

1. General Leakage of pipes & fittings during hydrostatic test may occur for a variety of reasons. This may include incorrect joint make-up, damage to the threads, impact damage, ..etc. In all such cases, the pipeline shall be repaired as per the following repair procedure.

This repair procedure describes the replacement of the damaged area either during the installation, or after commissioning, of the pipeline or conducting the site hydrostatic test. If the thread is damaged during the installation process, it can be repaired with a new thread kit ( for low pressure series ) without replacing the whole pipe. In this case the damaged pipe shall be removed from the system and replaced with new parts using a flange repair joint. This is described in more detail in the below paragraphs.

2. Larger Size Coupled Connection Joint Repair On large size threaded and coupled pipe ( 8” and above ) backing off the coupled con-nection may be problematic. The repair of this joint can be performed as follows:

2.1 Remove the damaged joint by cutting the couplings off the adjacent male ends in the line. Precise location of cut is not important as the whole damaged pipe has to be removed.

The couplers adjacent to the damaged area will then be removed.

Fig. IV-2.1

Fig. IV-2.2 Fig. IV-2.3


2.2 Using a diamond wheel cutter makes two axial cuts over the entire coupler length about 30 degrees apart. Take adequate pre-cautions to prevent damage to the threads on the pin end.

2.3 With a hammer and flat chisel remove the cou-pling.

2.4 Remove additional material above the thread using a pencil grinder (Fig. IV-2.5) and a small flat chisel. Again take adequate pre-cautions to prevent damage to the threads on the pin end.

2.5 Once the material close to the threads has been cut and removed, the coupling can be removed with a strap wrench.

2.6 Thoroughly clean the threads and inspect closely for any damage.

2.7 Re-apply new Teflon tape on the male thread of the existing line then apply the required thread compound.

2.8 Make up the two new couplings to each exposed male thread on the line.

Fig. IV-2.4

Fig. IV-2.5

Fig. IV-2.6

Fig. IV-2.7

Fig. IV-2.8


2.9 Make-up the sub joint and nipple into each coupling separately. Lifting one, or both side(s) of the newly installed coupler may be required as the damaged pipe has to be replaced with a segment of equivalent length to the removed pipe section.

2.10 Re-position both ends in their original places in the trench and, after inserting the gasket, bolt the two flanges together. Small differences in length, due to the tolerance of the repaired pieces, may be present following re-installation. If the gap is less than 1”, it is permissible to jack both ends of the exposed line, with the flange studs to cover this gap. If the gap is greater than 1”, either replace the installed repair joint or put a filler ring with extra gasket between flanges.

Alternatively, if the repair joint is too long, ‘snake’ the pipe, being sure not to exceed the minimum allowed bending radius for the pipe and joint ( refer to Appendix A & B ).

Fig. IV-2.9

Fig. IV-2.10


3. Integral Joint RepairPipeline installed with integral joint can be repaired by removing the damaged portion and screwing out the remaining sides from the pipe as follows:

3.1 Mark up the damaged area with a colored marker.

3.2 Cut before and after the damaged area and remove that section.

3.3 Unscrew both pieces from the consecutive undamaged joints. Due to its small diameter, the pieces can be removed using hand strap wrench.

Fig. IV-3.1

Fig. IV-3.2

Fig. IV-3.3


3.4 Make up the two repair joint flanges, one is consisting of flange with short Box piece and the other will be consisting of flange with nipple. Threading on site is not recommended and thus a spare piece in the required length shall be available to perform the required repair.

3.5 In order to keep the same length of the removed pipe, you may need to lift up one or both sides of the installed pipeline since the damaged pipe has to be replaced with a segment of equivalent length to the removed pipe section. In certain cases you may have to expose one or both sides in order to facilitate the lifting.

3.6 Re-install the flanged sides to the ditch and introduce the gasket with the required bolts & nuts, then start tightening the joint.

3.7 Re-test the line according to the field hydrostatic test procedure.

Fig. IV-3.4

Fig. IV-3.5

Fig. IV-3.6


Yellow Box 500 STD : Mill Test Pressure = 630 psi.

NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]

NominalWall Th.[inches]

NominalWeight[lbs/ft]

CollapseRating[psi]

AxialTensionRating[lbs]

Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.13 0.06 0.5 160 2,500 106

Refer to Table A, page 33

2-1/2 2.47 2.37 2.59 0.06 0.6 90 3,000 130

3 3.00 2.9 3.12 0.06 0.8 50 3,500 156

3-1/2 3.33 3.24 3.46 0.06 1.0 40 4,000 173

4 3.98 3.89 4.12 0.07 1.1 40 5,500 206

5 4.42 4.33 4.58 0.08 1.6 40 6,500 229

6 5.43 5.33 5.62 0.10 2.4 40 10,000 281

6-L 6.21 6.11 6.43 0.11 2.5 40 13,000 321

8 7.84 7.75 8.12 0.14 5.2 40 21,000 406

10 8.85 8.76 9.17 0.16 6.5 40 26,500 458

10-L 10.72 10.62 11.10 0.19 8.7 40 39,000 555

12 11.97 11.87 12.39 0.21 11.0 40 49,000 620

14-1/2 14.48 14.39 15.00 0.26 15.0 40 71,500 750

16-1/2 16.6 16.5 17.19 0.30 20.8 40 94,000 859

18 17.98 17.89 18.62 0.32 23.5 40 110,500 931

Yellow Box 800 STD : Mill Test Pressure = 1,000 psi.

NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.13 0.06 0.5 160 2,500 106


2-1/2 2.47 2.37 2.61 0.07 0.6 130 3,500 130

3 3.00 2.9 3.17 0.09 1.0 130 5,000 158

3-1/2 3.33 3.24 3.52 0.10 1.3 130 6,000 176

4 3.98 3.89 4.21 0.11 1.6 130 9,000 211

5 4.42 4.33 4.68 0.13 2.1 130 11,000 234

6 5.43 5.33 5.74 0.16 3.1 130 16,500 287

6-L 6.21 6.11 6.56 0.18 3.6 130 21,500 328

8 7.84 7.75 8.29 0.23 6.9 130 34,500 415

10 8.85 8.76 9.36 0.25 8.7 130 43,500 468

10-L 10.72 10.62 11.33 0.31 11.6 130 64,000 567

12 11.97 11.87 12.65 0.34 14.7 130 80,000 633

14-1/2 14.48 14.39 15.31 0.42 21.0 130 117,000 766

16-1/2 16.6 16.5 17.55 0.48 28.8 130 153,500 878

18 17.98 17.89 19.02 0.52 32.8 130 180,500 951

Notes :1- Thread lengths may exceed the “L4” dimension in API 5B2- Laying length of 30 ft.3- Performance data valid within temperature range of -60 OF to + 210 OF

Appendix A : Yellow Box® Standard Technical Datasheets



NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.14 0.07 0.5 240 3,000 107


2-1/2 2.47 2.37 2.64 0.09 0.8 240 4,500 132

3 3.00 2.9 3.21 0.11 1.1 240 6,500 161

3-1/2 3.33 3.24 3.57 0.12 1.5 240 8,000 179

4 3.98 3.89 4.27 0.14 1.9 240 11,000 214

5 4.42 4.33 4.74 0.16 2.5 240 14,000 237

6 5.43 5.33 5.82 0.20 3.7 240 21,000 291

6-L 6.21 6.11 6.65 0.22 4.3 240 27,500 333

8 7.84 7.75 8.41 0.28 8.2 240 43,500 420

10 8.85 8.76 9.49 0.32 10.3 240 55,500 475

10-L 10.72 10.62 11.49 0.39 13.6 240 81,500 575

12 11.97 11.87 12.83 0.43 17.2 240 101,500 642

14-1/2 14.48 14.39 15.53 0.52 25.1 240 148,500 776

16-1/2 16.6 16.5 17.80 0.60 34.2 240 194,000 890

18 17.98 17.98 19.28 0.65 39.2 240 208,000 964


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.18 0.09 0.6 450 3,500 109


2-1/2 2.47 2.37 2.69 0.11 0.9 450 5,500 135

3 3.00 2.9 3.27 0.14 1.4 450 8,000 164

3-1/2 3.33 3.24 3.63 0.15 1.8 450 10,000 182

4 3.98 3.89 4.35 0.18 2.3 450 14,500 217

5 4.42 4.33 4.83 0.20 3.0 450 17,500 241

6 5.43 5.33 5.92 0.25 4.5 450 26,500 296

6-L 6.21 6.11 6.77 0.28 5.3 450 34,500 339

8 7.84 7.75 8.56 0.36 9.7 450 55,500 428

10 8.85 8.76 9.66 0.40 12.2 450 70,500 483

10-L 10.72 10.62 11.70 0.49 16.1 450 103,500 585

12 11.97 11.87 13.06 0.55 20.7 450 129,000 653

14-1/2 14.48 14.39 15.80 0.66 30.2 450 167,500 790

16-1/2 16.6 16.5 18.11 0.76 41.2 450 194,000 906

18 17.98 19.89 19.62 0.82 47.3 450 208,000 981




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.22 0.11 0.7 750 4,500 111


2-1/2 2.47 2.37 2.74 0.14 1.1 750 6,500 137

3 3.00 2.9 3.33 0.17 1.6 750 10,000 166

3-1/2 3.33 3.24 3.70 0.18 2.1 750 12,000 185

4 3.98 3.89 4.42 0.22 2.7 750 17,500 221

5 4.42 4.33 4.91 0.24 3.5 750 21,500 246

6 5.43 5.33 6.03 0.30 5.3 750 32,500 301

6-L 6.21 6.11 6.89 0.34 6.3 750 42,500 345

8 7.84 7.75 8.71 0.43 11.3 750 68,000 435

10 8.85 8.76 9.83 0.49 14.2 750 86,500 492

10-L 10.72 10.62 11.90 0.59 21.3 750 126,500 595

12 11.97 11.87 13.29 0.66 24.3 750 136,000 665

14-1/2 14.48 14.39 16.08 0.80 35.5 750 167,500 804

16-1/2 16.6 16.5 18.43 0.92 48.5 750 194,000 922

18 17.98 17.89 19.97 1.00 55.7 750 208,000 999


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.26 0.13 0.8 1,200 5,000 113


2-1/2 2.47 2.37 2.79 0.16 1.2 1,200 8,000 139

3 3.00 2.9 3.39 0.20 1.8 1,200 12,000 169

3-1/2 3.33 3.24 3.76 0.22 2.4 1,200 14,500 188

4 3.98 3.89 4.50 0.26 3.1 1,200 21,000 225

5 4.42 4.33 5.00 0.29 4.1 1,200 25,500 250

6 5.43 5.33 6.13 0.35 6.0 1,200 38,500 307

6-L 6.21 6.11 7.02 0.41 7.3 1,200 50,500 351

8 7.84 7.75 8.86 0.51 12.9 1,200 80,500 443

10 8.85 8.76 10.01 0.58 16.4 1,200 102,500 500

10-L 10.72 10.62 12.11 0.70 24.5 1,200 127,000 606

12 11.97 11.87 13.53 0.78 31.0 1,200 156,000 676

14-1/2 14.48 14.39 16.37 0.95 46.9 1,200 197,000 819

16-1/2 16.6 16.5 18.76 1.08 63.6 1,200 226,000 938

18 17.98 17.89 20.33 1.17 76.6 1,200 245,000 1016




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.3 0.15 0.9 1,700 6,000 115


2-1/2 2.47 2.37 2.84 0.19 1.4 1,700 9,500 142

3 3.00 2.9 3.45 0.23 2.1 1,700 13,500 172

3-1/2 3.33 3.24 3.83 0.25 2.7 1,700 17,000 192

4 3.98 3.89 4.58 0.30 3.6 1,700 24,000 229

5 4.42 4.33 5.09 0.33 4.6 1,700 30,000 254

6 5.43 5.33 6.24 0.41 6.9 1,700 45,000 312

6-L 6.21 6.11 7.14 0.47 9.1 1,700 59,000 357

8 7.84 7.75 9.02 0.59 15.2 1,700 94,000 451

10 8.85 8.76 10.18 0.67 19.4 1,700 119,500 509


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.34 0.17 1.1 2,400 7,000 117


2-1/2 2.47 2.37 2.89 0.21 1.6 2,400 10,500 144

3 3.00 2.9 3.51 0.26 2.3 2,400 15,500 176

3-1/2 3.33 3.24 3.90 0.29 3.1 2,400 19,500 195

4 3.98 3.89 4.67 0.34 4.1 2,400 28,000 233

5 4.42 4.33 5.18 0.38 5.2 2,400 34,500 259

6 5.43 5.33 6.35 0.46 7.8 2,400 51,500 318

6-L 6.21 6.11 7.27 0.53 10.3 2,400 67,500 363

8 7.84 7.75 9.18 0.67 17.1 2,400 107,500 459

10 8.85 8.76 10.37 0.76 21.9 2,400 137,500 518




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.38 0.19 1.2 2,700 8,000 119


2-1/2 2.47 2.37 2.94 0.24 1.8 2,700 12,000 147

3 3.00 2.9 3.57 0.29 2.7 2,700 18,000 179

3-1/2 3.33 3.24 3.97 0.32 3.4 2,700 22,000 199

4 3.98 3.89 4.75 0.38 4.6 2,700 31,500 237

5 4.42 4.33 5.27 0.43 5.8 2,700 39,000 264

6 5.43 5.33 6.47 0.52 8.7 2,700 58,500 323

6-L 6.21 6.11 7.40 0.60 11.7 2,700 76,500 370

8 7.84 7.75 9.35 0.75 19.1 2,700 122,000 467

10 8.85 8.76 10.55 0.85 24.6 2,700 155,500 528


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.43 0.21 1.3 2,900 9,000 121


2-1/2 2.47 2.37 2.99 0.26 2.0 2,900 13,500 150

3 3.00 2.9 3.64 0.32 2.9 2,900 20,000 182

3-1/2 3.33 3.24 4.04 0.36 3.8 2,900 24,500 202

4 3.98 3.89 4.84 0.43 5.8 2,900 35,500 242

5 4.42 4.33 5.37 0.47 6.5 2,900 43,500 268

6 5.43 5.33 6.59 0.58 9.9 2,900 65,500 329


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.47 0.24 1.4 3,200 10,000 124


2-1/2 2.47 2.37 3.05 0.29 2.2 3,200 15,000 152

3 3.00 2.9 3.70 0.35 3.2 3,200 22,500 185

3-1/2 3.33 3.24 4.12 0.39 4.2 3,200 27,500 206

4 3.98 3.89 4.92 0.47 6.3 3,200 39,500 246

5 4.42 4.33 5.46 0.52 7.2 3,200 48,500 273




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.52 0.26 1.6 3,400 11,000 126Refer to Table A, page 33

2-1/2 2.47 2.37 3.10 0.32 2.3 3,400 16,500 155

3 3.00 2.9 3.77 0.39 3.6 3,400 24,500 189

3-1/2 3.33 3.24 4.19 0.43 4.6 3,400 30,500 210


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches]



CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.56 0.28 1.7 3,700 12,000 128Refer to Table A, page 33



Table A : Connection Type of Standard Yellow Box®

Nominal Diameters

Nominal Pressure Ratings in PSI (bar); Connection type API 5B Table 14*, 7**, 6***Fourteenth Edition August ’96 and FPI Standard****

DN(inch)

DN(mm)

500(35)

800(55)

1000(70)

1250(85)

1500(105)

1750(120)

2000(140)

2250(155)

2500(170)

2750(190)

3000(210)

3250(225)

3500(240)

2 50 2-3/8” 8 Rd EUE Long* IJ

2½ 65 2-7/8” 8Rd EUE Long* IJ

3 75 3-1/2” 8Rd EUE Long* IJ

3½ 90 4” 8Rd EUE Long* TC

4 100 4-1/2” 8Rd EUE Long* IJ5-1/2” 8Rd

Casing Long** TC

5 125 5-1/2” 8Rd Casing Long** IJ TC

6 150 6-5/8” 8Rd Casing Long** IJ TC

6-L 150 7” 8Rd Casing Long** IJ7-5/8”

8Rd Casing Long** IJ

7-5/8” 8Rd

Casing Long**

TC

8 200 9-5/8” 8Rd Casing*** IJ 9-5/8” 8Rd Casing Long** TC

10 250 10-3/4” 8Rd Casing*** IJ TC

10-L 250 11-3/4” 8/6 Rd Casing***/Casing**** TC Csg Long TC

12 300 13-3/8” 8/6Rd Casing***/Casing**** TC

Csg Long TC

14½ 350 16” 6Rd Casing**** TCCsg Long TC

16½ 400 18” 6Rd Casing**** TCCsg Long TC

18 450 20” 6Rd Casing**** TCCsg Long TC

Note: EUE: External Upset EndTC: Threaded couplerIJ: Integral JointRd: Round


Yellow Box 500 API 15HR : Mill Test Pressure = 750 psi.

NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches


Min.Wall Th.[inches]


CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.13 0.06 0.06 0.5 160 2,500 106

Refer to Table B, page 39

2-12 2.47 2.37 2.59 0.06 0.06 0.6 90 3,000 130

3 3.00 2.9 3.13 0.07 0.06 0.8 60 4,000 156

3-1/2 3.33 3.24 3.48 0.07 0.07 1.1 60 4,500 174

4 3.98 3.89 4.16 0.09 0.08 1.3 60 6,500 208

5 4.42 4.33 4.61 0.10 0.09 1.8 60 8,000 231

6 5.43 5.33 5.66 0.12 0.11 2.6 60 12,500 283

6-L 6.21 6.11 6.48 0.14 0.013 2.9 60 16,000 324

8 7.84 7.75 8.18 0.17 0.16 5.9 60 26,000 409

10 8.85 8.76 9.24 0.19 0.18 7.4 60 33,000 462

10-L 10.72 10.62 11.18 0.23 0.22 9.7 60 48,000 559

12 11.97 11.87 12.49 0.26 0.25 12.3 60 60,000 624

14-1/2 14.48 14.39 15.11 0.32 0.30 17.1 60 88,000 756

16-1/2 16.6 16.5 17.32 0.36 0.34 23.3 60 115,500 866

18 17.98 17.89 18.76 0.39 0.37 26.6 60 136,000 938

Yellow Box 750 API 15HR : Mill Test Pressure = 1,130 psi.

NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.13 0.07 0.06 0.5 180 2,500 107


2-1/2 2.47 2.37 2.63 0.08 0.08 0.7 180 4,000 131

3 3.00 2.9 3.20 0.10 0.09 1.1 180 6,000 160

3-1/2 3.33 3.24 3.55 0.11 0.10 1.4 180 7,000 178

4 3.98 3.89 4.25 0.13 0.13 1.7 180 10,000 212

5 4.42 4.33 4.71 0.15 0.14 2.3 180 12,500 236

6 5.43 5.33 5.78 0.18 0.17 3.5 180 19,000 289

6-L 6.21 6.11 6.62 0.21 0.20 4.0 180 25,000 331

8 7.84 7.75 8.36 0.26 0.25 7.6 180 39,500 418

10 8.85 8.76 9.44 0.29 0.28 9.6 180 50,500 472

10-L 10.72 10.62 11.42 0.35 0.34 12.7 180 74,000 571

12 11.97 11.87 12.76 0.40 0.38 16.1 180 92,000 638

14-1/2 14.48 14.39 15.44 0.48 0.46 23.1 180 135,000 772

16-1/2 16.6 16.5 17.69 0.55 0.52 31.4 180 177,500 885

18 17.98 17.89 19.17 0.59 0.57 35.9 180 208,000 958

Notes :

1- Thread lengths may exceed the “L4” dimension in API 5B2- Laying length of 30 ft.3- Performance data valid within temperature range of -60 OF to + 210 OF

Appendix B: Yellow Box® API 15HR Technical Datasheets



NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.18 0.09 0.08 0.6 420 3,500 109


2-1/2 2.47 2.37 2.69 0.11 0.10 0.9 420 5,500 134

3 3.00 2.9 3.26 0.13 0.13 1.3 420 8,000 163

3-1/2 3.33 3.24 3.63 0.15 0.14 1.7 420 9,500 181

4 3.98 3.89 4.34 0.18 0.17 2.2 420 14,000 217

5 4.42 4.33 4.82 0.20 0.19 2.9 420 17,000 241

6 5.43 5.33 5.91 0.24 0.23 4.4 420 26,000 295

6-L 6.21 6.11 6.76 0.28 0.26 5.2 420 34,000 338

8 7.84 7.75 8.54 0.35 0.33 9.5 420 54,000 427

10 8.85 8.76 9.64 0.39 0.38 12.0 420 69,000 482

10-L 10.72 10.62 11.67 0.48 0.45 15.8 420 101,000 584

12 11.97 11.87 13.03 0.53 0.51 19.9 420 125,000 652

14-1/2 14.48 14.39 15.77 0.65 0.61 29.2 420 184,000 789

16-1/2 16.6 16.5 18.07 0.74 0.70 39.7 420 194,000 904

18 17.98 17.89 19.58 0.80 0.76 45.6 420 208,000 979


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.23 0.11 0.11 0.7 790 4,500 111


2-1/2 2.47 2.37 2.74 0.14 0.13 1.1 790 7,000 137

3 3.00 2.9 3.33 0.17 0.16 1.6 790 10,000 167

3-1/2 3.33 3.24 3.71 0.19 0.18 2.1 790 12,500 185

4 3.98 3.89 4.43 0.22 0.21 2.7 790 18,000 222

5 4.42 4.33 4.92 0.25 0.24 3.5 790 22,000 246

6 5.43 5.33 6.04 0.31 0.29 5.3 790 33,000 302

6-L 6.21 6.11 6.90 0.35 0.33 6.4 790 43,000 345

8 7.84 7.75 8.72 0.44 0.42 11.4 790 69,000 436

10 8.85 8.76 9.85 0.50 0.48 14.4 790 88,000 492

10-L 10.72 10.62 11.92 0.60 0.58 19.0 790 129,000 596

12 11.97 11.87 13.31 0.67 0.64 24.4 790 160,500 666

14-1/2 14.48 14.39 16.11 0.82 0.78 35.7 790 167,500 806

16-1/2 16.6 16.5 18.47 0.94 0.89 48.4 790 194,000 923

18 17.98 17.89 20.01 1.01 0.97 55.7 790 208,000 1,000

Notes :




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.27 0.14 0.13 0.9 1,400 5,500 114


2-1/2 2.47 2.37 2.80 0.17 0.16 1.3 1,400 8,500 140

3 3.00 2.9 3.41 0.21 0.20 1.9 1,400 12,500 170

3-1/2 3.33 3.24 3.79 0.23 0.22 2.5 1,400 15,500 189

4 3.98 3.89 4.53 0.27 0.26 3.3 1,400 22,000 226

5 4.42 4.33 5.03 0.30 0.29 4.2 1,400 27,000 251

6 5.43 5.33 6.17 0.37 0.35 6.3 1,400 40,500 308

6-L 6.21 6.11 7.05 0.42 0.40 7.7 1,400 53,000 353

8 7.84 7.75 8.91 0.54 0.51 13.4 1,400 85,000 446

10 8.85 8.76 10.06 0.61 0.58 17.0 1,400 108,000 503

10-L 10.72 10.62 12.18 0.73 0.70 25.1 1,400 158,500 609

12 11.97 11.87 13.60 0.82 0.78 28.9 1,400 136,000 680

14-1/2 14.48 14.39 16.46 0.99 0.94 42.3 1,400 167,500 823

16-1/2 16.6 16.5 18.87 1.14 1.08 57.1 1,400 194,000 943

18 17.98 17.89 20.44 1.23 1.17 65.8 1,400 208,000 1022


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.941 2.32 0.16 0.15 1.0 2,100 6,500 116


2-1/2 2.47 2.37 2.86 0.20 0.19 1.5 2,100 10,000 143

3 3.00 2.9 3.48 0.24 0.23 2.2 2,100 15,000 174

3-1/2 3.33 3.24 3.87 0.27 0.26 2.9 2,100 18,500 193

4 3.98 3.89 4.63 0.32 0.31 3.8 2,100 26,000 231

5 4.42 4.33 5.14 0.36 0.34 4.9 2,100 32,000 257

6 5.43 5.33 6.30 0.44 0.42 7.3 2,100 48,500 315

6-L 6.21 6.11 7.21 0.50 0.48 9.7 2,100 63,500 360

8 7.84 7.75 9.11 0.63 0.60 15.5 2,100 101,500 455

10 8.85 8.76 10.28 0.72 0.68 19.7 2,100 129,000 514

10-L 10.72 10.62 12.45 0.87 0.83 29.0 2,100 127,000 622

12 11.97 11.87 13.90 0.97 0.92 36.6 2,100 156,000 695

14-1/2 14.48 14.39 16.82 1.17 1.12 55.2 2,100 197,000 841

16-1/2 16.6 16.5 19.28 1.34 1.28 74.2 2,100 226,000 964

18 17.98 17.89 20.89 1.45 1.39 88.8 2,100 245,000 1,044

Notes :




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.37 0.19 0.18 1.2 2,600 7,500 119


2-1/2 2.47 2.37 2.93 0.23 0.22 1.7 2,600 11,500 146

3 3.00 2.9 3.56 0.28 0.27 2.6 2,600 17,500 178

3-1/2 3.33 3.24 3.95 0.31 0.30 3.3 2,600 21,500 198

4 3.98 3.89 4.73 0.37 0.36 4.4 2,600 30,500 236

5 4.42 4.33 5.25 0.41 0.39 5.6 2,600 37,500 262

6 5.43 5.33 6.44 0.51 0.48 8.4 2,600 57,000 322

6-L 6.21 6.11 7.37 0.58 0.55 11.1 2,600 74,500 368

8 7.84 7.75 9.31 0.73 0.70 18.3 2,600 118,500 465

10 8.85 8.76 10.51 0.83 0.79 23.3 2,600 151,000 525


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.43 0.21 0.20 1.3 2,900 9,000 121


2-1/2 2.47 2.37 2.99 0.26 0.25 2.0 2,900 13,500 150

3 3.00 2.9 3.64 0.32 0.30 2.9 2,900 20,000 182

3-1/2 3.33 3.24 4.04 0.36 0.34 3.7 2,900 24,500 202

4 3.98 3.89 4.83 0.43 0.40 5.7 2,900 35,500 242

5 4.42 4.33 5.36 0.47 0.45 6.4 2,900 43,500 268

6 5.43 5.33 6.58 0.58 0.55 9.6 2,900 65,500 329

6-L 6.21 6.11 7.53 0.66 0.63 12.6 2,900 85,500 376

8 7.84 7.75 9.51 0.84 0.80 20.7 2,900 137,000 476

10 8.85 8.76 10.74 0.94 0.90 26.5 2,900 161,500 537

Notes :




NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.48 0.24 0.23 1.5 3,200 10,000 124


2-1/2 2.47 2.37 3.06 0.30 0.28 2.2 3,200 15,500 153

3 3.00 2.9 3.72 0.36 0.34 3.3 3,200 23,000 186

3-1/2 3.33 3.24 4.13 0.40 0.38 4.2 3,200 28,000 207

4 3.98 3.89 4.94 0.48 0.46 6.4 3,200 40,500 247

5 4.42 4.33 5.48 0.53 0.51 7.2 3,200 49,500 274

6 5.43 5.33 6.73 0.65 0.62 11.5 3,200 74,500 336

6-L 6.21 6.11 7.70 0.75 0.71 14.4 3,200 86,500 385


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.54 0.27 0.26 1.7 3,600 11,500 127


2-1/2 2.47 2.37 3.13 0.33 0.31 2.5 3,600 17,500 156

3 3.00 2.9 3.80 0.40 0.38 3.7 3,600 26,000 190

3-1/2 3.33 3.24 4.22 0.45 0.43 4.7 3,600 32,000 211

4 3.98 3.89 5.05 0.53 0.51 7.1 3,600 45,500 253


NominalDia.

[inches]

NominalI.D.

[inches]

NominalDrift Dia.

[inches]

NominalO.D.

[inches




CollapseRating[psi]


Min.BendingRadius

[ft]

Connection Type

2 2.00 1.91 2.59 0.30 0.28 1.8 3,900 13,000 130


2-1/2 2.47 2.37 3.20 0.37 0.35 3.1 3,900 19,500 160

3 3.00 2.9 3.89 0.44 0.42 4.6 3,900 29,000 194

3-1/2 3.33 3.24 4.32 0.49 0.47 5.8 3,900 35,500 216

4 3.98 3.89 5.17 0.59 0.56 7.8 3,900 51,000 258

Notes :



Table B : Connection Type of API rated Yellow Box®

NominalDiameters

Nominal Pressure Ratings in PSI (bar); Connection type API 5B Table 14*, 7**, 6*** Fourteenth Edition August ’96 and FPI Standard****

DN(inch)

DN(mm)

500(35)

750(52)

1000(70)

1250(85)

1500(105)

1750(120)

2000(140)

2250(155)

2500(170)

2750(190)

3000(210)

2 50 2-3/8” 8 Rd EUE Long* IJ

2½ 65 2-7/8” 8Rd EUE Long* IJ

3-1/2” 8Rd EUE

Long* TC

3 75 3-1/2” 8Rd EUE Long* IJ

4” 8Rd EUE

Long* TC

3½ 90 4” 8Rd EUE Long* TC

4-1/2” 8Rd EUE

Long* TC

4 100 4-1/2” 8Rd EUE Long* IJ 5-1/2” 8Rd Casing Long** TC

5 125 5-1/2” 8Rd Casing Long** IJ

6 150 6-5/8” 8Rd Casing Long** IJ

7” 8Rd

Casing Long ** TC

6-L 150 7” 8Rd Casing Long** IJ 7-5/8” 8Rd Casing Long** IJ

7-5/8” 8Rd

Casing Long ** TC

8 200 9-5/8” 8Rd Casing*** IJ9-5/8” 8Rd

Casing Long** TC

10 250 10-3/4” 8Rd Casing*** IJ TC

10-L 250 11-3/4” 8/6Rd Casing***/Casing**** TC Csg Long TC

12 300 13-3/8” 8/6Rd Casing***/Casing**** TC Csg Long TC

14½ 350 16” 6Rd Casing**** TC Csg Long TC

16½ 400 18” 6Rd Casing**** TC Csg Long TC

18 450 20” 6Rd Casing**** TC Csg Long TC

Note: EUE: External Upset EndTC: Threaded couplerIJ: Integral JointRd: Round


Dimensions of Tee

Dia. [inches] A [inches] B [inches]

2 4.375 3.75

2-1/2 5.813 4.25

3 7.938 5.125

4 8.125 6.563

5 8.00 7.625

6 9.50 9.125

6-L 10.125 10.50

8 13.25 12.07

Dimensions of 90O Elbow


2 5.125 3.75

2-1/2 5.75 4.25

3 7.938 5.125

4 8.00 6.563

5 8.00 7.625

6 9.00 9.125

6-L 9.875 10.50

8* 20.00 12.07

10* 20.00 13.21

10-L* 20.00 12.58

12* 20.00 14.68

* Threaded & Coupled

Dimensions of 45O Elbow


2 4.25 3.75

2-1/2 4.75 4.25

3 6.50 5.125

4 6.75 6.563

5 7.25 7.625

6 8.125 9.125

6-L 8.375 10.50

8* 20.00 12.07

10* 20.00 13.21

10-L* 20.00 12.58

12* 20.00x 14.68

* Threaded & Coupled

All threads are API 5B, 2”-4”: 8 Rd EUE Long (table 14), 5”-8”: 8 Rd Csg Long (table 7), 10”-12”: 8 Rd Csg (table 6)

Appendix C


Dimensions of Coupler


2 7 3.75

2-1/2 7.63 4.25

3 8.13 5.13

4 8.88 6.56

5 8.88 7.63

6 9.63 9.13

6-L 10.13 10.5

8 10.21 13.1

10 10.21 13.5

10-L 11.10 14

12 11.10 16

Dimensions of Field Thread


2 6-1/2 2-5/8

2-1/2 7-1/4 3-1/4

3 7-1/2 3-7/8

4 9 4-7/8

5 9-1/2 5-5/8

6 9-1/4 6-3/4

6-L 9-1/2 7-3/4

8 9-1/2 9-3/4

10 9-1/2 10-7/8

10-L 11 11-7/8

12 11 13-5/8

Dimensions of Nipple


2 8 2.69

2-1/2 8 3.19

3 8 3.85

4 8 4.85

5 12 5.60

6 12 6.72

6-L 12 7.72

8 14 9.72

10 14 10.85

10-L 14 11.85

12 14 13.48



Dimensions of Reducer Coupling


2-1/2 x 2 7-5/8 4-1/4

3 x 2 8-1/2 5-1/8

3 x 2-1/2 8-1/4 5-1/8

4 x 2 9-1/8 6-1/2

4 x 2-1/2 9-1/8 6-1/2

4 x 3 9-1/8 6-1/2

5 x 3 9-3/8 7-5/8

5 x 4 9-1/4 9-1/8

6 x 3 10-3/4 9-1/8

6 x 4 10-5/8 9-1/8

6 x 5 9-7/8 10-1/2

6-L x 4 11-3/8 10-1/2

6-L x 5 10-5/8 10-1/2

6-L x 6 11-3/8 10-1/2

8 x 6 11 12-1/2

8 x 6-L 11-3/4 12-1/2

10 x 6 13 13

10 x 6-L 13 13

10 x 8 14-1/4 13

10-L x 6 13 14

10-L x 6-L 14 14

10-L x 8 13 14

10-L x 10 14 14

12 x 8 15 15

12 x 10 15 15

12 x 10-L 15 15

Dimensions of Reducer Bushing


2-1/2 x 2 7-5/8 4-1/4

3 x 2 8-1/2 5-1/8

3 x 2-1/2 8-1/4 5-1/8

4 x 2-1/2 9-1/8 6-1/2

4 x 3 9-1/8 6-1/2

5 x 3 9-3/8 7-5/8

5 x 4 9-1/4 9-1/8

6 x 3 10-3/4 9-1/8

6 x 4 10-5/8 9-1/8

6 x 5 9-7/8 10-1/2

6-L x 4 11-3/8 10-1/2

6-L x 5 10-5/8 10-1/2

6-L x 6 11-3/8 10-1/2

8 x 6 11 12-1/2

8 x 6-L 11-3/4 12-1/2

10 x 6 13 13

10 x 6-L 13 13

10 x 8 14-1/4 13

10-L x 6 13 14

10-L x 6-L 14 14

10-L x 8 13 14

10-L x 10 14 14

12 x 8 15 15

12 x 10 15 15

12 x 10-L 15 15



Dimensions of Reducer Bushing


2-1/2 x 2 9-1/2 4

3 x 2 10 4-1/8

3 x 2-1/2 10 4-1/8

4 x 2 10-1/8 5

4 x 2-1/2 10-3/8 5

4 x 3 10-1/2 5

5 x 3 10-5/8 5-5/8

5 x 4 11 5-5/8

6 x 3 11-1/8 6-3/4

6 x 4 11-1/2 6-3/4

6 x 5 11-1/2 6-3/4

6-L x 4 11-1/2 7-3/4

6-L x 5 11-1/2 7-3/4

6-L x 6 12 7-3/4

8 x 6 12-3/4 9-3/4

8 x 6-L 12-3/4 9-3/4

10 x 6 14-3/4 10-7/8

10 x 6-L 14-3/4 10-7/8

10 x 8 14-3/4 10-7/8

10-L x 6 15 11-7/8

10-L x 6-L 15 11-7/8

10-L x 8 16 11-7/8

10-L x 10 16 11-7/8

12 x 8 16 13-1/2

12 x 10 16 13-1/2

12 x 10-L 16 13-1/2

Dimensions – ANSI 150

Dia. [inches]

A [inches]

B [inches]

C[inches]

D[inches]

Bolt Ø[inches]

BoltNo.

2 3-1/2 4-3/4 6 3/4 5/8 4

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

3 4 6 7-1/2 3/4 5/8 4

4 4-3/8 7-1/2 9 3/4 5/8 8

5 4-1/2 8-1/2 10 7/8 3/4 8

6 5-1/8 9-1/2 11 7/8 3/4 8

6-L 5-5/8 9-1/2 11 7/8 3/4 8

8 6 11-3/4 13-1/2 7/8 3/4 8

10 6-1/8 14-1/4 16 1 7/8 12

10-L 5-3/8 17 19 1 7/8 12

12 5-5/8 17 19 1 7/8 12




Dia. [inches]

A [inches]

B [inches]

C[inches]

D[inches]

Bolt Ø[inches]

BoltNo.

2 3-1/2 5 6-1/2 3/4 5/8 8

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

3 4 6-5/8 8-1/4 7/8 3/4 8

4 4-3/8 7-7/8 10 7/8 3/4 8

5 4-1/2 9-1/4 11 7/8 3/4 8

6 5-1/8 10-5/8 12-1/2 7/8 3/4 12

6-L 5-5/8 10-5/8 12-1/2 7/8 3/4 12

8 6 13 15 1 7/8 12

10 6-1/8 15-1/4 17-1/2 1-1/8 1 16

10-L 5-3/8 17-3/4 20-1/2 1-1/4 1-1/8 16

12 5-3/8 17-3/4 20-1/2 1-1/4 1-1/8 16


Dia. [inches]

A [inches]

B [inches]

C[inches]

D[inches]

Bolt Ø[inches]

BoltNo.

2 3-1/2 5 6-1/2 3/4 5/8 8

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

3 4 6-5/8 8-1/4 7/8 3/4 8

4 4-3/8 8-1/2 10-3/4 1 7/8 8

5 4-1/2 10-1/2 13 1-1/8 1 8

6 5-1/8 11-1/2 14 1-1/8 1 12

6-L 5-5/8 11-1/2 14 1-1/8 1 12

8 6 13-3/4 16-1/2 1-1/4 1-1/8 12

10 6-1/8 17 20 1-3/8 1-1/4 16

10-L 5-3/8 19-1/4 22 1-3/8 1-1/4 20

12 5-5/8 19-1/4 22 1-3/8 1-1/4 20




Dia. [inches]

A [inches]

B [inches]

C[inches]

D[inches]

Bolt Ø[inches]

BoltNo.

2 3-1/2 6-1/2 8-1/2 1 7/8 8

2-1/2 3-3/4 7-1/2 9-5/8 1-1/8 1 8

3 4 7-1/2 9-1/2 1 7/8 8

4 4-3/8 9-1/4 11-1/2 1-1/4 1-1/8 8

5 4-1/2 11 13-3/4 1-3/8 1-1/4 8

6 5-1/8 12-1/2 15 1-1/4 1-1/8 12

6-L 5-5/8 12-1/2 15 1-1/4 1-1/8 12

8 6 15-1/2 18-1/2 1-1/2 1-3/8 12

10 6-1/8 18-1/2 21-1/2 1-1/2 1-3/8 16

10-L 5-3/8 21 24 1-1/2 1-3/8 20

12 5-5/8 21 24 1-1/2 1-3/8 20


Dia. [inches]

A [inches]

B [inches]

C[inches]

D[inches]

Bolt Ø[inches]

BoltNo.

2 3-1/2 6-1/2 8-1/2 1 7/8 8

2-1/2 3-3/4 7-1/2 9-5/8 1-1/8 1 8

3 4 8 10-1/2 1-1/4 1-1/8 8

4 4-3/8 9-1/2 12-1/4 1-3/8 1-1/4 8

5 4-1/2 11-1/2 14-3/4 1-5/8 1-1/2 8

6 5-1/8 12-1/2 15-1/2 1-1/2 1-3/8 12

6-L 5-5/8 12-1/2 15-1/2 1-1/2 1-3/8 12

8 6 15-1/2 19 1-3/4 1-5/8 12

10 6-1/8 19 23 2 1-7/8 12

10-L 5-3/8 22-1/2 26-1/2 2-1/8 2 16

12 5-5/8 22-1/2 26-1/2 2-1/8 2 16



Appendix I : Conversion Tables

Conversion figures for anglo-saxon units into metric units

Length (SI = m)

1 inch = 002540 m

1 foot = 12 inch = 0.30480 m

1 yard = 3 feet = 0.91440 m

1 mile = 1760 yards = 1.609 * 103 m

1 seamile = 1.852 * 103 m

Area (SI = m2)

1 square inch = 4516 * 10-4 m2

1 square foot = 144 square inch = 9.2903 * 10-2 m2

1 square yard = 9 square feet = 0.8361 m2

1 acre = 4840 square yards = 4,046.85 m2

1 square mile = 6640 acres = 2.58998 * 106 m2

1 circular inch = π/4 square inch = 5.0671 * 10-4 m2

Volume (SI = m3)

1 cubic inch = 16.387 * 10-3 m3

1 cubic foot = 28.317 * 10-3 m3

1 cubic yard = 0.76455 m3

1 imperial gallon = 4.5461 * 10-3 m3

1 US gallon = 3.7854 * 10-3 m3

1 US barrel (petrol) = 0.158762 m3

1 barrel (imperial) = 0.163656 m3

Mass (SI = kg) = 0.0648 * 10-3 kg

1 ounce = 437.5 grains = 0.0283495 kg

1 pound = 16 ounces = 0.4535924 kg

1 US long ton = 2240 pound = 1,016.05 kg

1 US short ton = 2000 pound = 907.185 kg

1 hundred weight (imp.) = 50.80235 kg

1 hundred weight (US) = 45.3592 kg

Mass per length (SI = kg/m)

1 pound per inch = 17.858 kg/m

1 pound per foot = 1.488 kg/m

1 pound per yard = 0.4961 kg/m

Mass per area (SI = kg/m2)

1 pound per square inch = 0.0703 * 104 kg/m2

1 pound per square foot = 4.8825 kg/m2

1 pound per square yard = 0.5425 kg/m2

Density (SI = kg/m3)

1 grain per cubic foot = 2.288 * 10-3 kg/m3

1 pound per cubic foot = 16.0256 kg/m3

1 grain per gallon (US) = 1.71 kg/m3

1 pound per gallon (US) = 119.8 kg/m3

Pressure (SI=Pa= 1 N/m2 = 10-5 bar) = 6.8948 * 103 N/m2

1 pound per square inch = 47.876 N/m2

1 pound per square foot = 5.3201 N/m2

1 pound per square yard = 1.0725 * 105 N/m2

1 long ton per sq. inch (imp.) = 1.5444 * 107 N/m2

1 long ton per sq. foot (imp.) = 1.3789 * 107 N/m2

1 short ton per sq. inch (US) = 0.9850 * 102 N/m2

1 grain per square inch = 4.3092 * 102 N/m2

1 ounce per square inch = 4.3092 * 102 N/m2

1 ounce per square foot = 2.9925 N/m2

1 ounce per square yard = 0.3313 N/m2

1 inch head of water = 249.089 N/m2

1 inch head of mercury = 3.3864 * 103 N/m2

1 foot head of water = 2.9879 * 102 N/m2

Power (SI = W)

1 foot pounds per second = 1.35582 W

1 foot pounds per minute = 2.25 * 10-2 W

1 British thermal unit per sec. = 1.0549 * 10-3 W

1 centigrade thermal unit per sec. = 1.8987 * 10-3 W

1 horsepower (Hp) = 7.457 * 10-4 W

Work (SI = Nm = J)

1 foot pound = 1.3558 J

1 yard pound = 4.0675 J

1 foot ton (US) = 2.7164 * 103 J

1 foot ton (imp.) = 3.0371 * 103 J

1 HPh = 2.6815 * 106 J

1 Btu = 1.0555 * 103 J

1 Ctu = 1.8991 * 103 J

Acceleration (SI = m/s2)

feet per second squared = 0.3048 m/s2

Flow rate

1 cubic feet per hour = 0.02679 m3/h

1 gallon per minute = 227.1 dm3/h

Mass Base

Pounds per hour = 0.01088 tons per day

MT/D = 0.4536 kg/h

Force (SI = N)

Pounds force = 4.448 N

Heat

Btu per pound = 2.326 KJ / kg

Btu per hour = 0.2931 W

Btu / hr.ft2OF = 5.678 W/m2.OC

Btu / lb.OF = 4.187 KJ / kg.OC

Btu / hr.ft2 = 3.155 W / m2

Btu.ft / hr.ft2.OF = 1.731 W / m.OC

ft2.hr.OF / Btu = 0.1761 m2.OC / W

Moment of inertia

inch4 = 4.162 * 10-6 m4

Moment of bending (SI = Nm)

1 inch pound = 0.1130 Nm

1 foot pound = 1.356 Nm

Velocity (SI = m/s)

1 ft / second = 0.3048 m / s

1 ft / minute = 0.00508 m / s

1 mile / hr = 0.44704 m / s


Conversion figures for metric into anglo-saxon units

Length

1 meter = 1.094 yards

= 3.281 feet

= 39.37 inches

1 kilometer = 0.621 statute mile

= 0.540 nautical mile

Area

1 square millimeter = 15.51 square inch

1 square meter = 1.196 square yards

= 10.76 square feet

1 square kilometer = 0.3861 square mile

= 0.02471 acres

Volume

1 cubic meter = 61.024 cubic inch

= 35.31 cubic feet

= 1.308 cubic yards

= 220 imperial gallon

= 264.2 US gallon

= 6.290 US barrel

= 6.286 imperial barrel

Mass

1 kilogram = 15430 grains

= 35.27 ounces

= 2.205 pounds

1 metric ton = 1.102 US short tons

= 0.984 long ton

Mass per length

1 kilogram per meter = 0.056 pounds per inch

= 0.672 pounds per foot

= 2.016 pounds per yard

Mass per area (specific pressure)

1 kilogram per sq. meter = 0.0014 psi

= 0.2048 psf

= 1.8433 lb / sq.yard

Density

1 kilogram per cubic meter = 0.0624 pcf

= 437 grain per cubic foot

= 58.4 grain per gallon

Moment of inertia

Millimeters 4 = 2.40269 * 10-6 in 4

Moment of bending

Nm = 8.850 inch pounds

= 0.07375 foot pounds

Pressure

1 N / m2 = 0.0001450 psi

= 0.0208873 psf

= 0.18797 lb / sq . yard

= 0.0102 grains / sq . inch

= 3.0184 ounces / sq . yard

= 0.0023 ounces / sq . inch

1 MN / m2 = 9.324 long tons / ft2 (eng)

= 0.648 long tons / in2 (eng)

= 0.725 short tons / in2 (US)

Power

1 kilowatt = 738 foot pounds / sec.

= 4.428 * 104 ft lb / min.

= 0.94799 Btu / sec.

= 0.526676 Ctu / sec.

= 1.340536 Horse Power

Work

1 Joule = 0.73756 foot pound

= 0.24585 yard pound

= 0.3681 * 10-3 ft . tons (US)

= 0.3293 * 10-3 ft . tons (Eng)

= 0.3250 * 10-6 Hph

= 0.9474 * 10-3 Btu

= 0.5266 * 10-3 Ctu

Heat

1 kj / kg = 0.42992 Btu / pound

1 W = 0.341180 Btu / hour

1 W / m2 . OC = 0.17612 Btu / hr . ft2 . OF

1 W / m2 = 0.31696 Btu / hr . ft2

1 W / m. OC = 0.5777 Btu . ft / hr . ft2 . OF

1 m2 . OC / W = 5.686 ft2 . hr . OF / Btu

1 kj / kg . OC = 0.23883 Btu / lb . OF

Velocity

1 m / s = 3.28084 ft / sec.

= 196.8504 ft / min.

= 2.236936 mile / fr.

Acceleration

1 m / s2 = 3.28084 ft / sec2

Flow rate

1 m3 / hr = 37.32736 ft3 / hour

= 0.00440 gallons / minute

Force

1 N (Newton) = 0.22481 pounds force

Prefixes

Prefix Factor Symbol

giga 109 G

mega 106 M

kilo 103 k

milli 10-3 m

micro 10-6 µ


Conversion figure for metric units into SI-units

Length (SI = m)

1 km = 103 m

1 cm = 10-2 m

1 mm = 10-3 m

1 micron = 10-6 m

Area (SI = m2)

1 km2 = 106 m2

1 cm2 = 10-4 m2

1 mm2 = 10-6 m2

Volume (SI = m3)

1 dm3 = 1 liter = 10-3 m3

1 cm3 = 10-6 m3

1 mm3 = 10-9 m3

Mass (SI = kg)

1 gram = 10-3 kg

1 metric ton = 103 kg

1 milligram = 10-6 kg

Mass per length (SI = kg / m)

1 den = (1/9) * 10-6 kg / m

1 tex = 10-6 kg / m

Mass per area

1 gram / dm3 = 1 gram / ltr

= 10-3 kg / dm3

= 1 kg / m3

Pressure

1 bar = 105 Pa = 105 N / m2

1 kgf / cm2 = 98066 Pa

1 atm. = 101.325 * 103 Pa

1 at = 98066.5 Pa

1 Torr = 133.322 Pa

1 meter water column = 9.80665 * 103 Pa

1 meter mercury column = 133.322 * 102 Pa

Power

1 kgf . m / s = 9.80665 W

1 metric horsepower = 735.499 W

1 kcal / h = 1.163 W

Work

1 Nm = 1 J

1 kgf . m = 9.80665 J

1 kWh = 3.6 * 106 J

1 kcal = 4186.8 J

1 metric horsepower . hour = 2.64780 * 106 J

1 erg = 1 dyn . cm = 10-7 J

Acceleration

g = gravitation = 9.8067 m / s2

Velocity

1 km / h = 0.2778 m /s

1 m / min. = 0.0167 m /s

1 knot = 0.5144 m /s

Flow rate

1 liter / h = 10-3 M3 / h

1 m3 / h = 0.2778 M3 / h

Mass base

1 kg / h = 24.0 MT / D

Force

1 kgf = 9.80665 N

1 dyn = 1 g . cm / s2 = 10-5 N

Heat

1 kcal / hr = 1.163 W

1 kcal = 4186.8 J

1 kcal (h.m) = 1.163 W / m

1 kcal (h.m2) = 1.163 W / m2

1 cal (s.cm) = 418.68 W / m


Appendix II : Conversion Graph PSI vs Bar

900

1000

1100

1200

1300

1400

65

70

75

80

85

90

95

96.52

400

500

600

700

800

900

28

30

32

34

36

38

40

42

44

46

48

50

52

60

62.1

54

56

58

200

220

240

260

280

300

320

340

360

380

400

14

15

16

17

18

19

20

21

22

23

24

25

26

27

27.6

100

110

120

130

140

150

160

170

180

190

200

7.0

8.0

9.0

10.0

11.0

12.0

13.0

13.8

7.5

8.5

9.5

10.5

11.5

12.5

13.5

50

55

60

65

70

75

80

85

90

95

100

3.5

4.0

4.5

5.0

5.5

6.0

6.5

6.89

0

5

10

15

20

25

30

35

40

45

50

0

0.5

1.0

1.5

2.0

2.5

3.0

3.54

psi bar psi bar psi barpsi bar psi bar psi bar


Appendix III : Conversion Graph OC vs OF

30

80

20

10

0

-10

-20

-30

-40

70

60

50

40

30

20

10

0

-10

-20

-30

-40

100

90

80

70

60

50

40

30

210

200

190

180

170

160

150

140

130

120

110

100

90

800

700

600

500

400

300

200

100

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

1500

1400

1300

1200

1100

1000

900

800

2700

2600

2500

2400

2300

2200

2100

2000

1900

1800

1700

1600

1500

OC OF OC OF

OC OF OC OF

OF = (OC * 9/5) + 32OC = (OF – 32) * 5/9OK = OC + 273.15

HIGH PRESSURE PIPELINE SYSTEMYELLOW BOX

Date post:	18-Mar-2020
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