Professional Documents
Culture Documents
1) WHAT IS WPS ?
ITS 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.
2) ANSI CODE :
4) E – 7016 is a type of welding rod. What does under lined number indicate ?
STPG 42
List of unfinished work or unmatched item according to DRWG and spec. before Hydrotest.
1
12) What is Steam Trap ?
Limit fluids Resistance and minimize choak of pipe due to foreign material.
Way of protecting metal against corrosion by passing a small electric current between the metal
surface and the surrounding ground or water.
Spring support, Hanger support, Dummy support, Shoe, Anchor, Guide and Pick up.
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 choosen to be smaller than line size to avoid throttling and consequent
rapid wear of the Seat.
2
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.
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 standby 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).
30) Diaphragm : These forms of diaphragm valve are popular for regulating the flow of slurries
and corrosive fluids and for vacuum.
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.
35) 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.
36) 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.
37) Steam Tracing : To prevent fluid from congealing, forming hydrates, condensing,
interfering with operation or causing any damage to piping, equipment
and instrument.
38) Expansion Joint : To accommodate movement in piping due to temperature changes and
also used to absorb vibration.
39) Control Station : Is an arrangement of piping in which a control valve is used to reduced
3
and regulate the pressure or rate of flow of steam, gas or liquid.
40) 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.
41) Vents: Are needed to let gas usually air in and out of service. Basically remove
the air pocket from the line.
42) Break Flange : Piping connected to channel head nozzle should be furnished with
break flange to facilitate the removal of the channel head.
43) Separators : Used to collect droplets from a gaseous stream. ( Ex : To collects oil
droplets from a compressed air, or condensates droplets from wet
steam.
44) Temporary strainers: Used for start – up operations on the suction side of pumps and
compressors, after start – up the screen usually is removed.
45) 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.
46) 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.
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.
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
liquification in the condenser and is 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
4
condensing equipment.
57) Heat Exchanger : The principal application of a heat exchanger is to maintain a heat
balance through the addition or removal source or between stream of
two different operating temperature.
58) Reactor : Are used in processing facilities to contain catalyst that promote
chemical reaction of feeds. Reactor are 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.
62) 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 allow the liquid
to separate and collect.
63) 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.
65) Venturi meter : Instrument for measuring of gas or liquid measuring the decreased
pressure so caused.
66) Slip on flange : Has poor resistance to shock and vibration easier to align than the
welding neck flange, calculated strength under internal pressure are
about one third that of the corresponding the weld neck flange.
67) Weld Neck Flange : Suitable where extreme temperature shear impact and vibratory stresses
apply primarily use for vessel and equipment nozzle.
5
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.
69) Seal Welds : may be used only to prevent leakage of threaded joints and not to be
considered as contributing any strength to the joints.
71) How many threads can be visible after seal welding threaded joints ?
Zero. Seal welding must cover all threads.
72) What is the gap requirement for socket welds for new construction?
1.5 mm to 3.0 mm gap prior to welding.
74) What is the minimum fillet weld size for a socket welded connection?
1-1/4t but not less than 3.2 mm.
75) What are common failures in the quality system during fit up that leads to hydro test failures?
Failure to properly clean, de burr and degrease fittings and piping prior to welding.
Oil residue from cutting causes through weld porosity and leakage during hydro tests.
Fit up, elevation and slope per AFC drawings, this checked by survey or level
( string line ) in accordance with PIPS and procedures.
6
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.
80) Give Examples of unique support details that allow piping freedom of movement for thermal
expansion :
a) Teflon slides, wear pads, spring hangers, hydraulic snubbers, Expansion joints.
81) 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.
82) 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.
83) Gaskets : Are used to make a fluid resistant seal between two surfaces.
85) Drip legs : Often made from pipe and fittings, the drip leg is an inexpensive means of
collecting condensate. Removal of condensates from steam lines.
86) Hanger Support : Device which suspends piping ( usually a single line ) from structural steel, or
steel and concrete. Hanger are usually adjustable for height.
87) Saddle : a welded attachment for pipe requiring insulation and subject to longitudinal
or rolling movement ( resulting from temperature changes )
88) 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.
89) 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.
90) Wet Steam : Consists of water vapor and suspended water particles at the same
7
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.
91) 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
super heat. Thus Super heat is sensible heat – that is it can be measured
by a thermometer.
93) 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 refered 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.
94) what are the common type of valves and its function?
Gate Valve – on / off service
Globe valve – throttling service
Check valve – non return valve
95) Where will you place the level gauge of a kettle type re boiler?
After the weir.
8
Specific type of work in basic sequence of QC activity steps.
98) A Quality Control Procedure?
A document that details the specific steps needed to fulfill the QC activity in the ITP.
101) What types of inspection action points are found in the ITP?
Hold, Witness, Surveillance, Review.
9
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 )
119) What are the NDT methods are required during orifice flange installations?
Visual and PT / MT.
122) Flange connects to a pump or other equipment, is there any physical tolerance involved?
Yes, Manufacturer tolerance.
# Check that correct bolts and gaskets are installed at all reinstated joints completed and
Recorded.
# Check that all process blinds and spades have been correctly installed as indicated on the
P& ID.
# Check that correct valves have been installed in the correct ‘Flow’ position.
# Check that specified block valves have locking devices correctly installed.
10
# Check that all valves are functioning properly and that spindle has been coated with copa-slip
are equal there specified.
# Check that all pump suction strainers have been correctly installed.
# check that correct flow through filters, and strainers, traps, check valves and globe valves.
11
17) Drain and vent. Location, size, orientation.
18) Piping line class break. Material, location, rating cla ss as
shown in P&ID.
TABLE FOR GASKET :
NOTE : This is calculated as following condition. ASTM A 53 SCH. 40. Full water, continuous beam.
12
Table – 1
Guide for selection of Welding Electrodes and Filler Metal Rods.
Base metal ( ASTM / ASME ) Welding Metal ( AWS )
Product Forms
PLATE PIPE FORGIN TUBE CASTING ELECTRO FILLER
G DE METAL
( SMAW ) ( GTAW )
CARBON STEEL
A516 GR. A106 GR.B A105 A179 A216- WCB E - 7018 ER – 70S-2
70 API 5L – B
A515 GR. A53 GR.B
70
A285 GR. B
LOW ALLOY STEEL
A387 GR.1 A335 – P1 A182-F1 A213-T1 A217-WC1 E-7018-A1 ER-80S-G
A387 GR.12 A335 – P12 A182-F12 A213-T12 A217-WC4 E-8018-B2 ER-80S-B2
A387 GR.11 A335 – P11 A182-F11 A213-T11 A217-WC6 E-8018-B2 ER-80S-B2
A387 GR.22 A335 – P22 A182-F22 A213-T22 A217-WC9 E-9018-B3 ER-90S-B3
STAINLESS STEEL
A240-304L A312- A182- A213- A351-CF3 E 308L-16 ER-308L
TP304L F304L TP304L
A240-316L A312- A182- A213- A351-CF3M E 316L-16 ER-316L
TP316L 316L TP316L
904 L A790 A789 FOX CN
20 / 25M
SAF 2205 A790 A789 E2209-17 ER-2209
SPECIALITY ALLOYS
316L U.G. 316L U.G. 316L U.G. 316L U.G. - Thermanit
19 / 15H
310MoL 310MoL 310MoL 310MoL E310LMo Thermanit
25 / 22H
Alloy 20 Inconel 112 Inconel 625
Incoloy Incoloy Incoloy Inconel 117 Inconel 617
800HT 800HT 800HT
HK-40 HK-40 E310 H ER-310H
25-35-Cb 25-35-Cb Inconel 117 Inconel 617
Mod. Mod.
13
SPECIFICATIONS FOR CARBON STEEL SYSTEM
SL.NO. COMMODITY B31.3
1 Pipe ASTM A53 / API 5L
2 Pipe – Low Temperature ASTM A333 Gr6
3 Pipe – High Temperature ASTM A106
4 Bolting ASTM A193 B7 / ASTM A320
5 Nut ASTM A194 2H
6 Fittings ASTM A234 WPB
7 Fittings – Low Temperature ASTM A420 WPL6
8 Fittings – High Temperature ASTM A234 WPB
ASTM A216 WCB
9 Valves ASTM A105 / API 600
10 Valves – Low Temperature ASTM A350 LF2 / ASTM A352 LCB
11 Valves – High Temperature ASTM A216 WCB
12 Flanges ASTM A105/ ASTM A181/ ASME B16.5
13 Flanges – Low Temperature ASTM A350 LF2 / ASTM A352 LCB
14 Flanges – High Temperature ASTM A105/ ASTM A181/ ASTM A216 WCB
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.
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.
14
VALVE INSPECTION AND TESTING : ( API 598 )
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 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.
A Process Wherein the lighters fluid is separated from the heavier fluid.
Saddle support.
Skirt support.
15
132) What is the minimum class rating of bypass valve?
300 lbs.
300 lbs.
134) What is the common material use for pipe, fittings, valves, flanges, gasket & bolts?
135) 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.
2.1 meters.
1 meter.
2.1 meters.
16
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.
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.
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.
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.
150) While GTAW welding at what wind speed do you have to install wind protection.
0.5 m / sec.
Fe – Cr – Ni.
153) 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.)
17
154) Defects that cannot be detected with Visual Examination :
Internal Porosity, Slag Inclusion, Lack of Fusion, Burn through, Tungsten Inclusion.
18
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.
166) 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 )
END
19