QAULITY CONTROL ENGINEER’S- PIPING GUIDE
1) WHAT IS WPS?
It’s an abbreviation for welding procedure specification is a specification for all
the piping materials and filler material which will be used in a plant to ASME
code and ANSI B31 Series.
2) ANSI/ASME CODES :
a) ASME B 31.1
- Power Piping
b) ASME B 31.3
- Process Piping
c) ASME B 31.4
- Pipeline Transport Systems for Liquid Hydrocarbons
And Other Liquids.
d) ASME B 31.8
- Gas Piping
e) ASME BPV CODE: - ASME IX (Welding and Brazing Qualifications), ASME V
(Non Destructive Examinations), ASME VIII Div.1 (Rule
For Construction for Pressure Vessels).
3) FOUR TYPES OF GASKET :
a) Asbestos gasket
b) Ring gasket ( ring, octagonal, oval )
c) Spiral wound ( metal )
d) Titanium gasket
4) E – 7016 is a type of welding rod. What does under lined number indicate?
Tensile strength is – 70 ksi (70,000 psi)
5) What is FF elevation?
Elevation of pipe flange faces which is connected to equipment nozzle.
1
6) Five Types of Non Destructive Examination :
a) Liquid Penentrant Test
b) Magnetic Particle Test
c) Radiographic Test
d) Ultrasonic Test
e) Visual Test
7) Three Types of Destructive Examination :
a) Impact Test
b) Bend Test
c) Tensile Test
8) What is Expansion Joint?
Joint that is fabricated to allow lines expansion or contraction due to fluids
Temp. Change.
9) What is JIS equivalent of ASTM A53 Gr B?
STPG 42
10) What is punch list?
List of unfinished work or unmatched item according to DRWG and spec.
Before Hydro test.
11) Explain color coding?
Marking of piping bulk materials to identify the Material.
12) What is Steam Trap?
Trap Water which is formed when the steam is condensate.
13) What is the use of Lateral?
Limit fluids Resistance and minimize choak of pipe due to foreign material.
14) What does holiday detector detect?
Pin holes in Coating and Wrapping.
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15) What is the role of Venturi?
Fluid amount check.
16) What is the Reason for installing a loop in piping?
To ease Expansion and contraction of pipe due to fluid temp. Change.
17) What is cathodic protection?
Way of protecting metal against corrosion by passing a small electric current
Between the metal surface and the surrounding ground or water.
18) What is the break flange?
For Maintenance of Vertical pump, Exchanger, Drums and other equipment.
19) What is the Insulation Kit?
To isolate between above ground and under ground.
20) Type of Supports:
Spring support, Hanger support, and Dummy support, Shoe, Anchor, Guide
And Pick up.
21) Welding Rods to be used according to AWS CODES :
a) A312 TP 316L
-GTAW ER 316L
SMAW – E316L
b) A312 TP321
-GTAW ER 347
SMAW – E347
c) A335 P22
-GTAW ER 90S – B3
SMAW - E9016 B3
22) What Backing gas should be used when welding stainless steel or Alloy
Steel and what shall be the purity of this Gas?
Argon – 99.9 %.
23) Control Valve?
Is usually chosen to be smaller than line size to avoid
Throttling and consequent rapid wear of the Seat.
24) Design of any processing plant is usually accomplished in Three Phases :
a) Conceptual Design – are made when sketchy or minimal information is
used to prepare an abstract arrangement of a plot plan or an equipment
and piping layout.
b) Preliminary or study phase – design are made with unchecked or
uncertified data to design a facility in sufficient detail so that the
document produced can be used for detail design.
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c) Detail phase – All design are finalized, the design used such checked
Data as steel and concrete, drawings, hydraulic and certified vendors
Drawings for equipment valves and Instruments.
25) Open system: Is one in which the content of a line are discharged and not
Recovered.
26) Closed system: Is one which the contents of relief system or steam trap
Condensates are recovered.
27) Steam Turbine: Are used where there is a readily available source of steam
And are also used to drive stand by process pumps in critical
Service in the event of an electrical power failure and
Emergency stand by equipment such as fire water pumps and
Electrical generators.
28) Turbine: Is a machine for deriving mechanical power (rotating shaft) from the
Expansion of a gas or Vapor (usually air or steam in industrial
Plants).
29) Diaphragm: These forms of diaphragm valve are popular for regulating the
Flow of slurries and Corrosive fluids and for vacuum.
30) NPSH: Net Positive Suction Head.
31) Safety Relief Valve: Relieves excess pressure of either gas or liquid which may
Suddenly develop A vapor phase due to rapid and
Uncontrolled heating from Chemical reaction in liquid
Laden vessel.
32) Butterfly Valve: Used for liquid, slurries, powders and vacuum. The usual
Resilient plastic seat has a temperature limitation but tight
Closure at high temperature.
33) Check Valve: Designed to permit flow of liquid or gas in a one direction and
Close if flow reverses.
34) Gate Valve: Use for water, gas, steam, slurries line suitable for throttling and
Full flow use.
34) Globe Valve: Use for regulating flow should be from seat stem side, assist
Closure and to Prevent the disc chattering against the seat in
The Throttling position
.
35) Carbon Steel: Lose strength at high temperature; electric resistance welder
(ERW) pipe is not considered satisfactory for service about
750*F and furnace butt Welded (FBW) pipe above about 650*F.
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36) Steam Tracing: To prevent fluid from congealing, forming hydrates,
Condensing, interfering with Operation or causing any
Damage to piping, equipment and instrument.
37) Expansion Joint: To accommodate movement in piping due to temperature
Changes and also used to absorb vibration.
38) Control Station: Is an arrangement of piping in which a control valve is used
To reduced and regulate the pressure or rate of flow of
Steam, gas or liquid.
39) In Horizontal runs: The taps are located at the tops of the flanges in gas,
Steam and vapors Lines, an approximately horizontal
Position avoids vapors locks in Liquid lines.
40) Vents: Are needed to let gas usually air in and out of service. Basically remove
The air pocket from the line.
41) Break Flange: Piping connected to channel head nozzle should be furnished
With break flange to facilitate the removal of the channel head.
42) Separators: Used to collect droplets from a gaseous stream. ( Ex : To collects
Oil droplets from a Compressed air or condensates droplets from
Wet Steam.
43) Temporary strainers: Used for start – up operations on the suction side of
Pumps and Compressors, after start – up the screen
Usually are removed.
44) Thermal Stresses: Changes in temperature of piping due either to change
Temperature of The environment or of the conveyed fluid
Cause changes in length of the piping.
45) Steam Traps: The purpose of fitting traps is to obtain fast heating of system
And equipment by Freeing the steam lines of condensates and
Air.
47) Heater: Heats a process stream by condensing steam.
48) Condenser: Condenses vapors by transferring heat to cooling water,
Atmospheric air or other Media.
49) Chiller: Cools a process stream to very low temperature by evaporating a
Refrigerant
50) Two kinds of Steam Turbine:
a) Back Pressure Turbine: Are driven by high pressure steam and
Do not require surface condenser.
b) Condensing Turbine: Are usually driven by low pressure steam.
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51) Gas Turbines: Are used in various application including gas transmission
Gas lift, liquid pumping, gas re injection and process
Compressor.
52) Inter Coolers: Are primarily used to reduce the operating temperature with in
A compressor Circuit which allows the use a smaller machine
With fewer cylinders
53) Compressor Machine: Are used to increase the pressure of a gas by
Mechanically reducing its Volume with in its case.
54) Condensate Pump: The condensate pump is usually vertical removes the
Condensates from the hot well in the surface condense.
Condensates form during Liquefaction in the condenser
And are collected in the hotwell.
55) Drums: Collects liquids from vapors circuits and pump it to other process
Groups, disposal or product storage. Used in process plant as
Intermediate containers that Received liquid from distillation and
Condensing equipment
56) Coolers: Cools a process stream by transferring heat to cooling water,
Atmosphere and other media.
57) Heat Exchanger: The principal application of a heat exchanger is to maintain
A heat balance through the addition or removal source or
Between streams of two different operating temperatures.
58) Reactor: Are used in processing facilities to contain catalyst that promote
Chemical reaction of feeds. Reactor is generally vertical steel
Hallow Vessels and often operate under very high temperature and
Pressure.
59) Tower: Are cylindrical steel vessel that are used for distillation of materials
In the production of such products as gasoline, diesel and heating oil.
60) Non- Destructive: Knowing the internal defect of weld without changing the
Appearance of the Material.
61) Inconel: A High Nickel Alloy containing chromium and Iron, resistant to
Oxidation and Corrosion.
61) Knock out Drum: A stream of gas containing drops of liquid is passed
Through a knock out Drum in order to slow down the flow
And allows the liquid to separate and collect.
62) Pump Suction: Eccentric reducers are used in lines 2 ½” and larger and
Arranged to avoid Creating a vapor space and creating a
Pocket which would need to be drained.
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63) Valves are used for these purposes:
a) Process control during operation.
b) Controlling services and utilities, steam, water, and
air, gas, and Oil.
c) Isolating equipment or instruments for maintenance.
d) Discharging gas, vapor and liquid.
e) Draining piping and equipment – on shutdown.
f)
Emergency shutdown in the event of plant mishap or
Fire.
64) Venturi meter: Instrument for measuring of gas or liquid measuring the
Decreased pressure so caused.
65) Slip on flange: Has poor resistance to shock and vibration easier to align
Than the welding neck Flange, calculated strength under
Internal pressure is about one third that of the corresponding
The weld neck flange.
66) Weld Neck Flange: Suitable where extreme temperature shear impact and
Vibratory stresses Apply primarily use for vessel and
Equipment nozzle.
67) Support types are defined as follows:
a) Anchor - a support fixing the piping completely.
b) Guide - a support restricting the movement perpendicular to pipe
axis, but the axial movement is allowed.
c) Hanger - a support hanging the piping.
d)
Spring - a resilient support which allows vertical movement.
e)
Resting Support - a simple support bearing the pipe weight only.
f)
Directional Stop - a support restricting the movement of a certain
Direction.
g)
3 – Way Restraint - a support restricting the movements of three
Directions, but permitting the rotation.
h) Pick up Support - a support resting small diameter pipe using large
Diameter pipe instead of steel structure.
68) Seal Welds: may be used only to prevent leakage of threaded joints and not to
Be considered as contributing any strength to the joints.
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69) Threaded joints checklist:
a) What is the maximum diameter piping allowed in
hazardous Service?
( 1.1/2” )
b) What is the minimum sized piping that can be installed
on pipe racks?
( 1” )
70) How many threads can be visible after seal welding threaded joints?
Zero. Seal welding must cover all threads.
71) What is the gap requirement for socket welds for new construction?
1.5 mm to 3.0 mm gap prior to welding.
72) What is the best way to assure consistent gap is maintained?
Use of gap –o- let rings.
73) What is the minimum fillet weld size for a socket welded connection?
1-1/4t but not less than 3.2 mm.
74) What are common failures in the quality system during fit up that leads
To hydro test failures?
Failure to properly clean, de burrs and degreases fittings and piping prior to
Welding. Oil residue from cutting causes through weld porosity and leakage
During hydro tests.
75) Welded branch connections (check lists):
a) Follow spec. branch connection tables and standard drawings to
determine required construction.
b) Have the tell- tale holes for air testing been drilled, tapped, de
burred and oil removed by cleaning ( sand blasting ).
c) Has the branch to header weld been welded flush. NDT performed,
accepted prior to fit up of reinforcement pad.
d) Has the repad been properly cold worked and radiuses to meet the
piping OD and assure good fit up. No hammer marks.
e) Do not allow flange tack welding above the branch connection until
the repad fit is acceptable. Maximum gap is 1.6 mm.
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f)
A 6 mm gap maximum is allowed between repad and branch for
root opening.
g) Follow preheat tables and W – 011 requirements for GTAW &
SMAW process on welding.
76) Supports – Check lists:
a) What critical over looked requirement on support installation
causes the most
Rework?
Fit up, elevation and slope per AFC drawings, this checked by
survey or level
( String line ) in accordance with PIPS and procedures.
b) What is an expansion loop?
Expansion loop is the piping arrangement, which allows the
movement of the pipe
During operation with high temperature and pressure and during
the shut down , piping will come down to cool condition. During the
both period, with the help of Expansion Loop, the pipes are Expand
/ contract accordingly.
77) What is a guide?
It will control the horizontal movements of the pipe.
78) When should shims be installed?
To correct movement and correct misalignment and provide full bearing of
Support as needed.
79) Give Examples of unique support details that allow piping freedom of
Movement for thermal Expansion:
a) Teflon slides, wear pads, spring hangers, hydraulic
Snobbery and expansion Joints.
80) Clearances:
a) 50 mm rule between all piping and supports.
b) 24” clearance from supports, dead legs, drain and vents.
c) 300 mm from grade @ all piping.
d) Fittings, butt welds, etc, adjacent to hangers, clamps,
supports, etc must be spaced to allow freedom of piping
movement. Alternatively, flush grind and NDT can be allowed
as long as weld location will not restrict piping movement.
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81) Serrated Finish: Is used with asbestos and other gaskets. The regular smooth
Finish is used with Gaskets made from hard materials and
With spiral wound gaskets. Cold water finish is normally
Used without gaskets.
82) Gaskets: Are used to make a fluid resistant seal between two surfaces.
83) Choice of gasket is decided by:
a) Temperature, pressure and corrosive nature of the conveyed
fluid.
b) Whether maintenance or operation requires repeated
uncoupling.
c) Code requirements that may apply.
d) Cost.
84) Drip legs: Often made from pipe and fittings, the drip leg is an inexpensive
Means of collecting Condensate. Removal of condensates from
Steam lines.
85) Hanger Support: Device which suspends piping (usually a single line) from
Structural steel, or Steel and concrete. Hanger is usually
Adjustable for height.
86) Saddle: A welded attachment for pipe requiring insulation and subject to
Longitudinal or rolling Movement (resulting from temperature
Changes)
87) Piping and Instrument diagram: This drawing is commonly referred to as
The P & ID. Its object is to indicate all process and service lines, instrument
And controls, equipment, and data necessary for the design group. The
Process flow diagram is the primary source of information for Developing the
P&ID’S.
88) Dry Steam: Is a gas, consisting of water vapor only. Placed in contact with
Water at the same Temperature, dry steam will not condense, nor
Will more steam form – Liquid and vapor are in equilibrium.
89) Wet Steam: Consists of water vapor and suspended water particles at the
Same temperature as the vapor. Heating ability ( quality ) varies
With the percentage of dry steam in the mixture ( the Water
Particles contain to latent heat of Vaporization ) Like dry steam,
Wet steam is in equilibrium with water at the same temperature.
90) Super heated steam: If heat is added to a quantity of dry steam, the
Temperature of the steam Will rise and the number of
Degrees rise in temperature is the degrees of superheat.
Thus Super Heat is sensible heat – that is it can be
Measured by a thermometer.
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91) Condensate: What it is & how it forms: Steam in a line will give up heat to the
Piping and surroundings, and will gradually become Wetter, its
Temperature remaining the same. The change of state of part of
The vapor to liquid Gives heat to the piping without lowering the
Temperature in the line. The water that forms is termed
‘Condensate’ of the line initially contains super heated steam,
Heat loss to the piping and Surroundings will first cause the
Steam to lose sensible heat until the steam temperature drops
To that of dry steam at the line pressure.
92) Steam Traps: Are designed to react to changes in temperature, pressure or
Density.
Temperature sensitive (or Thermostatic) traps – Are of Two Types:
The first Type operates by the movement of a liquid filled
bellows, and the second uses a bimetal element. Both
types are open when cold and readily discharge air and
Condensate at start up. As these traps are actuated by
temperature differential, they are economic at steam
pressure greater than 6 PSIG.
Impulse traps: are also referred to as ‘thermo dynamic’
and controlled disc. These traps are most suitable to
applications where the pressure down stream of the trap
is less than half the up stream pressure. Water hammer
does not affect Operation. They suitable for steam
pressure over 8 PSIG.
Density Sensitive Traps are made in float and bucket
designs. The float trap is Able to discharge air unless
fitted with a temperature sensitive vent ( the Temperature
limitation of the vent should be checked ).
Floats traps some times may fail from severe water
Hammer.
Inverted bucket trap is probably the most used type. The
trap is open when Cold, but will not discharge large
quantities of air at start – up unless the bucket is fitted
with a temperature sensitive vent. The action in
discharging condensate is rapid inverted bucket traps will
operate at pressure down to ¼ psig.
93) What are the common type of valves and its function?
Gate Valve – on / off service
Globe valve – throttling service
Check valve – non return valve
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94) Where will you place the level gauge of a kettle type reboiler?
After the weir.
95) What is insulated flange?
A flange said that is electrically insulated, composed of insulating gasket,
Washer and sleeve.
96) An Inspection & Test Plan?
A mandatory item in the quality plan that guides and assures quality in a
Specific type of work in Basic sequence of QC activity steps.
97) A Quality Control Procedure?
A document that details the specific steps needed to fulfill the QC activity in
The ITP.
98) Quality Control Form?
A written documentation detailing a specific activity in the ITP & QC procedure
99) What is a specification?
A specification is a guide line to assure that minimum Quality standards are
Met.
100) what types of inspection action points are found in the ITP?
Hold, Witness, Surveillance, and Review.
101) what is the differences between the 4 types of inspection points?
Detail answer and ensure a clear under standing by candidate.
102) what is a P& ID?
Piping and instrument diagram will show the piping layout and detailed notes
Relating to piping and instrumentation.
103) what is SIS?
Safety Instruction Sheet that gives full design details related to a piping
System or Line.
104) what is a piping system?
Describes the specific service or fluid.
105) what is the piping line class designation?
A specific name in alphanumeric designation describes features of a piping
System.
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106) Show example of a line designation from isometric drawing?
ICS1P3 = 150# class, Carbon Steel, 1/16” CA, General hydro carbon.
107) what is an isometric drawing?
A detailed piping system/line drawing with reference to construction and
Material Requirements
108) what things are found in a piping isometric drawing?
Line conditions, references to drawings, materials of construction, elevations,
Orientation, piping And drawing details and notes, revision control and
Approval status.
109) what is a Material list or Material Take off Sheet (MTO)?
Details of materials used in construction of piping, using with isometrics.
110) what is a PIP?
Process Industry Practice details requirements for fabrication an Industry
Practice. These are often the basis for SA standards.
111) Material Inspection:
a) How do you verify the material, and mention several items to check?
Mill Certificate, heat number, color coding and PMI, schedule, rating,
Carbon equivalent
Value for PREHEAT, diameter, class, grade.
b) How do you identify fitting and flanges?
Correct ratings, sizes, class, schedules as marked on fittings & mill
certificates.
c) How do you check piping for the correct schedule?
Use a Vernier Caliper and ensure piping is within tolerances.
d) What are the tolerances for physical piping straightness and defects?
Check the ASTM or API piping specification.
e) What is standard mill tolerance for piping?
87 ½ % (all) to 115% (greater than 2”), 120% (2” & less) of nominal.
f)
How to check Valves of the correct rating and material?
CMTRs & trim during Valve testing (Visual inspection)
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112) Name the different types of mating flanges?
RFWNF, RFSO, RTJ and FF.
113) what kind of the inspection required during Gasket installation?
Check the Gasket material as per the drawing and specification, size, rating
And visual Inspection of surface damages.
114) what is the difference between bolt torque of CS and SS bolting?
Yield strength is greater in Carbon and torque values are greater.
115) Explain ‘Spectacle’ plate:
Used for Service and shutdown (isolation) for maintenance purposes.
116) what are Jack Screws and when are they required?
They are located at flanged connections to facilitate maintenance and removal
Of flange and Orifice plates to facilitate maintenance.
117) what item to be checked during orifice flange fabrication?
Flush Grinding of butt welds of the orifice flange inside and seal welding of o
Orifice tapping Pipes.
118) what are the NDT methods are required during orifice flange
Installations?
Visual and PT / MT.
119) what is cold spring?
Application of Mechanical Stress ( bending, twisting, pulling ) upon a piping
Segment to Achieve
Bolting and on to another segment.
120)
Is cold spring acceptable?
No!
121)
Flange connects to a pump or other equipment, is there any physical
Tolerance involved?
Yes, Manufacturer tolerance.
122) Check list for Reinstatement:
# Check that correct bolts and gaskets are installed at all reinstated joints
Completed and Recorded.
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# Check that all process blinds and spades have been correctly installed as
Indicated on the P&ID.
# Check that spectacle blinds are in the correct position.
# Check that correct valves have been installed in the correct ‘Flow’ position.
# Check that specified block valves have locking devices correctly installed.
# Check that all valves are functioning properly and that spindle has been
Coated with copa-slip Are equaled there specified.
# Check that relief valve have been correctly installed.
# Check that all pump suction strainers have been correctly installed.
# checks that correct flow through filters, and strainers, traps, check valves
And globe valves.
# Release for final equipment alignment.
# Hydro test completed.
123) HYDRO TEST PACKAGE REVIEW:
1) P&ID for correct revision.
2) Isometric drawing for correct revision.
3) Isometric Drawing confirm to P&ID.
4) Boundaries of hydro test, filling / draining / vent point and
ensure all necessary P&ID‘s / Isometric are in the package.
5) Ensure all line listed in test package are identified and test
pressure is correct as per LDT.
6) Check blind lists of sizes, thickness and rating.
7) Check exception list.
124)
THE CONTENTS OF TEST PACKAGES ARE:
1) Marked up P&ID and isometric drawings showing the location
and type of Pipes support, the boundaries of the test, valve
position and the location of Vents, drains, temporary blinds ( size
and thickness ), and the water fill Point and pressure gauges.
2) The test medium and pressure.
3) A piping line list.
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125) SOME APPLICABLE LINE CHECK PUNCH:
Check Point:
Description:
1) Completion of Welding Inspection Report
& WPS
Inspection class, NDE, PWHT
2) Appearance of welds
Crack, under cut, overlap, arc
Strike, fillet size etc.
3) Distance Between welds Closeness.
4) Orifice flange, Orifice run, Nozzle orientation.
5) Position of welding earth
6) Deformation of material.
Orientation of tapping, smoothness
Of Inside surface.
No structure and temporary
Support.
7) Weep hole.
Dent, deforming by construction
Work.
On pad, support, PSV vent.
8) Branch and Nozzle.
Orientation, location.
9) Verticality, Horizontality and slope.
As per isometric drawing.
10) Piping connection to Equipment nozzle.
Any extra force or movement is
Prohibited.
11) Support and shoe.
Type, location, removal, clearance
12) Gasket.
Type, material, size, gasket no.
13) Valve.
Type, material, size, flow direction.
14) Bolt & nuts.
15) Blank plate.
Type, material, size, length,
Tightness.
Type, material, size, blind no.
16) Jack screw.
Type, material, size.
17) Drain and vent.
Location, size, orientation.
18) Piping line class break.
Material, location, rating class as
Shown in P&ID.
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TABLE FOR GASKET:
GASKET MATERIAL
Synthetic rubbers
Vegetables Fiber
Solid Teflon
Compressed Asbestos
Carbon Steel
Stainless Steel
Spiral Wound
a) Teflon
b) Cs / Asbestos
c) SS / Asbestos
d) SS / Ceramics
PIPE SIZE
12”
8”
6”
4”
3”
2”
1-1/2”
1”
¾”
½”
EXAMPLE USE
Water, Air
Oil
Chemicals
Most
High Pressure Fluid
HP.Fluid / Corrosive
Chemicals
Most
Corrosive
Chemicals
Hot Gases
MAX. SPAN ( M )
12
11
10
8.6
8
6.7
5.4
4.5
4.5
4
MAX. TEMP. DEG.F
250
250
500
750
750
1200
750
1200
500
1900
DEFLECTION ( MM )
3
3
3.3
3.3
4.3
4.6
4.6
4.8
4.6
4.3
NOTE : This is calculated as following condition. ASTM A 53 SCH. 40. Full water, continuous beam.
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Table – 1
Guide for selection of Welding Electrodes and Filler Metal Rods.
Base metal ( ASTM / ASME )
Product Forms
PLATE
PIPE
Welding Metal ( AWS )
FORGING
TUBE
A106 GR.B
API 5L – B
A53 GR.B
A105
CARBON STEEL
A179
A216- WCB
A387 GR.1
A387 GR.12
A387 GR.11
A387 GR.22
A335 – P1
A335 – P12
A335 – P11
A335 – P22
A182-F1
A182-F12
A182-F11
A182-F22
A240-304L
A312-TP304L
A240-316L
A312-TP316L
904 L
A790
SAF 2205
A790
316L U.G.
316L U.G.
316L U.G.
310MoL
310MoL
310MoL
Incoloy 800HT
Alloy 20
Incoloy 800HT
A516 GR. 70
A515 GR. 70
A285 GR. B
LOW ALLOY STEEL
A213-T1
A217-WC1
A213-T12
A217-WC4
A213-T11
A217-WC6
A213-T22
A217-WC9
STAINLESS STEEL
A182-F304L A213A351-CF3
TP304L
A182-316L
A213A351-CF3M
TP316L
A789
A789
SPECIALITY ALLOYS
316L U.G.
310MoL
HK-40
25-35-Cb
Mod.
SL.NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CASTING
ELECTRODE
( SMAW )
FILLER METAL
( GTAW )
E - 7018
ER – 70S-2
E-7018-A1
E-8018-B2
E-8018-B2
E-9018-B3
ER-80S-G
ER-80S-B2
ER-80S-B2
ER-90S-B3
E 308L-16
ER-308L
E 316L-16
ER-316L
FOX CN 20 /
25M
E2209-17
ER-2209
E310LMo
Incoloy 800HT
HK-40
25-35-Cb
Mod.
Inconel 112
Inconel 117
E310 H
Inconel 117
Thermanit
19 / 15H
Thermanit
25 / 22H
Inconel 625
Inconel 617
ER-310H
Inconel 617
SPECIFICATIONS FOR CARBON STEEL SYSTEM
COMMODITY
B31.3
Pipe
ASTM A53 / API 5L
Pipe – Low Temperature
ASTM A333 Gr6
Pipe – High Temperature
ASTM A106
Bolting
ASTM A193 B7 / ASTM A320
Nut
ASTM A194 2H
Fittings
ASTM A234 WPB
Fittings – Low Temperature
ASTM A420 WPL6
Fittings – High Temperature
ASTM A234 WPB
ASTM A216 WCB
Valves
ASTM A105 / API 600
Valves – Low Temperature
ASTM A350 LF2 / ASTM A352 LCB
Valves – High Temperature
ASTM A216 WCB
Flanges
ASTM A105/ ASTM A181/ ASME B16.5
Flanges – Low Temperature
ASTM A350 LF2 / ASTM A352 LCB
Flanges – High Temperature
ASTM A105/ ASTM A181/ ASTM A216 WCB
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THE CHECK LIST FOR PIPING WORK COMPLETION NEEDS TO BE CONFIRMED
BEFORE THE
PRESSURE TEST CAN COMMENCE:
CHECK LIST IS AS FOLLOWS:
1) Piping should be Correct Dimension, Location and Orientation.
2) Welding Completed.
3) NDE Completed.
4) PWHT and Hardness Test Completed.
5) Valve, in line item and line Equipment Completed.
6) Support and Hanger installation Completed.
7) Material Thickness Verification / Color Code.
8) P&ID Walk through in accordance with Isometric drawings.
9) All instruments are disconnected or not.
BEFORE THE TESTING COMMENCES SOME OF THE GENERAL REQUIREMENT TO
BE CHECK AND REVIEW.
1) Test Pressure to be used shall not less than 1.5 times the design pressure.
2) Water to be used shall be fresh water and free from sediments. The Maximum
Chloride content shall be less than 30 ppm.
3) For Pneumatic testing, the test medium shall be Air or any other non-flammable
gas and the test pressure shall be 110 % of the design pressure. For pneumatic
test, the soap solution spray shall be used during leakage detection.
4) The Temporary supports are to be examined to ensure that they will adequately
support the line during testing.
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TEST SEQUENCES ARE:
1) Filling Test System Completely with water or Air.
2) Fill the water from the down side.
3) Open all vent valves during Water filling.
4) Applying pressure gradually until the specified test pressure is reached.
5) Holding time is 10 minutes minimum. The test pressure is attained until all
welds and connection have been examined. (shall not over pressurize the
system)
6) After the test, the system was drained to minimize standing water in the line. Air
blowing to be performed to remove the remaining water.
VALVE INSPECTION AND TESTING: (API 598)
The following tests and examinations are specified in this standard.
a) Shell Test.
b) Back Seat Test.
c) Low Pressure Closure Test.
d) High Pressure Closure Test.
e) Visual Examination of Castings.
SAMPLE OF PUNCH LIST ITEM:
1) To install permanent gasket after test.
2) Apply Molycote to all bolts.
3) Bolt Length not correct.
4) Apply Grease to all Valve spindles.
5) Re install cap with Teflon tape.
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VALVE INSTALLATION GUIDE:
a) The height of the hand wheel of normal operating valve shall not be more
than 1800 mm above operating level. As alternative permanent plat form
may be provided.
b) Maintenance valves more than 2000 mm above operating level for NPS 2”
and larger shall be provided with chain operating with client approval.
Valve should not be positioned with their stem pointing down ward below
horizontal with following exceptions:
a) No horizontally positioned stems in low temperature service.
b) Butterfly valves shall not be installed with the spindle in the vertical
position for services where collection of dirt in the lower shaft bearing
could occur.
c) Gate valves installed around safety / relief valves and in flare lines shall
be positioned with the stem pointing horizontally.
126)
what is Fractionation?
A Distillation Process Where in several distillates such as Wax Distillates,
Gas oil, heating oil, Naphtha and Fuel Gases are formed. Usual feed is
the Crude oil.
127)
What is Distillation?
A Process Wherein the lighters fluid is separated from the heavier fluid.
128)
What type of support for horizontal vessel?
Saddle support.
129)
What type of support for Vertical vessel?
Skirt support.
130)
What is the minimum class rating for a Control Valve?
300 lbs.
131)
What is the minimum class rating of bypass valve?
300 lbs.
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132)
What is the minimum class rating for an orifice flange?
300 lbs.
133)
What is the common material use for pipe, fittings, valves, flanges,
gasket & bolts?
Pipe – A53, API 5L
Fittings – A234 Gr.B
Valves – ANSI B16.5
Flanges – A105 Gr.11
Gasket – ANSI – B16.5
Bolts & Nuts – ANSI B1.1
134)
What is the position of the reducer in the suction side of pump and
its purpose?
It must be position top flat not to create bubbles of Air that will corrode
the surface of the blade.
135)
What is a Flare?
A system that disposes the plants waste gases.
136)
What is HAZOP?
Hazop is hazards in the installation of Equipment and operability of the
equipment.
137)
What is the minimum spacing of platform?
2.1 meters.
138)
What is the minimum horizontal spacing for personnel?
1 meter.
139)
What is the minimum vertical spacing for personnel?
2.1 meters.
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140)
What are the common basic functions of Instruments?
1) To sense 2) to transmit 3) to indicate 4) to record 5) to control
141)
Thermal Stresses:
Changes in temperature of piping, due either to change in temperature
Of the environment or of the conveyed fluid, cause changes in length of
the piping. This expansion or contraction in turn causes strains in
piping, supports and attached equipment.
142)
Flexibility in piping :
To reduce strains in piping caused by substantial thermal movement,
Flexible and Expansion joints may be used. How ever the use of these
Joints may be minimized by arranging piping in a flexible manner. Pipe
Can flex in a direction perpendicular to its Length, thus the longer an
Offset, or the deeper a loop, the more flexibility is gained.
143)
Where to place the valves :
a) Preferably place valves in lines from headers (on pipe racks) in
Horizontal rather than Vertical runs, so that lines can drain when the
Valves are closed.
b) To avoid spooling unnecessary length of pipe, mount valves directly
Onto flanged Equipment.
c) A relief valve that discharges into a header should be placed higher
Than the header in
Order to drain into it.
d) Locate heavy valves near suitable supports points. Flanges should be
Not closer than 12 Inches to nearest support, so that installation is not
Hampered.
144)
Utility station:
Usually comprises four service lines carrying Steam, Utility Air, Service
Water and Nitrogen.
145)
Two Basic types of spring support:
a) Variable Load.
b) Constant Load.
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146)
Relief Headers :
Headers should be sized to handle adequately the large amounts of Vapor
and liquid that may be discharged during major mishap. Relief Headers
taken to knock out drums, receivers or incinerators are normally sloped.
147)
Steam Pressure for Tracing:
Steam pressures in the range of 10 to 200 psig are used. Some times
steam will be available at a suitable pressure for the tracing system.
148)
Correct Pre heating temperature:
a) A335 P9 ( all thk )………… 177*C over.
b) A335 P11 ( all thk ) ………..149*C over.
c) A53 Gr. B ( thk < 25 mm )…10 *C over.
d) A106 Gr. B (thk > 25 mm) 79 *C over.
149)
While GTAW welding at what wind speed do you have to install wind
protection.
0.5 m / sec.
150)
Chemical composition of Incoloy material:
Fe – Cr – Ni.
151)
Strongest material at low temperature service:
A312 – TP304 ( C-0.8 / tensile strength 75 ksi / yield strength 30 ksi )
152)
What should be the Internal Gap of the socket weld joint and what is
the reason for
Leaving the gap?
1.6 mm minimum (to avoid crack caused by thermal expansion when
Socket joint Welding.)
153)
Defects that cannot be detected with Visual Examination:
Internal Porosity, Slag Inclusion, Lack of Fusion, Burn through, Tungsten
Inclusion.
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154)
The difference between electrode E – 308 and E – 308L:
E – 308L contains less Carbon than E – 308.
155)
Four main parts of Spiral wound Gasket:
Filler, Outer Ring, Inner Ring and Hoop.
156)
RAISED FACE:
Is 1/16” high for 150 and 300 lbs flanges, and ¼” high for all other
pressure classes.
250 psi cast iron flanges and flanged fittings also have the 1/16” raised
face.
157)
FLAT FACE:
Most common uses are for mating with non – steel flanges on bodies of
pumps, etc. and for mating 125 psi cast iron valve and fittings. Flat faced
flanges are used with a Gasket
Whose outer diameter equals that of the flange- this reduces the danger
of cracking a cast iron, bronze or plastic flange when the assembly is
tightened.
158)
RING JOINT FACING:
Most efficient for high temperature and high pressure service. Ring joint
facing is not prone to damage in handling as the surfaces in contact with
the gasket are recessed. Use of facing of this type may increase as hollow
metal O- ring gain acceptance for process
Chemical seals.
159)
THREE ADVANTAGES OF USING STUD BOLTS ARE:
a) The stud bolt is more easily removed if corroded.
b) Confusion with other bolts at the site is avoided.
c) Stud bolts in the less frequently used sizes and materials can
be readily made from round stock.
160)
TWO PRINCIPAL TYPES OF FINISH ( FLANGE RAISED FACE ) ARE:
a) Serrated
b) Smooth
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161)
SMOOTH FINISH:
Is usually specially ordered and is available in two qualities. The
smoother surface is termed “ cold water “ finish. The regular smooth
finish shows no tool marks to the naked eye.
162)
ORIFICE PLATE:
Is a flat disc with a precisely made hole at its center, it offers a well
defined obstruction to flow when inserted in a line. The resistance of the
orifice sets up a pressure difference in the fluid either side of the plate,
which can be used to measure the rate of flow.
163)
JOINT USING FLANGE OF DIFFERENT RATINGS:
Where flanges of different rating are bolted together, the rating of the
joint shall not exceed that of the lower flange. Bolting torque shall be
limited so that excessive loads will not be imposed on the lower rated
flange in obtaining a tight joint.
164)
NORMAL LOCATION FOR THE PRESSURE TEST GAUGE:
Basically required two nos. pressure gauges. One in the top side, and the
other in the down side. Test pressure should be monitored only in the
Top side pressure Gauge.
Every 10 meter height, 1 barg head pressure to be added with the top
Side pressure Readings.
To control the accuracy of the readings, the pressure gauge range should
be 1.5 times to 3.0 times of the test pressure. It is mandatory to use only
the calibrated gauges.
165)
ACCEPTANCE CRITERIA FOR INSPECTION OF 6” DIA, SCH. 40 BUTT
WELD
JOINT:
a) Bevel Angle ……………………….. 37.5* deg.( tolerance  2.5* )
b) Root Gap…………………………... 1.6mm
( tolerance  0.8mm )
c) Internal Alignment ( Hi- Lo )……. 1.6mm below.
d) Root Face…………………………... 1.6mm
(tolerance  0.8mm)
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166)
TWO REASONS FOR HAVING VENT HOLE ON REINFORCING PAD OF
BRANCH CONNECTION:
a) To reveal leakage in the weld between branch and header.
b) To allow venting during welding and heat treatment.
167)
CROMIUM CONTENT OF THE FOLLOWING METAL:
a) A335 Gr.P5………………0.5%
b) A335 Gr.P9………………0.9%
c) A335 Gr.P11……………..1 ¼ %
d) A335 Gr.P22…………….. 2 ¼ % Page
END OF GUIDELINES! THANKS GOD!!!
Prepared By:
ARNOLD M. DADIOS
Licensed Civil Engineer
Sr. QA/QC Engineer – II
(Civil/Structural, Mechanical and Piping Inspector)
Quality Assurance/Quality Control Department
Al Rushaid Construction Co.Ltd./EEI Corporation J.V.
Petroleum Center, 4th Floor Tower A Doha Road
P.O. Box 31688, Al Khobar 31952
Kingdom of Saudi Arabia
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