Engineering Standards

Standard

4780
Page

1 of 8
SELECTION AND DESIGN OF
BRANCH CONNECTIONS AND REINFORCEMENT

Issue Date

Rev. No.
Date

1.

06/86
8
05/97

SCOPE
This standard provides criteria for the selection and design of typical branch connections and associated header
piping. Allowable branch connection types for various design and construction conditions are given in Table 1.
Branch weld and reinforcement weld details are given in Engineering Standards 8375 and 8380. A typical hot tap
branch connection for farm taps and small sales meters is shown in Engineering Standard 4815.

2.

CODES, STANDARDS (ES) AND PROCEDURES

49 CFR Part 192, 192.111, 151, 155 and 157
American National Standards Institute (ANSI), B31.8
ASME Guide for Gas Transmission and Distribution Piping Systems
ES 3101, Design Guideline for Unfired Pressure Vessels
ES 3120, Standard for Purchase of Pulsation Bottles
ES 4710, Design Guideline for Small Diameter Gas Piping for Instrument, Control and Supply Lines
ES 4815, Typical 1" Hot Tap Connection for Farm Tap or Sales Meter
ES 4900, Standard for Purchase of High Test, Y-Grade, Wrought Welding Fittings and Extruded Outlet Headers.
ES 8312, Design and Installation of Hot Taps and Stopples
ES 8375, Typical Weld - Branch to Header
ES 8380, Reinforcement for Branch Connections
Operating Procedure 80.203, Tapping Pipelines

3.

CRITERIA

3.1

The header design factor (F) shall be per 49 CFR 192.111 except as modified in this standard. Note that
installation of a fabricated branch connection in a Class 1 location consisting of a tee or similar fitting and
associated components will require the installation of pipe meeting a 0.6 design factor for at least five (5)
pipe diameters or five (5) feet, whichever is greater, in the header on both sides of the tee.

3.2

Individual branch connections or individual branch connections with a valve (i.e. hot tap connections) are
not, in themselves, considered fabricated assemblies. However, fabricated assemblies may contain branch
connections and hot taps.

3.3

When a welded branch connection is used requiring the use of a saddle or full encirclement reinforcement,
the design must meet the requirements of 49 CFR 192.155 and the reinforcement calculations as outlined
in the ASME Guide for Gas Transmission and Distribution Piping Systems and contained in Section 4 of
this standard.

3.4

When extruded outlets are specified, the design must meet the requirements of 192.157 and Engineering
Standard 4900.

3.5

All "Y" grade tee connections shall comply with Engineering Standard 4900, regardless of their size.

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4780
Page

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SELECTION AND DESIGN OF
BRANCH CONNECTIONS AND REINFORCEMENT

Issue Date

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Date

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3.6

This Standard should not be applied to the design of pulsation dampener nozzles other than for
reinforcement calculations for welded branch connections or for the specification of ASME vessels. For
the design and specification of these items, see Engineering Standards 3120 and 3101.

3.7

Reinforcement thickness should be uniform to the extent practical and known in order that valid area
replacement calculations can be made as prescribed in Section 4 of this standard. For reinforcing sleeves
made from pipe, the nominal pipe wall thickness may be used. For reinforcing saddles having extruded
outlets, the specified or nominal wall thickness of the skirt may be used.

3.8

Purchased reinforcement items shall be marked per MSS SP-25. Reinforcing saddles having extruded
outlets must meet the specified thickness only in the skirt. Material, chemical and tensile properties of
saddles and full encirclement reinforcements (wrap around saddles and sleeves) shall meet the
requirements of the specifications listed below.
Extruded Outlet Saddles
"B" Grade: ASTM A-234 WPB
"Y" Grade: MSS SP-75

3.9

Sleeves (split pipe)

"B" Grade: API-5L or ASTM A106
"X" Grade: API-5L

One Branch Connection may be made to a pipe fitting, unless more than one is allowed by another
Engineering Standard, with the following restrictions. See also Engineering Standard 4710 for design
guidelines for small diameter piping.
3.9.1

Connection will utilize a coupling, weldolet or threadolet.

3.9.2

Size limitations will be in accordance with Table 1.

3.9.3

If piping is connected to the branch, tubing or flexible hose shall be used, unless it connects to
another part of the same fabrication, in which case pipe may be used.

3.9.4

A branch may be applied to the following locations of a fitting:

FITTING TYPE
Tee
Weld Cap
Concentric Reducer
Eccentric Reducer
Ell (90 or 45)

* Indicates revised paragraph, this Rev. No.

INSTALLATION LOCATION
Opposite the branch, centered end to end
On the center at the end
On the straight portion
On the straight side
On the outside radius of the fitting with the angle between the
fitting tangent at the point of branch attachment and the branch
centerline not less than 45.

Standard

Engineering Standards

4780
Page

3 of 8
SELECTION AND DESIGN OF
BRANCH CONNECTIONS AND REINFORCEMENT

Issue Date

06/86
8
05/97

Rev. No.
Date

TABLE 1:

TYPE
CONNECTION

ALLOWABLE BRANCH CONNECTION TYPES

BRANCH TO HEADER RATIO = d/D, where d = nominal branch diameter,

D = nominal header diameter.
d/D = 1
1 > d/D > 1/2
1/2 > d/D > 1/3
1/3 > d/D>1/4
1/4 > d/D
Unpressurized

Hot
Tap

Unpressurized

Hot
Tap

Unpressurized

Hot
Tap

Unpressurized

Hot
Tap

Unpressurized

Hot
Tap

Forged Tee
A
N/A
A
N/A
A
N/A
A
N/A
A
N/A
Full Enc. Split Tee
N/A
A
N/A
A
A
A(2)
A(2)
A
A(2)
A(2)
(T.D.W.)
(1)
(2)
Extruded Outlet
N/A
N/A
A
N/A
A
N/A
A
N/A
A
N/A
Full Encirc. Reinforcement
N/A
N/A
N/A
N/A
A(3)
A(3)
A(3)
A(3)
(4) & &
(4) A(3)
(4) & &
(4) A(3)
(4) & &
(4)
Saddle (d > 4")
N/A
N/A
N/A
N/A
N/A
N/A
A(4)
N/A
A(4)
N/A
Saddle (1" <d< 4")
N/A
N/A
N/A
N/A
N/A
N/A
A(4)
A(4)
A(4)
A(4)
45 Lateral
A(5)
N/A
A(5)
N/A
A(5)
N/A
A(5)
N/A
A(5)
N/A
Coupling or Weldolet (6)
N/A
N/A
N/A
N/A
N/A
N/A
A
A
A
A
(d < 1")
NOTES:
"Unpressurized" means pressure containing facilities to be constructed while at atmospheric pressure and not
containing the operating fluid.
"A" means allowed; "N/A" means not applicable or not allowed.
(1) T.D. Williamson or approved equivalent split tee (pressure containing) to be used only in stopple
connection.
(2) Use of pressure containing split tee as a permanent branch connection is discouraged since considered
impractical and should be limited to special operating conditions or during an emergency.
(3) A manufactured reinforcing sleeve including a nozzle (non-pressure containing split tee) or a full
encirclement sleeve made from pipe plus a saddle may be used.
*

(4) For branch openings 2" and larger, reinforcement must meet area of replacement criteria in Section 4.
Welded branch connections larger than 2-3/8" O.D. installed on existing headers having insufficient wall
thickness for the design pressure using a 0.6 design factor must be reinforced using a full encirclement
type reinforcement having a minimum thickness of 0.375".
(5) Its use is generally considered impractical. If unusual circumstances warrant use of a 45 lateral, it shall
be commercially manufactured to meet 49 CFR Part 192.
(6) Weldolet includes related "olet" type fittings such as threadolets, sockolets, latrolets and elbolets. Note
that Table 1 indicates couplings or olet fittings of 1 or less are acceptable. Greater than 1 nominal
couplings or olets for branch connections are not acceptable for gas or hazardous liquid pipiing.

* Indicates revised paragraph, this Rev. No.

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Standard

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SELECTION AND DESIGN OF
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BRANCH REINFORCEMENT CALCULATIONS

4.1

The design of branch reinforcement for welded branch connections having branch openings larger than
two (2) inches on pressurized piping shall meet the requirements of this section as determined by the
calculations prescribed herein. For persons normally engaged in branch reinforcement design or
verification, use of a computer or programmable calculator and a suitable program is recommended to
make these "area of replacement" calculations.

4.2

When a welded branch connection is used on a new or existing pipeline, the design factor (F) used in the
design of the header and branch reinforcement shall be 0.6 unless the pipeline is in a location where
192.111 requires a lower factor.

4.3

The "reinforcement area required" (A R) shall be based on the required nominal wall thickness (t h) of the
header using the design factor (F) that would be applied if the header were being installed new.

4.4

If the reinforcement is comprised of a full encirclement sleeve made from pipe plus a weld saddle, use the
sleeve wall thickness in the area replacement calculations. The weld saddle shall be considered structural
only and shall not be included in the area replacement calculation.

4.5

Symbol Definition
4.5.1

See Figure 1 for illustration of typical reinforced branch connection geometry and symbols for
parameters used in the equations in addition to the following.

4.5.2

Input Parameters
P

= Design pressure (psig)

Sh

= Specified minimum yield strength of header material (psi)

e.g., 35,000 psi for Grade B, 42,000 psi for X-42, etc.

Sb

= Specified minimum yield strength of branch material (psi)

Ss

= Specified minimum yield strength of reinforcing saddle (or sleeve) material (psi)

= Design Factor (0.6 maximum)

Eh

= Header longitudinal joint factor

Eb

= Branch longitudinal joint factor

= Temperature derating factor

= Header nominal wall thickness (in.)

Dh
B

= Header outside diameter (in.)

= Branch nominal wall thickness (in.)

Db

= Branch outside diameter (in.)

= Saddle (or sleeve) thickness (in.) (See 3.7 of this standard)

= Saddle (or sleeve) width (in.)

= Saddle nozzle height (in.)

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4780
Page

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SELECTION AND DESIGN OF
BRANCH CONNECTIONS AND REINFORCEMENT

Issue Date

Rev. No.
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4.5.3

06/86
8
05/97

Calculated Parameters
d
K
L
J
th
tb
AR
A1
A2

= Branch inside diameter (in.)

= Intermediate dimension used in calculations (in.)
= Intermediate dimension used in calculations (in.)
= Intermediate dimension used in calculations (in.)
= Required header wall thickness (in.)
= Required branch wall thickness (in.)
= Required area of reinforcement (in 2)
= Available area of reinforcement in header wall (in 2)
= Available area of reinforcement in branch wall (in 2)

A3
A4

= Available area of reinforcement in saddle nozzle (in 2)

= Available area of reinforcement in saddle/sleeve (in 2)

a.

* = multiplication symbol

b.

Be sure to maintain the proper algebraic sign (+/-).

c.

If Sb/Sh > 1.0, use 1.0 and if Ss/Sh > 1.0, use 1.0 because credit is not allowed for
branch or reinforcement material grade greater than that of the header.

d.

If nozzle height (V) is less than or equal to saddle or sleeve thickness (M), calculated
areas represent the geometry of a straight sleeve or pad without an extruded nozzle.

AA = Total available area of reinforcement (in 2)

4.6

Equations
NOTES:

*
*

= (2.5*H) or [(2.5*B) + M], whichever is less.

= (L) or (V + 0.125), whichever is less.

= Db - (2*B).

If d > [(W/2) + 0.125], J = (W/2) + 0.125 - (d/2).

If d < [(W/2) + 0.125], J = d/2.
th

= (P*Dh )/(2*Sh *F*Eh*T).

tb

= (P*Db)/(2*Sb*F*Eb*T).

AR

= d*th .

A1

= d*(H - th).

A2

= 2*L*(B - tb)*(Sb/Sh). (See note c.)

*
*

If V > M, A3 = 1.5708*[K2 - (K - M)2]*(Ss/Sh ). (See note c.).

If V < M, A3 = 0. (See note d.)

If V > M, A4 = 2*M*(J - B - K)*(Ss/Sh ). (See note c.)

* Indicates revised paragraph, this Rev. No.

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Standard

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SELECTION AND DESIGN OF
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If V < M, A4 = 2*M*(J - B)*(Ss/Sh). (See notes c & d.)

AA = A1 + A2 + A3 + A4.

* Indicates revised paragraph, this Rev. No.

06/86
8
05/97

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Standard

4780
Page

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SELECTION AND DESIGN OF
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Issue Date

Rev. No.
Date

4.7

4.8

06/86
8
05/97

Acceptance Criteria
4.7.1

If H > th , header wall thickness is adequate. Otherwise see Section 4.8.

4.7.2

If B > tb, branch wall thickness is adequate.

4.7.3

If AA > AR, area of reinforcement is adequate.

Inadequate Wall Thickness in Existing Headers

When a welded branch connection is made to an existing header with an actual design factor numerically
greater than 0.6, a deficiency in header wall thickness will result requiring the following considerations or
modifications in the design.
4.8.1

The equation for "area available for reinforcement in the header wall" (A 1) is based on the
header wall thickness in excess of that required. This results in a negative A 1 when the actual
header wall thickness (H) is less than the required header wall thickness (t h ). Therefore, the
thickness of the added reinforcement must, as a minimum, provide a composite area of
reinforcement sufficient to offset the negative A1. This is properly accounted for in the
equations and area of replacement acceptance criteria provided the proper algebraic signs are
maintained throughout the calculations.

4.8.2

Welded branch connections larger than 2-3/8" O.D. installed on existing headers having an
actual design factor numerically greater than 0.6 must be reinforced using a full encirclement
type reinforcement having a minimum thickness of 0.375".

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4780
Page

8 of 8
SELECTION AND DESIGN OF
BRANCH CONNECTIONS AND REINFORCEMENT

Issue Date

Rev. No.
Date

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FIGURE 1
TYPICAL REINFORCED BRANCH CONNECTION

NOTES
1.

Boundary of reinforcement area established per GPTC Guide for Gas Transmission and
Distribution Piping Systems.

2.

AR = Required area of reinforcement.

3.

A1 + A2 + A3 + A4 = Available area for reinforcement.

4.

In the case of a split-sleeve reinforcement not having a nozzle, A3 will be zero (0) and
A4 will extend to the outside wall of the branch.

* Indicates revised paragraph, this Rev. No.