If memory serves, misalignment of 1/16 inch is acceptable. However, an abrupt change of thickness constitutes a stress riser, which might not be allowed in high-pressure or critical piping. In that case, the thicker I.D. could be tapered (3:1 length/depth ratio) so that the joint matches. Check the governing codes.
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• For calculating the thickness of pipe whatever it is a header or subheader (run or branch), see the following CR4 Thread: Designing High-Pressure Pipes.
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