PFI Standard ES-16

(Revised September 2008)

ACCESS HOLES, BOSSES AND PLUGS

FOR RADIOGRAPHIC INSPECTION
OF PIPE WELDS

Prepared by
Pipe Fabrication Institute Engineering Committee

All PFI Standards are advisory only. There is no

agreement to adhere to any PFI Standard and
their use by anyone is entirely voluntary.

Copyright by

PIPE FABRICATION INSTITUTE

Dedicated to Technical Advancements and Standardization in
the Pipe Fabrication Industry
Since 1913
USA CANADA
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New York, NY 10011 Lachine, QC H8T 3G6

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 PFI Standard ES-16
(Revised September 2008)

ACCESS HOLES, BOSSES AND PLUGS

FOR RADIOGRAPHIC INSPECTION OF PIPE WELDS

METRIC CONVERSIONS

The conversion of quantities between systems of units involves a determination of the number of significant digits to
be retained. All conversions depend upon the intended precision of the original quantity and are rounded to the
appropriate accuracy.
Pipe sizes together with applicable wall thickness are not shown with metric equivalents.
The SI (metric) values where included with the customary U.S. values in this Standard are the rounded equivalents of
the U.S. values and are for reference only.
Metric units were derived utilizing the following conversion factor:

Conversion Factor
_________ _____
inches to 25.4
millimeter

1. Scope
1.1 This standard covers recommendations for access holes, bosses and plugs for the radiographic inspection of pipe
butt welds where the radiographic source is located on the inside of the pipe.

2. Access Hole and Plug

2.1 For pipe wall thickness less than 5/8 in. (16mm) thick, the location and design of the access hole and plug shall be
as shown in Fig. 1 or Fig. 6.

1 1/4"
* 6"(152mm) (32mm)
4"min(102mm)
TAP 1"-8UNC-2B
2 1/4" 1/2" (13mm)
WELD METAL 1/32"(1mm) R.x.020"(1mm)
(57mm)
BUILDUP DEEP IDENT. TOOL
MARK 3/8" (10mm)
NECK 1/4" (6mm) x
5/8" 1/8" (3mm) DEEP
T (16mm)
1"-8UNC-3A 5/8" (16mm)

T = Nominal Wall
* Prefered

FIGURE 1
 PFI Standard ES-16
(Revised September 2008)

2.2 For pipe wall thickness 5/8 in. (16 mm) through 1 3/8 in. (35 mm), the location and design of the access hole and
plug shall be shown in Fig. 2.

1 1/4"
* 6"(152mm) (32mm)
4"min(102mm)
TAP 1"-8UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
NECK 1/4" (6mm) x
T 1/8" (3mm) DEEP
1"-8UNC-3A H

T = Nominal Wall
H = tm (minimum wall)
* Prefered
FIGURE 2

2.3 For pipe wall thickness over 1 3/8 in. (35 mm) through 3 in., (76 mm) the location and design of the access hole
and plug shall be as shown in Fig. 3.

1 1/4"
(32mm)

* 6"(152mm)
4"min(102mm) 1/2" (13mm)
TAP 1"-8UNC-2B 1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
NECK 1/4" (6mm) x
1 3/8" 1/8" (3mm) DEEP
(35mm) T
1 1/4"
1"-8UNC-3A (32mm)
H

T = Nominal Wall
H = tm (minimum wall)
* Prefered 13/16"
(21mm)

FIGURE 3
 PFI Standard ES-16
(Revised September 2008)

2.4 For pipe wall thickness over 3 in. (76 mm) through 5 in., (127 mm) the location and design of the access hole and
plug shall be as shown in Fig. 4.

1 3/4"
(44mm)
* 6"(152mm)
4"min(102mm) TAP 1 1/2"-6UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
1 5/8" NECK 1/4" (6mm) x
(41mm) 1/8" (3mm) DEEP
T
1 1/2"
1 1/2"-6UNC-3A (38mm)
H

T = Nominal Wall
H = tm (minimum wall)
* Prefered

1 15/64"
FIGURE 4 (31mm)

2.5 For pipe wall thickness over 5 in., (127 mm) the location and design of the access hole and plug shall be as shown
in Fig. 5.

2 1/4"
(57mm)
* 6"(152mm)
4"min(102mm) TAP 2" - 4½UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
2 1/8" NECK 1/4" (6mm) x
(54mm) 1/8" (3mm) DEEP
T
2" (51mm)
2" - 4½UNC-3A
H

T = Nominal Wall
H = tm (minimum wall)
* Prefered

1 21/32"
FIGURE 5 (42mm)
 PFI Standard ES-16
(Revised September 2008)

3. Radiographic Boss and Plug

3.1 Radiographic boss may be used in lieu of weld build-up (Fig. 1) for wall thicknesses 5/8 in. (16mm) or less to
minimize or eliminate distortion and out-of-roundness. Attachment of the boss and the plug shall be as shown in
Fig. 7.

1 1/4"
(32mm)

TAP 1"-8UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
1 3/4" DEEP IDENT. TOOL
(44mm) 1/16" MARK 3/8" (10mm)
(2mm)
NECK 1/4" (6mm) x
1/8" (3mm) DEEP

1" (25mm) 1" (25mm) 1" + T

1"-8UNC-3A (25mm) + T

9/32" (7mm) x 45° 1/16" (2mm) T

13/16"
(21mm)

T = Nominal Wall

FIGURE 6

4. Attachment of the Radiographic Boss and Seal Welding of Access Hole Plug
4.1 Attachment of the radiographic boss and seal welding of the access hole plug shall be as shown in Fig. 7.

3/8" (10mm) FILLET WELD

(TWO OR MORE PASSES)
3/8" (10mm) FILLET WELD
(TWO OR MORE PASSES)

FULL PENETRATION
WELD 1/4" (6mm) MIN.
FILLET
REINFORCEMENT

1/16" (2mm)
Boss Type Integral Type

FIGURE 7
 PFI Standard ES-16
(Revised September 2008)

5. General Comments
5.1 Upon completion of radiography and acceptance of the weld, a plug shall be inserted to close the access hole and
shall be seal welded to the pipe. Seal weld is not designed or intended to be a pressure retaining weld.

5.2 Plug and boss material selected from acceptable material specifications as listed in the applicable code and
compatible with the pipe material shall be used. Proper consideration shall be given to the integrity of the plug and
boss stock material.

5.3 Plug material designation shall be permanently marked on either the head or the side of each plug.

5.4 The boss material designation shall be permanently marked on the side of each boss.

5.5 The female RT plug threads may extend through the full thickness of the pipe wall.

5.6 It is recommended that the female threads for the plug be chased just prior to installation of the plug when PWHT
has been performed.
 CHARTER MEMBERS
ACCO ENGINEERED SYSTEMS Glendale, California
AECON INDUSTRIAL Cambridge, Ontario (Canada)
A & G PIPING, INC. Forth Worth, Texas
ARMISTEAD MECHANICAL, INC. Mahwah, New Jersey
BASSETT MECHANICAL, INC. Kaukauna, Wisconsin
DIXIE MECHANICAL, INC. Tuscaloosa, Alabama
ENERPIPE SYSTEMS, INC. New London, Wisconsin
GASTIER INTERNATIONAL, INC. Anjou, Quebec (Canada)
GEM INDUSTRIAL, INC. Walbridge, Ohio
GREAT LAKES MECHANICAL, INC. Little Chute, Wisconsin
HIGH PURITY SYSTEMS, INC. Manassas, Virginia
IDEAL WELDERS, LTD. Delta, British Columbia (Canada)
INDUSTRIAL POWER SYSTEMS, INC. Toledo, Ohio
J. F. AHERN CO. Fond du Lac, Wisconsin
JOHN E. GREEN COMPANY Highland Park, Michigan
KINETIC SYSTEMS, INC. Union City, California
LAWDAN UNDUSTRIES St. Paul, Minnesota
MARELICH MECHANICAL CO. INC. Hayward, California
MC ABEE CONSTRUCTION, INC. Tuscaloosa, Alabama
MC CARL’S, INC. Beaver Falls, Pennsylvania
MECHANICAL INC. – A HELM GROUP CO. Freeport, Illinois
MURPHY COMPANY St. Louis, Missouri
NARDEI FABRICATORS, LTD. Calgary, Alberta (Canada)
P1 GROUP, INC. Lawrence, Kansas
PERFORMANCE MECHANICAL, INC. Pittsburg, California
PIONEER PIPE, INC. Marietta, Ohio
PIPE FABRICATING & SUPPLY CO. Woods Cross, Utah
PIPING SYSTEMS, INC. Kaukauna, Wisconsin
S. A. COMUNALE COMPANY, INC. Barberton, Ohio
S & D / OSTERFELD MECHANICAL CONTRACTORS Dayton, Ohio
SCHECK MECHANICAL WI CORP. Kaukauna, Wisconsin
SHAW MID-STATES PIPE FABRICATING, INC. El Dorado, Arkansas
TEAM INDUSTRIES, INC. Kaukauna, Wisconsin
UNIVERSITY MECHANICAL & ENGINEERING CO. San Diego, California
WESTLAKE INDUSTRIES, INC. Burlington, Ontario (Canada)
W. SOULE & COMPANY Portage, Michigan
W. J. O'NEIL COMPANY Livonia, Michigan
Associate and Affiliate member contributors
Dave Stanzel Miller Electric Mfg. Co. Appleton, WI
Walter Sperko Sperko Engineering Services, Inc. Greensboro, NC
Thomas Warrelmann Victaulic Company of America Easton, PA
Sheryl Michalak Welding Outlets, Inc. Houston, TX

Visit our website www.pfi-institute.org for an up to date list of all PFI Members and their website

A current index of the latest revised ES Standards, Technical Bulletins and Safety Training Guideline is available from the Pipe
Fabrication Institute.
PFI Safety Training Guideline, Standards and Technical Bulletins are published to serve proven needs of the pipe fabricating industry
at the design level and in actual shop operations. Hence, such needs are continually considered and reviewed by the Engineering
Committee of the Pipe Fabrication Institute to provide recommended procedures, which have been demonstrated by collective
experiences to fulfill requirements in a manner for Code compliance. However, as the PFI Standards are for minimum requirements the
designer or fabricator always has the option of specifying supplementary conditions in the form of requirements beyond the scope of
the PFI publications.