[7:54 AM, 11/12/2017] +91 77080 23736: What are the meaning of PIPE AND PIPING ?

PIPE is a hollow cylinder of metal, wood, or other material, used for the conveyance of water, gas,
steam, petroleum, etc.

PIPING is not only the pipes but including all fittings, flanges, valves, gauges, bolting, gaskets, pipe
hangers, supports and other mechanical equipment

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- What is Jack Screws and when are they required?

Ans:- They are located at flanged connections to facilitate maintenance and removal of flange and

Orifice plates to facilitate maintenance.

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- Material Inspection?

Ans:-

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 % (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)

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- What is a PIP?

Ans:- Process Industry Practice details requirements for fabrication an Industry Practice.

These are often the basis for SA standards.

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- PIPING GENERAL ARRANGEMENT DRAWING CHECK LIST?

Ans:-

Title Block.

North Arrow Orientation.

Matchline Continuation.

Line Continuation.

Equipment Location To Grid.

Equipment Nozzle Details (No., Size & Rating).

Pipeline Location To Grid/Equipment. By Piping Or Valves).

Structural Penetrations.

Locations Of Item.

Pipeline Elevations Shown.

Dimensional Completion.

Valve Orientation. (is enough space provided for:)

Electrical And Instrument Cable Trays And Junction Boxes.

Erection Of Equipment.

Tube Bundles.

Maintenance Space (Including Choke And Safety Valves).

Equipment Removal.
 Operating Space.

Manway Clearance.

Davit Dropping.

Overhead Clearance.

Future Installation Area.

Ducting And H.V.A.C. Equipment.

Platforms And Walkways (I.E. Not Blocked By Piping Or Valves)

Do Drawing Comply With Piping & Instrument Diagrams And Line List

Direction Of Flow And Flow Arrows.

Valve And Specialities In Each Line.

Instrument Conn's In Lines And Equipment.

Steam/Electric Tracing.

Insulation.

Equipment Numbers And Titles.

Completeness Of Lines.

Pipeline Numbers.

Instrument Tag Numbers.

Valve Tag Numbers.

Vapour And Gas Lines Without Pockets.

No Inverted Pocket In Suction Lines.

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- What is the difference between LTCS and Carbon steel?

Ans:- Steel is considered to be carbon steel when no minimum content is specified or required for
chromium, cobalt, columbium [niobium], molybdenum, nickel, titanium, tungsten, vanadium or
zirconium, or any other element to be added to obtain a desired alloying effect; when the specified
minimum for copper does not exceed 0.40 per cent; or when the maximum content specified for any of
the following elements does not exceed the percentages noted: manganese 1.65, silicon 0.60, copper
0.60.

*Low-temperature carbon steels have been developed chiefly for use in low-temperature equipment
and especially for welded pressure vessels.

They are low- to medium-carbon (0.20 to 0.30%), high-manganese (0.70 to 1.60%), silicon (0.15 to
0.60%) steels, which have a fine-grain structure with uniform carbide dispersion. They feature moderate
strength with toughness down to 50F (46C).

For grain refinement and to improve formability and weldability, carbon steels may contain 0.01 to
0.04% columbium. Called columbium steels, they are used for shafts, forgings, gears, machine parts, and
dies and gages. Up to 0.15% sulfur, or 0.045 phosphorus, makes them free-machining, but reduces
strength.

*LTCS is a Nickel based alloy steel plates especially used for low temperature applications below - 150
deg F. Mainly used in cryogenic construction of space ships, low temperature application in chemical
plant below -55 deg C.

Examples:

SA-203 Steel Plate Grades A, B, D, E and F Nickle Alloy Steel Plates. For low temperatures (-150 deg F)

Low Temperature Carbon Steel Tubes ASTM A334 Gr.1

ASTM A333Seamless and Welded Steel Pipe for Low-Temperature Service:

Mainly Grade

Grade 1, Grade 3, Grade 4, Grade 6, Grade 7, Grade 8, Grade 9, Grade 10, Grade 11

*ASTM A420 For LTCS Fittings.

*A350-LF2 is a standard For Flanges.

**Steel that are generally killed include:

Steels with carbon contents greater then 0.25%

All forging grades of steel.

Structural steels with carbon content between 0.15 to 0.25%.

Some special steel in the lower carbon ranges.

[7:54 AM, 11/12/2017] +91 77080 23736: Rubber Gaskets

Rubber is a soft gasket material. A wide range of elastomers can be used, such as neoprene, nitrile,
EPDM and natural rubber. Rubber gaskets are used in a wide range of applications such as pipe gaskets,
heat exchangers, and manways.

Non-Asbestos Gaskets

Non-asbestos gaskets are manufactured from a compressed fibre with an elastomer binding; and are
used in many applications such as acid, steam, oil and water.

Cork Gaskets

Natural cork combined with elastomer bindings giving high flexibility and compression. These gaskets
are widely used in applications involving oil, fuel and solvents.

Full Faced

A Full Face gasket is one that covers the whole of the flange. It will be easily recognised by the fact that
the holes for the bolts to pass through are cut into the gasket material.

I.B.C (Inner Bolt Circle)

Inner Bolt Circle gaskets (IBC) are also known as ring type or raised face. They sit within the circle of the
bolts used to secure the joint and are purely a continuous ring of material.

Segmented

Segmented gaskets are used when the flange is an unusual shape, extremely large or expensive. A
segmented gasket is formed by two or more gasket parts being arranged with an overlap, tab, or shaped
joint arrangement so that when it is compressed it provides a continuous seal within the flange joint.
Spiral Wound Gaskets

Spiral wound gaskets are made by winding a metal strip, typically stainless steel, and a softer filler
material such as graphite or PTFE. The materials are wound from opposite sides giving alternating layers
of metal and filler, with the filler material acting as the sealant and the metal as the structural strength.

These gaskets offer the use of lower clamping forces, but are a relatively expensive method of sealing.

Gasket Applications

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- Where a Reinforced Branch Connection is required?

Ans:- With large pipe dimensions, it is customary, to form a TEE intersection by cutting a hole in the
straight run (the header) and welding in the leg perpendicular (the branch), this is called a STUB-IN.

Similarly, nozzles are installed on pressure vessels by cutting a hole in the side of the vessel and welding
in an appropriately sized pipe to form the nozzle. These intersections ensure a "hole weakening" on the
vessel or piping system, due to the metal removed and the stress concentration created.

In critical systems, this weakness must be compensated, and can be restored with a Reinforcing Pad, to
strengthen the piping branch connection or the pressure vessel nozzle.

Branch Connection with Reinforcing Pad (Set-On type)

Reinforced Branch Connection Set-On type

Dimensions Reinforcing Pad

For the dimensions of a reinforcing pad you can handle as rule:

1. Material = same material as the run pipe

2. Width = half a diameter of the branch pipe (at least 50 mm)

3. Thickness = same thickness as the run pipe, with a min. of 3 mm

and a max. of 20 mm
However, it is customary for most companies a so-called Branch table handling. This document defined
the methods, which must be applied, if a branch (with or without a reinforcing pad) in a run pipe must
be made. It is also usually present a specification that defines own dimensions, because each company
has their own criteria. (e.g. type of product, pressure and temperature, national regulations, local
markets)

[7:54 AM, 11/12/2017] +91 77080 23736: Q:- What is punch list?

Ans:- List of unfinished work or unmatched item according to DWG and specifications before Hydro
test.

A - To be done before Hydro test

B - To be done before MC

C - To be done after MC but before commissioning

D - To be done before Plant Acceptance

[7:54 AM, 11/12/2017] +91 77080 23736: The following are the characteristics of catalyst which are
common to must of catalytic reactions.

1. A catalyst increases the speed of a reaction, and it also improves the yield of the intended product.

2. A catalyst actually takes part in the reaction even though it itself is not consumed or used up in the
course of the reaction.

3. A catalyst makes the reaction faster by providing an alternative pathway with a lower activation
energy.
4. A catalyst is reaction-specific. It may not be effective in another reaction even if the two reactions are
of similar type.

5. In a reversible reaction, a catalyst accelerates both the forward and the reverse reactions. So, the
inclusion of a catalyst does not alter the equilibrium constant of a reversible reaction.

1. What is the scope of ASME B 31.3? What does it covers and what does not?

Ans: Refer to the ASME B 31.3-Process Piping section from my earlier post.
Link: http://www.whatispiping.com/?p=44
Alternatively refer the below attached figure ( Figure 300.1.1 from code ASME B 31.3)

2. What are the disturbing parameters against which the piping system must be designed?
Ans: The piping system must stand strong (should not fail) against the following major effects:

Design Pressure and Temperature: Each component thickness must be sufficient to withstand
most severe combination of temperature and pressure.
 Ambient effects like pressure reduction due to cooling, fluid expansion effect, possibility of
moisture condensation and build up of ice due to atmospheric icing, low ambient temperature etc.
Dynamic effects like impact force due to external or internal unexpected conditions, Wind force,
Earthquake force, Vibration and discharge (Relief valve) reaction forces, cyclic effects etc.
Component self weight including insulation, rigid body weights along with the medium it transport.
Thermal expansion and contraction effects due to resistance from free displacement or due to
thermal gradients (thermal bowing effect) etc.
Movement of pipe supports or connected equipments etc.

3. How to calculate the allowable stress for a carbon steel pipe?

Ans: The material allowable stress for any material other than bolting material, cast iron and malleable
iron are the minimum of the following:

1. one-third of tensile strength at maximum temperature.

2. two-thirds of yield strength at maximum temperature.
3. for austenitic stainless steels and nickel alloys having similar stressstrain behavior, the lower of
two thirds of yield strength and 90% of yield strength at temperature.
4. 100% of the average stress for a creep rate of 0.01% per 1 000 h
5. 67% of the average stress for rupture at the end of 100 000 h
6. 80% of the minimum stress for rupture at the end of 100 000 h
7. for structural grade materials, the basic allowable stress shall be 0.92 times the lowest value
determined (1) through (6) above.

4. What is the allowable for Sustained, Occasional and Expansion Stress as per ASME B 31.3?
Ans: Calculated sustained stress (SL)< Sh (Basic allowable stress at maximum temperature)
Calculated occasional stress including sustained stress< 1.33 Sh
Calculated expansion stress< SA = f [ 1.25( Sc + Sh) SL]
Here f =stress range factor, Sc =basic allowable stress at minimum metal temperature and
SL=calculated sustained stress. The sustained stress (SL) is calculated using the following code
formulas:

Here,
Ii = sustained in-plane moment index. In the absence of more applicable data, Ii is taken asthe greater of
0.75ii or 1.00.
Io = sustained out-plane moment index. In the absence of more applicable data, Io is taken as the greater
of 0.75io or 1.00.
Mi = in-plane moment due to sustained loads, e.g.,pressure and weight
Mo = out-plane moment due to sustained loads, e.g.,pressure and weight
Z = sustained section modulus
It = sustained torsional moment index. In the absence of more applicable data, It is taken
as 1.00.
Mt = torsional moment due to sustained loads, e.g.,pressure and weight
Ap = cross-sectional area of the pipe, considering nominal pipe dimensions less allowances;
Fa = longitudinal force due to sustained loads, e.g.,pressure and weight
Ia = sustained longitudinal force index. In the absence of more applicable data, Ia is taken as 1.00.
5. What are steps for calculating the pipe thickness for a 10 inch carbon steel (A 106-Grade B)
pipe carrying a fluid with design pressure 15 bar and design temperatre of 250 degree centigrade?
Ans: The pipe thickness (t) for internal design pressure (P) is calculated from the following equation.
Here, D=Outside diameter of pipe, obtain the diameter from pipe manufacturer standard.
S=stress value at design temperature from code Table A-1
E=quality factor from code Table A-1A or A-1B
W=weld joint strength reduction factor from code
Y=coefficient from code Table 304.1.1
Using the above formula calculate the pressure design thickness, t.
Now add the sum of the mechanical allowances (thread or groove depth) plus corrosion and erosion
allowances if any with t to get minimum required thickness, tm.
Next add the mill tolerance with this value to get calculated pipe thickness. For seamless pipe the mill
tolerance is 12.5% under tolerance. So calculated pipe thickness will be tm/(1-0.125)=tm/0.875.
Now accept the available pipe thickness (based on next nearest higher pipe schedule) just higher than
the calculated value from manufacturer standard thickness tables.
6. How many types of fluid services are available for process piping?
Ans: In process piping industry following fluid services are available..

Category D Fluid Service: nonflammable, nontoxic, and not damaging to human tissues, the
design pressure does not exceed 150 psig, the design temperature is from -20 degree F to 366
degree F.
Category M Fluid Service: a fluid service in which the potential for personnel exposure is judged
to be significant and in which a single exposure to a very small quantity of a toxic fluid, caused by
leakage, can produce serious irreversible harm to persons on breathing or bodily contact, even
when prompt restorative measures are taken.
Elavated Temperature Fluid service: a fluid service in which the piping metal temperature is
sustained equal to or greater than Tcr (Tcr=temperature 25C (50F) below the temperature
identifying the start of time-dependent properties).
Normal Fluid Service: a fluid service pertaining to most piping covered by this Code, i.e., not
subject to the rules for Category D, Category M, Elevated Temperature, High Pressure, or High
Purity Fluid Service.
High Pressure Fluid Service: a fluid service for which the owner specifies the use of Chapter IX
for piping design and construction. High pressure is considered herein to be pressure in excess of
that allowed by the ASME B16.5 Class 2500 rating for the specified design temperature and
material group.
High Purity Fluid Service: a fluid service that requires alternative methods of fabrication,
inspection, examination, and testing not covered elsewhere in the Code, with the intent to
produce a controlled level of cleanness. The term thus applies to piping systems defined for other
purposes as high purity, ultra high purity, hygienic, or aseptic.

7. What do you mean by the term SIF?

Ans: The stress intensification factor or SIF is an intensifier of bending or torsional stress local to a piping
component such as tees, elbows and has a value great than or equal to 1.0. Its value depends on
component geometry. Code B 31.3 Appendix D (shown in below figure) provides formulas to calculate the
SIF values.
8. When do you feel that a piping system is not required formal stress analysis?
Ans: Formal pipe stress analysis will not be required if any of the following 3 mentioned criteria are
satisfied:

1. if the system duplicates, or replaces without significant change, a system operating with a
successful service record (operating successfully for more than 10 years without major failure).
2. if the system can readily be judged adequate by comparison with previously analyzed systems.
3. if the system is of uniform size, has no more than two points of fixation, no intermediate restraints,
and falls within the limitations of empirical equation mentioned below:

Here,
D = outside diameter of pipe, mm (in.)
Ea = reference modulus of elasticity at 21C (70F),MPa (ksi)
K1 = 208 000 SA/Ea, (mm/m)2 = 30 SA/Ea, (in./ft)2
L = developed length of piping between anchors,m (ft)
SA = allowable displacement stress range
U = anchor distance, straight line between anchors,m (ft)
y = resultant of total displacement strains, mm (in.), to be absorbed by the piping system
9. How will you calculate the displacement (Expansion) stress range for a piping system?
Ans: Expansion stress range (SE) for a complex piping system is normally calculated using softwares like
Caesar II or AutoPipe. However, the same can be calculated using the following code equations:

here
Ap = cross-sectional area of pipe
Fa = range of axial forces due to displacement strains between any two conditions being evaluated
ia = axial stress intensification factor. In the absence of more applicable data, ia p 1.0 for elbows, pipe
bends, and miter bends (single, closely spaced, and widely spaced), and ia =io (or i when listed) in
Appendix D for other components;
it = torsional stress intensification factor. In the absence of more applicable data, it=1.0;
Mt = torsional moment
Sa = axial stress range due to displacement strains= iaXFa/Ap
Sb = resultant bending stress
St = torsional stress= itXMt/2Z
Z = section modulus of pipe
ii = in-plane stress intensification factor from Appendix D
io = out-plane stress intensification factor from Appendix D
Mi = in-plane bending moment
Mo = out-plane bending moment
Sb = resultant bending stress
10. What do you mean by the term Cold Spring?
Ans: Cold spring is the intentional initial deformation applied to a piping system during assembly to
produce a desired initial displacement and stress. Cold spring is beneficial in that it serves to balance the
magnitude of stress under initial and extreme displacement conditions

EEWRRT