SPECIFICATION OF FITTINGS FOR HOT

TAPPING WORK
MATERIAL REQUIREMENTS

SPECIFICATION SAJ OT/ HT/ 001

(REV 1.0/12.2018)

QUALITY ASSURANCE DEPARTMENT

RANHILL SAJ SDN BHD

Ref. No. : OT / HT / 001

Date : 24/12/2018

Total Pages : 20/20

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT

OFRANHILL SAJ SDN BHD
QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

SAJ SPECIFICATION OF FITTINGS FOR HOT TAPPING WORK

TABLE OF CONTENT

Contents Page

Table of Content 2-3

1.0 General 4

2.0 Material 4

3.0 Coating 5

4.0 Features Required 6-19

5.0 Design and Dimension 20

6.0 Tests and Inspection 20

7.0 Mandatory Marking 20

8.0 Packing 20

9.0 Delivery Inspection and Evaluation 20

TABLE

Table 1 – Type 1 Component and Materials 4

Table 2 – Type 2 Component and Materials 4

Table 3 – Physical properties of EPDM compounds 5

Table 4 – Size of pipe, tapping and coring head for Welded Joint 6

Table 5 – Size of pipe, tapping and coring head for Bolted Joint 7-13

Table 6 – The sizes of bolt and washer 14

Table 7 – Dimensions of Compensation Plate 15-17

Table 8 – Short piece dimensions for values of h 17-18

Table 9 – The dimensions of sleeve type 2 19

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

SAJ SPECIFICATION OF FITTINGS FOR HOT TAPPING WORK

TABLE OF CONTENT

Contents Page

Table of Content 2-3

FIGURE

Figure 1 – Short piece diagrams 17

Figure 2 – Dimensions of flanges 18

Figure 3 – The diagrams Illustrates 19

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

SAJ SPECIFICATION OF FITTINGS FOR HOT TAPPING WORK

1.0 General

1.1 The specification is applicable for hot tapping’s fittings.

1.2 These specifications will provide necessary information on the product dimension and
fabrication for water work purposes.

2.0 Material

2.1 Two types of hot tapping’s fittings:-

Type 1 - Sleeve with welded joint.

Type 2 - Sleeve with bolted joint.

2.2 The sleeve shall comply with the requirements of Table 1 for type 1, sleeve with welded joint.

Table 1 – Type 1 Component and materials

Component Materials Reference
Ductile Iron BS EN 1092-2
Flange
Mild Steel BS EN 1092-1
Compensation plate Mild Steel BS EN 10025
Short piece Mild Steel Cement Lining SPAN TS 21827

2.3 For type 2, sleeve shall be ductile iron and others requirements as specified in Table 2 below.

Table 2 – Type 2 Component and materials

Component Materials Reference
Flange Ductile Iron BS EN 109 2-2
Clamp Ductile Iron BS EN 545 :2010
Short piece Ductile Iron BS EN 545 :2010
Bolts, screws and Carbon steel BS 4190:2014
nuts, washer (Hot dip galvanized coated)
Gasket EPDM MS 672-1 :2012
(Top and Bottom) MS 672-2 :2012

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

2.4 Flanges

Flanges shall be manufactured from the materials specified in BS EN 1092.

2.5 Compensation Plate

The compensation plate shall be made from flat products, seamless rolled, pressed and
forged. The manufactured shall be machined from rolled or forged bars an d forged
sectional steel.

2.6 Short Piece

The short piece shall b e manufactured from tubes accordance with SPAN TS 21827 and
shall be protected against corrosion as specified in Item 3.0.

2.7 Bolts , screws and nuts and washer

The bolts, screws and nuts and washer shall be cleanly finished, sound and free from defects
and shall be hot dip galvanized coated and chosen according to pressure, temperature,
flange material and gasket.

2.8 Gasket

Gasket shall be of EPDM formulated for water service and has anti oxidant agents and anti-
tired to increase shelf life. This specified requirements shall conform to MS 672 : 2012.

Table 3 – Physical properties of EPDM compounds

Properties Requirements Requirements for
Change in Ageing, max
Thickness, mm , min 6 -
3
Specific Gravity, g/cm 1.40 -
Tensile Strength, MPa , min 11 20%
Hardness, IRHD 66-75 5
Elongation at break, % , min 200 30%
Compression set at 2 3±2°C for 70h, %, max 15 -
Compression set at 7 0±2°C for 22h, %, max 20 -

3.0 Coating

3.1 All machined surfaces shall be thoroughly cleaned by sand blasting and treated with a
protective composition before they become affected by rust.

3.2 All fitting shall be coated with heavy duty coating of not less than 350 µm thickness for both
internally and externally.

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

4.0 Features Required

4.1 Features required for tapping size with coring, as given in Table 4 for type 1 and Table 5 for
type 2.

Table 4- Size of pipe, tapping and coring head for Welded Joint
Outlet Branch(d)-mm
Pipe
Size (D)- 50 100 150 200 250 300 350 400 450 500 600
mm
Coring Head Size,min (mm)
50 46.0
100 46.0 82.0
150 46.0 82.0 130.0
200 46.0 82.0 130.0 180.0
250 46.0 82.0 130.0 180.0 230.0
300 46.0 82.0 130.0 180.0 230.0 270.0
350 46.0 82.0 130.0 180.0 230.0 270.0 320.0
400 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0
450 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0
500 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0
600 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
650 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
700 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
750 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
800 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
850 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
900 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
1000 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0
1200 46.0 82.0 130.0 180.0 230.0 270.0 320.0 350.0 400.0 450.0 550.0

no correlation values between particular pipe size and outlet branch

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Table 5 - Size of pipe, tapping and coring head for Bolted Joint
Outlet Branch, d (mm)
Pipe Type 50 100 150 200

PV
UPVC

UPV
Size,D of

HDP
U
HDP

HDP

HDP
AC
UPV

AC
AC

AC

C
DI

DI

DI

DI
(mm) pipe

E
C

E
DI 46 46 46
50 UPVC 46 46 46
HDPE 46 46 46
AC
DI 46 46 46
UPVC
60
HDPE
AC
DI
UPVC
63
HDPE 46 46 46
AC
DI 46 46 46
65 UPVC 46 46 46
HDPE
AC
DI
73 UPVC
HDPE 46 46 46
AC
DI 46 46 46
UPVC 46 46 46
80
HDPE
AC
DI
90 UPVC
HDPE 46 46 46
AC
DI 46 46 46 82 82 82 82
UPVC 46 46 46 82 82 82 82
100
HDPE
AC 46 46 46 82 82 82 82
DI
UPVC
110
HDPE 46 46 46 82 82 82
AC
DI 46 46 46 82 82 82
UPVC 46 46 46 82 82 82
125
HDPE 46 46 46 82 82 82
AC
DI
UPVC
140
HDPE 46 46 46
AC
DI 46 46 46 82 82 130 130
150 UPVC
HDPE
AC 82 82 82 130 130
DI
UPVC 46 46 46 82 82 82 130 130
155
HDPE
AC
DI
160 UPVC
HDPE 46 46 46 82 82 82 130 130
AC

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Outlet Branch, d (mm)

Pipe Type 50 100 150 200

PV

HDPE
UPVC

UPVC

HDP
Size,D of

AC

U
HDP

HDP
AC

UP
C

VC
AC

AC
DI

DI

DI

DI
(mm) pipe

E
E

E
DI
175 UPVC 46 46 46 82 82 82 130 130
HDPE
AC
DI
UPVC
180
HDPE 46 46 46 82 82 82 130 130
AC 130 130
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
200 UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC 46 46 46 82 82 82 130 130 18 0 180 180 180
DI
UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
225
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
250
HDPE 46 46 46 82 82 80 130 130 18 0 180 180 180
AC 82 82 82 130 130 18 0 180 180 180
DI
280 UPVC
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
300
HDPE
AC 82 82 82 130 130 18 0 180 180 180
DI
UPVC
315
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
350
HDPE
AC 82 82 82 130 130 18 0 180 180 180
DI
UPVC
355
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC
DI
375 UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
HDPE
AC
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
400
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC 46 46 46 82 82 82 130 130 18 0 180 180 180
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
450 UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC 82 82 82 130 130 18 0 180 180 180
DI 46 46 46 82 82 82 130 130 18 0 180 180 180
500 UPVC 46 46 46 82 82 82 130 130 18 0 180 180 180
HDPE 46 46 46 82 82 82 130 130 18 0 180 180 180
AC 46 46 46 82 82 82 130 130 18 0 180 180 180

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 QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Outlet Branch,d (mm)

Pipe Type 50 100 150 200

HDPE
UPVC

UPVC
Size,D of

HDP

UP
HDP

HDP

VC
UPV
AC

AC

AC

AC
DI

DI

DI

DI
(mm) pipe

E
C
E

E
DI
UPVC
560
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI
UPVC 46 46 46 82 82 82 130 130 180 180 180 180
575
HDPE
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
600 UPVC
HDPE
AC 46 46 46 82 82 82 130 130 180 180 180 180
DI
UPVC
630
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
700
HDPE
AC
DI
710 UPVC
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
800
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI
UPVC
900
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
1000
HDPE
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
1100
HDPE
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
1200 UPVC
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
1400
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
1500 UPVC
HDPE
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
1600 UPVC
HDPE 46 46 46 82 82 82 130 130 180 180 180 180
AC

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Outlet Branch, d (mm)

Pipe Type 50 100 150 200
Size,D of

UPV

UPVC
HDPE
HDPE
UPVC

UPVC
HDPE

HDPE
(mm) pipe

C
AC

AC

AC

AC
DI

DI

DI

DI
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
1800
HDPE
AC
DI 46 46 46 82 82 82 130 130 180 180 180 180
UPVC
2000
HDPE
AC

Outlet Branch, d (mm)

Pipe Type 250 300 350 400

UPV
Size,D of
UPVC

UPVC
HDPE
UPVC
HDPE

HDPE

HDPE
AC
(mm) pipe

C
DI
AC

AC

AC
DI

DI

DI
DI 230 230 230 2 30
UPVC 230 230 230 2 30
250
HDPE 230 230 230 2 30
AC 230 230 230 2 30
DI
280 UPVC
HDPE 230 230 230 2 30
AC
DI 230 230 230 2 30 270 270 270
300 UPVC 230 230 230 2 30 270 270 270
HDPE
AC 230 230 230 2 30 270 270 270
DI
315 UPVC
HDPE 230 230 230 2 30 270 270 270
AC
DI 230 230 230 2 30 270 270 270
UPVC 230 230 230 2 30 270 270 270
350
HDPE
AC 230 230 230 2 30 270 270 270
DI
UPVC
355
HDPE 230 230 230 2 30 270 270 270
AC
DI
UPVC 230 230 230 2 30 270 270 270
375
HDPE
AC
DI 230 230 230 2 30 270 270 270 35 0 350 350 350
400 UPVC 230 230 230 2 30 270 270 270 35 0 350 350 350
HDPE 230 230 230 2 30 270 270 270 35 0 350 350 350
AC 230 230 230 2 30 270 270 270 35 0 350 350 350
DI 230 230 230 2 30 270 270 270 35 0 350 350 350
UPVC 230 230 230 2 30 270 270 270 35 0 350 350 350
450
HDPE 230 230 230 2 30 270 270 270 35 0 350 350 350
AC 230 230 230 2 30 270 270 270 35 0 350 350 350
DI 230 230 230 2 30 270 270 270 35 0 350 350 350
UPVC 230 230 230 2 30 270 270 270 35 0 350 350 350
500
HDPE 230 230 230 2 30 270 270 270 35 0 350 350 350
AC 230 230 230 2 30 270 270 270 35 0 350 350 350

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Outlet Branch, d (mm)

Pipe Type 250 300 350 400

HDPE
PV
UPVC

UPVC

HDP
Size,D of

AC
DIU
HDP

UP
VC
C

HD
AC

AC

AC
PE
DI

DI

DI
(mm) pipe

E
E
DI
UPVC
560
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI
UPVC 230 230 230 230 270 270 270 350 350 350 350
575
HDPE
AC
DI 230 230 230 230 270 270 270 350 350 350 350
600 UPVC
HDPE
AC 230 230 230 230 270 270 270 350 350 350 350
DI
UPVC
630
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
700
HDPE
AC
DI
UPVC
710
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
800
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
900
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
1000
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
1100
HDPE
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
1200
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
1400
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC
DI 230 230 230 230 270 270 270 350 350 350 350
1500 UPVC
HDPE
AC
DI 230 230 230 230 270 270 270 350 350 350 350
UPVC
1600
HDPE 230 230 230 230 270 270 270 350 350 350 350
AC

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Pipe Outlet Branch, d (mm)

Size, Type 250 300 350 400

HDPE
UPVC
D of

HDP
UP
AC

VC

UP
VC
HDP

HDP
AC

AC
UP

AC
VC
DI

DI

DI

DI
(mm pipe

E
E

E
)
DI 230 230 230 230 270 270 270 350 350 350 350
180 UPVC
0 HDPE
AC
DI 230 230 230 230 270 270 270 350 350 350 350
200 UPVC
0 HDPE
AC

Outlet Branch, d (mm)

Pipe Type 450 500 600

UPVC

HDPE
HDP
UP

Size,D of

UPV
VC

HDP
AC

AC

AC
E
DI

DI

DI
C
(mm) pipe

E
DI 400 4000 400 400
450 UPVC 400 4000 400 400
HDPE 400 4000 400 400
AC 400 4000 400 400
DI 400 4000 400 400 450 450 450
UPVC 400 4000 400 400 450 450 450
500
HDPE 400 4000 400 400 450 450 450
AC 400 4000 400 400 450 450 450
DI
560 UPVC
HDPE 400 4000 400 400 450 450 450
AC
DI
UPVC 400 4000 400 400 450 450 450
575
HDPE
AC
DI 400 4000 400 400 450 450 450 550 550
UPVC
600
HDPE
AC 400 4000 400 400 450 450 450 550 550
DI
UPVC
630
HDPE 400 4000 400 400 450 450 450 550 550
AC
DI 400 4000 400 400 450 450 450 550 550
700 UPVC
HDPE
AC
DI
UPVC
710
HDPE 400 4000 400 400 450 450 450 550 550
AC
DI 400 4000 400 400 450 450 450 550 550
UPVC
800
HDPE 400 4000 400 400 450 450 450 550 550
AC
DI 400 4000 400 400 450 450 450 550 550
UPVC
900
HDPE
AC

SAJ OT/HT/001 (Rev. 1.0/12.2018)

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Outlet Branch, d (mm)

Pipe Type 450 500 600

HDPE

HDPE

PV
Size,D of

HDP
UP

U
VC

V
DI P

DI U

C
AC

AC

AC
DI
(mm) pipe

E
DI 400 4000 400 400 450 450 450 550 550
UPVC
1000
HDPE 400 4000 400 400 450 450 450 550 550
AC
DI 400 4000 400 400 450 450 450 550 550
UPVC 400 4000 400 400 450 450 450 550 550
1100
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550
DI 400 4000 400 400 450 450 450 550 550
UPVC 400 4000 400 400 450 450 450 550 550
1200
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550
DI 400 4000 400 400 450 450 450 550 550
UPVC 400 4000 400 400 450 450 450 550 550
1400
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550
DI 400 4000 400 400 450 450 450 550 550
UPVC 400 4000 400 400 450 450 450 550 550
1500
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550
DI 400 4000 400 400 450 450 450 550 550
UPVC 400 4000 400 400 450 450 450 550 550
1600
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550
DI 400 4000 400 400 450 450 450 550 550
UPVC 400 4000 400 400 450 450 450 550 550
1800
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550
DI 400 4000 400 400 450 450 450 550 550
2000 UPVC 400 4000 400 400 450 450 450 550 550
HDPE 400 4000 400 400 450 450 450 550 550
AC 400 4000 400 400 450 450 450 550 550

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

4.2 The size and dimension s of bolt and washer for flange shall conform to BS EN 1092 and
BS 4190:2014. These details are suitable for hot tapping’s fittings type 2 as shown in Table 6.

Table 6 – The Sizes of bolt and washer

NORMAL NO. OF NOMINAL WIDTH ACROSS HEIGHT OF HEAD, WA SHER THICKNESS

SIZE BOLT PER SIZE OF FLATS, s (mm) k FACE OF
SET BOLT DIA METER, WASHER,
(mm) Max. Min. Max. Min. min (mm) max (mm)

100 8 M16 24.00 23.16 10.45 9.55 2 2.0 0.8

150 8 M20 30.00 29.16 13.90 12.10 2 7.7 0.8
200 8 M20 30.00 29.16 13.90 12.10 2 7.7 0.8
250 12 M20 30.00 29.16 13.90 12.10 2 7.7 0.8
300 12 M20 30.00 29.16 13.90 12.10 2 7.7 0.8
350 16 M20 30.00 29.16 13.90 12.10 2 7.7 0.8
400 16 M24 36.00 35.00 15.90 14.10 3 3.2 *
450 20 M24 36.00 35.00 15.90 14.10 3 3.2 *
500 20 M24 36.00 35.00 15.90 14.10 3 3.2 0.8
600 20 M27 41.00 40.00 17.90 16.10 * 0.8
700 24 M27 41.00 40.00 17.90 16.10 * *
800 24 M30 46.00 45.00 20.05 17.95 4 2.7 0.8
900 28 M30 46.00 45.00 20.05 17.95 4 2.7 0.8
1000 28 M33 50.00 49.00 22.05 19.95 * *
1100 32 M33 50.00 49.00 22.05 19.95 * *
1200 32 M36 55.00 53.80 24.05 21.95 5 1.1 *
1400 36 M39 60.00 58.80 26.05 23.95 * *
1500 36 M39 60.00 58.80 26.05 23.95 * *
1600 40 M45 70.00 68.80 29.05 26.95 * *
( *) For other sizes of washer shall be provided by the manufacturer

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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

4.3 The thickness of plate equal to the thickness of pipe. The minimum thickness of plate for type
1 shall be 6.4mm. There are two (2) ways to determine the type of sleeve with welded joint
that will be used,

 If branch ratio, 0.50< d/D ≤1.00, split sleeve shall be used.

 If branch ratio, d/D≤ 0.50, compensation plate shall be used.
(William Jarvis, Williamson Industries Inc.)

4.4 Table 7 mentioned the dimensions of compensation plate for Type 1, sleeve with welded
joint.

Table 7 – Dimensions of Compensation Plate

For size, d=50mm to 100mm
Pipe Thickness Outlet Branch, d (mm)
size, D of Plate,t 50 65 80 1 00
(mm) (mm) S Lmin S Lmin S Lmin S Lmin
1
50 6.4 78.575 100
1 1
65 6.4 102.148 100 102.148 130
1 1
80 6.4 125. 720 100 125.720 130 125.720 160
1 1
100 6.4 157. 150 100 157.150 130 157.150 160 157.150 200
1
125 6.4 196. 438 100 196.438 130 196.438 160 196.438 200
150 6.4 235. 725 100 235.725 130 235.725 160 235.725 200
200 6.4 314. 300 100 314.300 130 314.300 160 314.300 200
250 6.4 392. 875 100 392.875 130 392.875 160 392.875 200
300 6.4 471. 450 100 471.450 130 471.450 160 471.450 200
350 6.4 550. 025 100 550.025 130 550.025 160 550.025 200
400 6.4 628. 600 100 628.600 130 628.600 160 628.600 200
450 6.4 707. 175 100 707.175 130 707.175 160 707.175 200
500 6.4 785. 750 100 785.750 130 785.750 160 785.750 200
600 6.4 942. 900 100 942.900 130 942.900 160 942.900 200
650 6.4 1021 .475 100 1021.475 130 1021.475 160 1021.475 200
700 6.4 1100 .050 100 1100.050 130 1100.050 160 1100.050 200
750 6.4 1178 .625 100 1178.625 130 1178.625 160 1178.625 200
800 7.1 1257 .200 100 1257.200 130 1257.200 160 1257.200 200
850 7.1 1335 .775 100 1335.775 130 1335.775 160 1335.775 200
900 8.0 1414 .350 100 1414.350 130 1414.350 160 1414.350 200
1000 8.0 1571 .500 100 1571.500 130 1571.500 160 1571.500 200
1200 10.0 1885 .800 100 1885.800 130 1885.800 160 1885.800 200
1400 10.0 2200 .100 100 2200.100 130 2200.100 160 2200.100 200
1600 11.0 2514 .400 100 2514.400 130 2514.400 160 2514.400 200
1
Note: 1) if branch ratio, 0.50< d/D ≤1.00, split sleeve shall be used
1
2) the value of S shall be 2S

For size, d=125mm to 250mm

Pipe Thickness Outlet Branch, d (mm)
size, D of Plate,t 125 150 200 2 50
(mm) (mm) S Lmin S Lmin S Lmin S Lmin
1
125 6.4 196.438 250
1 1
150 6.4 235.725 250 235.725 300
1 1
200 6.4 314. 300 250 314.300 300 314.300 400
1 1
250 6.4 392. 875 250 392.875 300 392.875 400 392.875 500
1
300 6.4 471. 450 250 471.450 300 471.450 400 471.450 500
1
350 6.4 550. 025 250 550.025 300 550.025 400 550.025 500
400 6.4 628. 600 250 628.600 300 628.600 400 628.600 500
450 6.4 707. 175 250 707.175 300 707.175 400 707.175 500
500 6.4 785. 750 250 785.750 300 785.750 400 785.750 500
600 6.4 942. 900 250 942.900 300 942.900 400 942.900 500
650 6.4 1021 .475 250 1021.475 300 1021.475 400 1021.475 500
700 6.4 1100 .050 500 1100.050 600 1100.050 700 1100.050 800

SAJ OT/HT/001 (Rev.1.0/12.2018)

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF RANHILL SAJ SDN BHD
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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

750 6.4 1178 .625 500 1178.625 600 1178.625 700 1178.625 800
800 7.1 1257 .200 500 1257.200 600 1257.200 700 1257.200 800
850 7.1 1335 .775 500 1335.775 600 1335.775 700 1335.775 800
900 8.0 1414 .350 500 1414.350 600 1414.350 700 1414.350 800
1000 8.0 1571 .500 500 1571.500 600 1571.500 700 1571.500 800
1200 10.0 1885 .800 500 1885.800 600 1885.800 700 1885.800 800
1400 10.0 2200 .100 500 2200.100 600 2200.100 700 2200.100 800
1600 11.0 2514 .400 500 2514.400 600 2514.400 700 2514.400 800
1
Note: 1) if branch ratio, 0.50< d/D ≤1.00, split sleeve shall be used
1
2) the value of S shall be 2S

For size, d=300mm to 450mm

Pipe Thickness Outlet Branch, d (mm)
size, D of Plate,t 300 350 400 4 50
(mm) (mm) S Lmin S Lmin S Lmin S Lmin
1
300 6.4 471.450 600
1 1
350 6.4 550.025 600 550.025 700
1 1 1
400 6.4 628.600 600 628.600 700 628.600 800
1 1 1
450 6.4 707. 175 600 707.175 700 707.175 800 707.175 900
1 1 1
500 6.4 785. 750 600 785.750 700 785.750 800 785.750 900
1
600 6.4 942. 900 600 942.900 700 942.900 800 942.900 900
650 6.4 1021 .475 600 1021.475 700 1021.475 800 1021.475 900
700 6.4 1100 .050 600 1100.050 700 1100.050 800 1100.050 900
750 6.4 1178 .625 600 1178.625 700 1178.625 800 1178.625 900
800 7.1 1257 .200 600 1257.200 700 1257.200 800 1257.200 900
850 7.1 1335 .775 600 1335.775 700 1335.775 800 1335.775 900
900 8.0 1414 .350 600 1414.350 700 1414.350 800 1414.350 900
1000 8.0 1571 .500 600 1571.500 700 1571.500 800 1571.500 900
1200 10.0 1885 .800 600 1885.800 700 1885.800 800 1885.800 900
1400 10.0 2200 .100 600 2200.100 700 2200.100 800 2200.100 900
1600 11.0 2514 .400 600 2514.400 700 2514.400 800 2514.400 900
1
Note: 1) if branch ratio, 0.50< d/D ≤1.00, split sleeve shall be used
1
2) the value of S shall be 2S

For size, d=500mm to 700mm

Pipe Thickness Outlet Branch, d (mm)
size, D of Plate,t 500 600 650 700
(mm) (mm) S Lmin S Lmin S Lmin S Lmin
1
500 6.4 785.750 1000
1 1
600 6.4 942.900 1000 942.900 1200
1 1 1
650 6.4 1021 .475 1000 1021.475 1200 1021.475 1300
1 1 1 1
700 6.4 1100 .050 1000 1100.050 1200 1100.050 1300 110 0.050 1400
1 1 1
750 6.4 1178 .625 1000 1178.625 1200 1178.625 1300 117 8.625 1400
1 1 1
800 7.1 1257 .200 1000 1257.200 1200 1257.200 1300 125 7.200 1400
1 1 1
850 7.1 1335 .775 1000 1335.775 1200 1335.775 1300 133 5.775 1400
1 1
900 8.0 1414 .350 1000 1414.350 1200 1414.350 1300 141 4.350 1400
1
1000 8.0 1571 .500 1000 1571.500 1200 1571.500 1300 157 1.500 1400
1200 10.0 1885 .800 1000 1885.800 1200 1885.800 1300 1885 .800 1400
1400 10.0 2200 .100 1000 2200.100 1200 2200.100 1300 2200 .100 1400
1600 11.0 2514 .400 1000 2514.400 1200 2514.400 1300 2514 .400 1400
1
Note: 1) if branch ratio, 0.50< d/D ≤1.00, split sleeve shall be used
1
2) the value of S shall be 2S

SAJ OT/HT/001 (Rev.1.0/12.2018)

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF RANHILL SAJ SDN BHD
16
QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

For size, d=750mm to 900mm

Pipe Thickness Outlet Branch, d (mm)
size, D of Plate,t 750 800 850 900
(mm) (mm) S Lmin S Lmin S Lmin SS Lmin
1
750 6.4 11788.625 1500
1 1
800 7.1 12577.200 1500 1257.200 1600
1 1 1
850 7.1 13355.775 1500 1335.775 1600 1335.775 1700
1 1 1 1
900 8.0 14144.350 1500 1414.350 1600 1414.350 1700 14144.350 1800
1 1 1 1
1000 8.0 15711.500 1500 1571.500 1600 1571.500 1700 15711.500 1800
1 1
1200 10.0 1885 .800 1500 1885.800 1600 1885.800 1700 18855.800 1800
1400 10.0 2200 .100 1500 2200.100 1600 2200.100 1700 2200.100 1800
1600 11.0 2514 .400 1500 2514.400 1600 2514.400 1700 2514.400 1800
1
Note: 1) if branch ratio, 0.50< d/D ≤1.00, split sleeve shall be used
1
2) the value of S shall be 2S

For size, d=1000mm to 1600mm

Pipe Thickness Outlet Branch, d (mm)
size, D of Plate,t 1000 1200 1400 1600
(mm) (mm) S Lmin S Lmin S Lmin SS Lmin
1
1000 8.0 15711.500 2000
1 1
1200 10.0 18855.800 2000 1885.800 2400
1 1 1
1400 10.0 22000.100 2000 2200.100 2400 2200.100 2800
1 1 1
1600 11.0 2514 .400 2000 2514.400 2400 2514.400 2800 25144.400 3200
1
Note: 1) if branch ratio, 0.50<
d/D ≤1.00, split sleeve shall be used
1
2) the value of S shall be 2S

4.5 The dimensions of height, h of short piece as shown in Table 8 and figure 1.

Figure 1 – Short piece diagram.

Table 8 – Short piece dimensions for values of h.

H h 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900
100 210
150 215 215
200 210 210 210
250 210 175 265 265
300 220 220 270 270 270
350 205 205 255 255 265 305
400 210 210 280 280 265 310 310
450 * 205 255 255 265 305 305 305
500 * 230 260 260 265 310 310 310 310
550 * 210 260 260 260 310 310 310 310 310
600 * 210 * * 260 310 400 310 310 310 *
650 * * * * * * * * * * * *
700 * * * * * * * * * * * * *
750 * * * * * * * * * * 325 * * *
800 * * * * * * * * * * * * * * *
850 * * * * * * * * * * * * * * * *

SAJ OT/HT/001 (Rev.1.0/12.2018)

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF RANHILL SAJ SDN BHD
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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

900 * * * * * * * * * * 325 * * * * * *
950 * * * * * * * * * * * * * * * * *
1000 * * * * * * * * * * * * * * * * 325
1050 * * * * * * * * * * * * * * * * 325
1200 * * * * * * * * * * * * * * * * 325
1350 * * * * * * * * * * * * * * * * 325
1500 * * * * * * * * * * * * * * * * 325

H h 950 1000 1050 1200 1250 1300 1350 1400 1450 1500 15550 1600
1650 * * * 491.7 * * * * * * * *
1800 * * * 475.0 * * * * * * * *
2100 * * * * * * * * * 591.7 * *
2250 * * * * * * * * * 591.7 * *
2400 * * * * * * * * * 591.7 * *
( *) For other sizes and outlets, h values shall be provided by the manufacturer..

Figure 2 – Dimensions of flange

SAJ OT/HT/001 (Rev.1.0/12.2018)

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF RANHILL SAJ SDN BHD
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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

Figure 3 – The diagram illustrates

4.6 For details of sleeve with bolted joint, type 2 as shown in Table 8 (see Figure 2 and Figure 3). For Figure
3, the diagram illustrates the arrangement but not necessarily the correct number of bolt holes; refer
to dimensions of sleeve type 2, sleeve with bolted joint, Table 9 for the actual nu mber.

Table 9 – The dimension s of sleeve type 2

Nominal Outside Diameter of Diameter of Flange Neck
Corner
Diameter of diameter of Bolt Circle,K Bolt Hole,L Thickness,C Diame ter,N
Radius,r (mm)
Pipe,d (mm) Flange,D ( mm) (mm) (mm) (mm) (mm)
50 19.0 84 5
100 220 180 19 19.0 14 0 6
150 285 240 23 19.0 19 0 8
200 340 295 23 20.0 24 6 8
250 400 355 28 22.0 29 6 10
300 455 410 28 24.5 35 0 10
350 520 470 28 26.5 41 0 10
400 580 525 31 28.0 45 8 10
450 640 585 31 30.0 51 6 12
500 715 650 34 31.5 57 6 12
600 840 770 37 36.0 69 0 12
700 910 840 37 39.5 76 0 12
800 1025 950 41 43.0 86 2 12
900 1125 1050 41 46.5 96 2 12
1000 1255 1170 44 50.0 1076 12
1200 1485 1390 50 57.0 1282 12
1400 1685 1590 50 60.0 1482 12
1600 1930 1820 57 65.0 1696 12

SAJ OT/HT/001 (Rev.1.0/12.2018)

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF RANHILL SAJ SDN BHD
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QUALITY ASSURANCE DEPARTMENT RANHILL SAJ SDN BHD

5.0 Design and Dimension

5.1 Refer to SAJ’s Standard Drawing number SAJ/STD/HT/01 and SAJ/STD/HT/02.

5.2 The dimensions of bolts and nuts shall be as specified with track head, or similar neck which
located in similarly shaped hole in the sleeve body, thus preventing rotation of the bolts and
permitting tightening o f the bolts using only one spanner. Refer Table 6.

6.0 Tests and Inspection

6.1 All hot tapping fitting shall comply with tests in accordance with the requirements of
specification.

6.2 For inspection and testing, the tests shall be carried out by the manufacturer in accordance
with their own procedures.

6.3 Leakage test and pressure test shall be carried out at site by the contractor with witnessed by
SAJ’s personnel.

7.0 Mandatory Marking

Each set shall have the following markings in raised letters of minimum 50mm high cast on
the body.

a) The Manufacturer’s name and trade mark

b) The year of manufacture (last two digits)
c) The body material identification
d) Made in Malaysia
e) Lettering “SAJ”

8.0 Packing

All hot tapping’s fitting shall be individually plastic wrapped and protected from damage
during transit.

9.0 Delivery Inspection and Evaluation

a) It is the responsibility of the tenderer to inform SAJ for inspection purposes during
manufacturing and before delivery
b) SAJ reserve the right to inspect and witness the testing of product offered.
c) At anytime, w hen requested, the supplier shall provide SAJ a sample of the product
offered for evaluation purposes. All costs shall be borne by the supplier.
d) If at any time the supplier fails to deliver the required sample, the products is
deemed fail to meet the specifications.

SAJ OT/HT/001 (Rev.1.0/12.2018)

NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF RANHILL SAJ SDN BHD
20