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Nuts are tightened only enough to make flanges stay in contact. The pressure does the rest. Lower tensing bolting is used. No special care is required. NO calculations here. Regards

RTJ octagonal for this pressure. Regards

Stop service before performing any repairs.

Any photo?

Also, seamless pipe for hygienic service (food, pharmaceutic).

OD= take a measurement of the external perimeter and divide by PI.

Metal gasket is better for external pressure (shell side pressure). Regards

How was the outer diameter measured? Do not confuse outer diameter with ovality.

How was the outer diameter measured? Do not confuse outer diameter with ovality. Regards

Seamless pipe for Lethal service and Nuclear.

@ jt1234 Again, you are not helping the OP. Do you have any experience with the OP issue?

A support welded to the pipe can cause excessive heat input to the pipe. Lack of preheat for welding can cause serious problems. Welds cause residual stress that is impossible to measure and may require PWHT. Some welds during installation are not inspected. The pad requires an air test. Kelow...

Where is the average term? Regards

Fillet weld is a pressure retaining in socket fitting. Regards

Never weld on pipes, elbows, ....fittings made of SS material and for any thickness.

Why don't you read b16.9? Regards

See ASME B16.9 2.2 .......fittings may have to be thicker than the pipe wall........

@ goutam You are very confused. I'm sorry to tell you, but I suggest you take some pressure vessel training. Regards

Piping: design pressure / temperature?, diameter of sch10s?

Once more you are wrong IT SEEMS IMPOSSIBLE for you to understand what the OP says in his NOV 2 sketch: the body flange is a WELDING NECK, it is full penetration butt weld !