Inspection Engineer Interview points

Piping
Commonly used Construction codes:
ASME B 31.1 (Power piping)
ASME B31.3 Process Piping,
ASME B31.4 Liquid transportation piping
ASME 31.8 Liquid petroleum transmission piping
API 1104 Welding of pipeline
What are the main deference between ASME B 31.3 & ASME B31.4?
The allowable stress is not the same. Minimum thickness formula is not same. One is for the piping inside the plant and the other one is for
transportation.
Inspection: API 570, API RP 574
Material: ASTM A53, ASTM A106, SA 135, SA 333, SA 671, SA 672, API 5L, SA 268, SA 213, SA 312, SA 790, etc.,
a) Carbon Steel Pipe
API 5L, Grade A or B, seamless
API 5L, Grade A or B, SAW, str. seam, Ej 0.95
API 5L, Grade X42, seamless
API 5L, Grade X46, seamless
API 5L, Grade X52, seamless
API 5L, Grade X56, seamless
API 5L, Grade X60, seamless
ASTM A 53, seamless
ASTM A 106
ASTM A 333, seamless
ASTM A 369
ASTM A 381, Ej 0.90
ASTM A 524
ASTM A 671, Ej 0.90
ASTM A 672, Ej 0.90
ASTM A 691, Ej 0.90
(b) Low and Intermediate Alloy Steel Pipe
ASTM A 333, seamless
ASTM A 335
ASTM A 369
ASTM A 426, Ec 0.90
ASTM A 671, Ej 0.90

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ASTM A 672, Ej 0.90

ASTM A 691, Ej 0.90
(c) Stainless Steel Alloy Pipe
ASTM A 268, seamless
ASTM A 312, seamless
ASTM A 358, Ej 0.90
ASTM A 376
ASTM A 451, Ec 0.90
(d) Copper and Copper Alloy Pipe
ASTM B 42
ASTM B 466
(e) Nickel
ASTM
ASTM
ASTM
ASTM

and Nickel Alloy Pipe

B 161
B 165
B 167
B 407

(f) Aluminum Alloy Pipe

ASTM B 210, Tempers O and H112
ASTM B 241, Tempers O and H112
Low temperature service material & fittings
Product Form

ASTM Spec. No.

Pipe

A 333

Tube

A 334

Fittings

A 420

Forgings

A 350

Castings

A 352

Bolting

A 320

Plate

A 20

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The primary elements in determining the minimum acceptable diameter of any pipe network are system design flow rates and pressure
drops. The design flow rates are based on system demands that are normally established in the process design phase of a project.
The hydraulic design of a piping system is premised on selecting the optimum pipe size (diameter) and thickness (schedule), for the
design flow rate and the allowable pressure drop in the system.

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For a specific flow rate, as the pipe diameter increases, the pressure drop increases at a fast rate (pressure drop varies approximately
with the square of the velocity). This means that the pumping horsepower required would increase resulting in a higher pump cost and
on-going operating energy costs. On the other hand, as the pipe diameter decreases, the installed cost of the piping system (pipe,
fittings, valves) also decreases. The optimal solution is to find the pipe size that would result in the lowest life cycle costs (initial
installed cost plus operating costs over the life of the piping system.
Piping and Instrumentation Diagram (P&ID)
The primary element of a piping design is the piping and instrumentation diagram (P&ID). Both the process engineer and the
instrument and controls engineer provide design information. The first version should represent all major equipment, process piping
with sizes, utility piping with sizes, and line-mounted instrument hardware. The piping design team is responsible for drafting the
P&ID.
The P&ID is commonly referred to as the control document for design and construction and subsequently for operation and
maintenance. For the pipe designer, the diagram is a complete mechanical description. It is an engineering expression of the processscope of work.
It is imperative to maintain the P&ID up to date and to control and communicate the revisions to the design group to ensure that the
design is based on the latest revision.
Piping components shall be designed for an internal pressure representing the most severe condition of coincident pressure and
temperature expected in normal operation. This condition is by definition the one that results in the greatest required pipe thickness
and the highest flange rating

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MATERIAL SELECTION
Materials selection is an optimization process, and the material selected for an application must be allowed by the applicable code; and
chosen for the sum of its properties (strength, toughness, corrosion resistance, etc), availability, and cost. Thus, the selected material
may not rank first in each evaluation category; but it should be the best overall choice
In practice it is usual to select materials which corrode slowly at a known rate and to make an allowance for this in specifying the
material thickness.
Material Selection Process
Piping material is selected by optimizing the basis of design.
1. Eliminate from consideration those piping materials that:
a. Are not allowed by code or standard;
b. Are not chemically compatible with the fluid;
c. Have system rated pressure or temperatures that do not meet the full range of process operating conditions; and
d. Are not compatible with environmental conditions such as: external corrosion potential, heat tracing requirements,
ultraviolet degradation, impact potential, and specific joint requirements.
2. The remaining materials are evaluated for advantages and disadvantages such as capital, fabrication and installation costs;
support system complexity; compatibility to handle thermal cycling; and cathodic protection requirements. The highest ranked
material of construction is then selected.
3. The design proceeds with pipe sizing, pressure integrity calculations and stress analyses. If the selected piping material does
not meet those requirements, then the second ranked material is used and the pipe sizing, pressure-integrity calculations and
stress analyses are repeated.

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PRESSURE-INTEGRITY DESIGN
The pressure-integrity design of a piping system normally requires the consideration of at least two issues. The first is the
determination of the minimum or nominal pipe wall thickness, and the second is the determination of the pressure rating of the in-line
components such as valves and fittings. The design process for consideration of pressure integrity uses allowable stresses, thickness
allowances based on system requirements, and manufacturing wall thickness tolerances to determine minimum wall thickness
Current Basis for Determining the Allowable Stress (S)
As a result of the introduction of new materials and increases in service temperatures, use
of Safety factors was abandoned and the factor became part of the allowable stress for a material at any temperature. The allowable
stress is based on the least of the following:

Room-temperature tensile strength / 3.5

Room-temperature yield strength / 1.5
The stress required to cause a creep rate of 0.0001%/1000 hours
The average stress to cause rupture at 100,000 hours / 1.5
The minimum stress to cause rupture at 100,000 hours / 1.25

Today, fracture mechanics allows an engineer to establish the minimum toughness required in a material based on the stress applied
and the maximum credible size flaw.
These changes eliminated concern over brittle fracture. In addition, Section VIII requires that hydrostatic testing be performed at the
minimum design metal temperature plus atleast 30F, ensuring that brittle failure will not occur during hydrostatic testing

Design Margin (Safety Factor) in the ASME Boiler and Pressure Vessel Code
In the 1999 addenda of the ASME Boiler Code, the design margin (formerly known as the Safety Factor) was changed from 4.0 to
3.5.
ASME B31.3 has had a design margin of 3.0 for more than 20 years
ASME B31.1 is in the process of changing to 3.5, but may change to 3.0.

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PIPING SYSTEM DESIGN PROCEDURE

The following flowchart shows the typical procedure used in designing piping systems

PIPING LAYOUT AND ISOMETRIC DRAWINGS

Flow diagrams, line lists and design specifications are all used by the piping designer to lay out the piping and generate design
drawings. Piping of the size and schedule must be routed between the appropriate pieces of equipment as shown on the flow diagrams.
Routing will be affected by system operating temperature, pipe weight, installation and material costs, applicable code requirements,
pressure drop requirements and equipment and building structure locations.
Piping isometrics are three-dimensional representations of the piping system using a 30 orientation of the two horizontal axes.
Piping not running parallel to one of the main axes is shown by its components in each direction. Isometrics need not be drawn to
scale; the piping segments may be drawn as long as is necessary for clarity

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Bolting material: ASTM A 193 grade B7 bolting for ordinary service. ASTM A 193 grade B7M bolting for areas exposed to hydrogen
sulfide service
Hydro test pressure: 1.5 X design pressure
What is the difference between pipe & tube?
The word pipe is used, as distinguished from tube, to apply to tubular products of dimensions commonly used for pipeline and piping systems. Pipes
NPS 12 (DN 300) and smaller have outside diameters numerically larger than their corresponding sizes. In contrast, the outside diameters of tubes
are numerically identical to the size number for all sizes.
Minimum required thickness calculation:
Pipe the minimum required thickness is t, the nominal thickness is t + corrosion allowance
The t as per API RP 574 is t=PD / 2SE where P-Design Pressure, D-OD of pipe, S-allowable stress as per the code, E-quality factor (for Seamless
pipe it is One). This formula is used for in-service piping.
The t as per ASME B31.3 is t=PD / 2(SE+PY) where P-Design Pressure, D-OD of pipe, S-allowable stress as per the code, E-quality factor (for
Seamless pipe it is One), Y-0.4 for carbon steel upto 400F. This formula is used only for new construction.
For OD of piping up to 12 refer API RP 574 piping schedule table. Above 12 the OD is the size of the pipe.

ASME B 31.3 formula

PD

tm = 2( SE Py ) C
Where
S Allowable Stress
D - Outside diameter
E - longitudinal joint factor obtained from relevant Table
P - Design Pressure
Y - temperature factor
C - Corrosion & mechanical allowance
ASME B 31.4 formula
tm =

PD
C
2S

Where
S Allowable Stress from ASME B 31.4
D - Outside diameter
P - Design Pressure
C - Corrosion & mechanical allowance

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API RP 574 formula

tm =

PD
C
2 SE

Where
S Allowable Stress
D - Outside diameter
E - longitudinal joint factor obtained from relevant Table
P - Design Pressure
C - Corrosion & mechanical allowance

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What is PMI?
Positive Material Identification by using isotopes, light or chemical. First two are portable. The code used is API RP 578. It is being used only for alloy
steel verification.
CUI
Corrosion under insulation occurs at what temperature range?
What are the NDT methods can be used to find the corrosion under insulation?
What are all the possible locations where one can expect CUI?
Piping components:
Flanges: ASME B 16.5 upto 24 diameter, B16.47 for diameter above 24
Flange Material: SA 105, SA 694,
Forged Fittings: SA 234, SA 403
Type of flanges: Weld neck, blind, slip on, orifice, threaded etc.,
Type of flanges:
Weld neck, Lap, socket
weld, slip on, blind &
threaded

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Piping system hydrotest pressure Vs flange rating

Flange rating
150#
300#
600#
900#
1500#

Hydrotest
psi
425
1100
2175
3250
5400

pressure

in

How will you identify flange rating if in doubt? Look for punch marking on the flange sides & check the dimension against the code
Where will you find the details of pipe fittings (elbows, reducers etc.,)
On the sides of fittings (elbow-sides, reducers-sides, flanges-sides)

API Std.1160
Hydrotest (Page 25 & 26)
Hydrostatic testing validates integrity at the time of the test by demonstrating the integrity of a pipeline with respect to the established MOP and the
leak tightness of a pipeline. Within limits, the greater the ratio of test pressure to operating pressure, the more effective the test. ASME
B31.4 currently requires a test pressure of not less than 1.25 times MOP for not less than four hours when the pipe is visually inspected
during the test, and not less than an additional four hours at 1.1 times MOP when the pipe is not visually inspected during the test. An
alternative test commonly called a spike test is conducted at 1.39 times MOP for approximately 30 minutes to detect linear type defects
associated with longitudinal seams
Retesting Frequency (Page 26)
The frequency of hydrostatic retesting required to assure continued serviceability of a pipeline segment depends on the test-pressure-to-operatingpressure ratio, and the rates of growth of the particular type of defects that exist in the pipeline. Typical defects that tend to become larger with the
passage of time are: external and internal corrosion-caused metal loss, stress-corrosion cracks, and any longitudinally oriented crack-like defect that
is subjected to pressure-cycle-induced
Determination of Inspection Interval/ Frequency (Page 26)
A hydrostatic test is one method to assess the integrity of a pipeline. When hydrostatic testing is selected to verify the integrity of a pipeline segment,
tests should be conducted at intervals sufficient to eliminate or prove the absence of critical defects before they reach a condition that can cause an
unintentional release

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Suggested Welding repair methods for piping according to API 1104 / API 570

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API 570 suggested repair methods

EXAMPLES OF REPAIRS
C.1 Repairs
Manual welding utilizing the gas metal-arc or shielded metal-arc processes may be used.
When the temperature is below 50F (10C), low-hydrogen electrodes, AWS E-XX16 or E-XX18, shall be used when welding materials conforming to ASTM A-53, Grades
A and B; A-106, Grades A and B; A-333; A-334; API 5L; and other similar material. These electrodes should also be used on lower grades of material when the
temperature of the material is below 32F (0C). The piping engineer should be consulted for cases involving different materials.
When AWS E-XX16 or E-XX18 electrodes are used on weld numbers 2 and 3 (see Figure C-1 below), the beads shall be deposited by starting at the bottom of the
assembly and welding upward. The diameter of these electrodes should not exceed 5/32 inch (4.0 mm). Electrodes larger that 5/32 inch (4.0 mm) may be used on weld
number 1 (see Figure C-1), but the diameter should not exceed 3/16 inch (4.8 mm).
The longitudinal welds (number 1, Figure C-1) on the reinforcing sleeve shall be fitted with a suitable tape or mild steel backing strip (see note) to avoid fusing the weld
to the side wall of the pipe.
Note: If the original pipe along weld number 1 has been checked thoroughly by ultrasonic methods and it is of sufficient thickness for welding, a backing strip is not
necessary. All repair and welding procedures for on-stream lines must conform to API Publ 2201 for hot tapping

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C.2 Small Repair Patches

The diameter of electrodes should not exceed 5/32 inch (4.0 mm). When the temperature of the base material is below 32F (0C), low-hydrogen electrodes shall be
used. Weaving of weld beads deposited with low-hydrogen electrodes should be avoided. All repair and welding procedures for on-stream lines must conform to API
Publication 2201.
Examples of small repair patches are shown below in Figure C-2.

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Intelligent Pigging
This method involves the movement of a device (pig) through the piping either while it is in service or after it has been removed from service. Several
types of devices are available employing different methods of inspection. The line to be evaluated must be free from restrictions that would cause the
device to stick within the line, i.e., usually five diameter bends are required (standard 90 pipe ells may not pass a pig). The line must also have
facilities for launching and recovering the pigs. Most plant piping systems are typically not suited to intelligent pigging
Underground piping
Leak Testing
Underground lines that cannot be visually inspected should be periodically tested for leaks. Several methods are available to achieve this objective:
a. Pressure decay methods involve pressurizing the line to a desired amount, blocking it in, and then removing the source of pressure. Monitoring
the line pressure over a period of time will provide an indication of system tightness. Tests may be conducted at a single pressure or multiple
pressures
b. Volume in/volume out methods make use of volumetric measuring meters at each end of the line
c. A marker chemical (tracer) may be added to the line as a leak detection method. Soil gas samples near the line are collected and tested for the
presence of the marker chemical. The absence of any marker chemical in the soil gas samples indicates the line is not leaking
d. Acoustic emission technology detects and locates leaks by the sound created by the leak. Sensors must be spaced to allow the sound generated
by a leak to be detected at the sensor locations. Sensors are attached directly to the pipe, so testing may require the removal of any protective
coating

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Acceptable under tolerances as per API RP 574

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Check list from API 570

APPENDIX AEXTERNAL INSPECTION CHECKLIST FOR PROCESS PIPING
A.1 Leaks
a. Process.
b. Steam tracing.
c. Existing clamps.
A.2 Misalignment
a. Piping misalignment/restricted movement.
b. Expansion joint misalignment.
A.3 Vibration
a. Excessive overhung weight.
b. Inadequate support.
c. Thin, small bore, or alloy piping.
d. Threaded connections.
e. Loose supports causing metal wear.
A.4 Supports
a. Shoes-off support.
b. Hanger distortion or breakage.
d. Brace distortion/breakage.
e. Loose brackets.
f. Slide plates/rollers.
g. Counterbalance condition.
h. Support corrosion.
A.5 Corrosion
a. Bolting support points under clamps.
b. Coating/painting deterioration.
c. Soil-to-air interface.
d. Insulation interfaces.
e. Biological growth.
A.6 Insulation
a. Damage/penetrations.
b. Missing jacketing/insulation.
c. Sealing deterioration.
d. Bulging.
e. Banding (broken/missing).
REVIEW OF RECORDS
Records of previous inspections and of inspections conducted during the current operating period should be reviewed soon after the inspections are
conducted to schedule the next inspection date. This review should provide lists of areas that are approaching retirement thickness, have previously
shown high corrosion rates, and current inspection has indicated a need for further investigation. From these lists, a work schedule should be
prepared for additional on-stream inspection, if possible, and for inspections to be conducted during the next shutdown period. Such a schedule will
assist in determining the number of inspectors to be assigned to the work.

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In addition, from the review of the records of previous inspections, a list should be made of all predictable repairs and replacements. This list should
be submitted to the maintenance department far enough in advance of the shutdown to permit any required material to be obtained or, if necessary,
fabricated. This list will also assist the maintenance personnel in determining the number of personnel required during the shut-down period.
THICKNESS DATA
A record of thickness data obtained during periodic or scheduled inspections provides a means of arriving at corrosion or erosion rates and expected
material life. Some companies use computerized record systems for this purpose. The data may be shown on sketches or presented as tabulated
information attached to the sketches
SKETCHES
Isometric or oblique drawings provide a means of documenting the size and orientation of piping lines, the location and types of fittings, valves,
orifices, etc. and the locations at which thickness measurements are to be taken. Although original construction drawings may be used, normally
separate sketches are made by, or for, the inspection department.
Sketches have the following important functions:
a. Identify particular piping systems and circuits in terms of location, size, material specification, general process flow, and service conditions.
b. Inform the mechanical department of points to be opened for visual inspection and parts that require replacement or repair.
c. Serve as field data sheets on which can be recorded the locations of thickness measurements, serious corrosion, and sections requiring immediate
replacement. These data can be transferred to continuous records at a later date.
d. Assist at future inspections in determining locations that urgently require examination.

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ASME B 31.3 Acceptance

Table 341.3.2 Acceptance Criteria for welds and Examination Methods for Evaluating Weld Imperfections

Liquid Penetrant

Magnetic particle

Radiography

Fillet Note(3)

Fillet Note(3)

Girth, Miter Groove & Branch Connection

(Note(4)

Branch Connection (Note(4)

Type of Weld
Longitudinal Groove Note(2)

Type of Weld

(Note(4)Girth, Miter Groove & Branch Connection

Category D fluid Service

Longitudinal Groove Note(2)

Severe Cyclic conditions

Fillet Note(3)

Girth, Miter Groove & Branch Connection

(Note(4)

Longitudinal Groove Note(2)

Normal and Category M

fluid Service
Type of Weld

Examination Methods
Visual

Criteria (A to M) for Types of Welds and for Service Conditions [Note(1)]

Weld Imperfection

Crack

N/A

Lack of fusion

..

..

N/A

N/A

N/A

Incomplete penetration

..

..

N/A

N/A

N/A

AN/A

N/A

N/A

Internal porosity

..

..

..

N/A

N/A

N/A

AN/A

N/A

N/A

..

..

..

Internal slag inclusion, tungsten

inclusion, or elongated indication
Undercutting

..

..

..

..

..

..

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Surface Porosity or exposed slag

inclusion [Note(5)]
Surface finish

..

..

..

N/A

N/A

N/A

Concave root surface (suck up)

..

..

Weld reinforcement or internal

protrusion

..

..

..

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General Notes:
a.
b.
c.
d.

Weld imperfections are evaluated by one or more of the types of examination methods given, as specified in paras. 341.4.1, 341.4.2, 341.4.3 & M341.4 or by the
engineering design
N/A indicates the Codes does not establish acceptance criteria or does not require evaluation of this kind of imperfection for this type of weld
Check () indicates examination method generally used for evaluating this kind of weld imperfection.
Ellipsis (..) indicates examination method not generally used for evaluating this kind of weld imperfection

Criterion Value Notes for Table 341.3.2

Criterion
Symbol

Measure

Acceptable Value Limits [Note (6)]

Extent of imperfection

Zero (no evident imperfection)

Depth of incomplete penetration

Cumulative length of incomplete penetration
Depth of Lack of fusion & incomplete penetration
Cumulative length of Lack of fusion & incomplete Penetration [Note
(7)]
Size and distribution of internal porosity

Size and distribution of internal porosity

For w 6 mm (1/4) limit is same as D

For w > 6 mm (1/4) limit is 1.5 X D

Slag inclusion, tungsten inclusion, or elongated indication

Individual length
Individual Width
Cumulative length
Slag inclusion, tungsten inclusion, or elongated indication
Individual length
Individual Width
Cumulative length
Depth of undercut

Depth of undercut

1.5 mm (1/16) and [w/4 or 1 mm (1/32)]

Surface roughness

500 min. Ra per ASME B46.1

Depth of root surface concavity

Total joint thickness, incl. Weld reinforcement, w

Height of reinforcement or internal protrusion [Note (8)] in any plane

through the weld shall be within limits of the applicable height value in
the tabulation at right, except as provided in Note (9). Weld metal
shall merge smoothly into the component surfaces.

For w mm (in)
6 (1/4)
>6 (1/4) 13 (1/2)
>13 (1/2) 25 (1)
>25 (1)
Limit is twice the value applicable for L above

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1 mm (1/32) and 0.2w

38 mm (1.5) in any 150 mm (6) weld length
0.2w
38 mm (1.5) in any 150 mm (6) weld length

See BPV Code, Section. VIII, Division 1, Appendix 4

w/3
2.5 mm (3/32) and w/3
w in any 12 w weld length
2 w
3 mm (1/8) and w/2
4w in any 150 mm (6) weld length
1 mm (1/32) and w/4

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Height, mm (in)
1.5 (1/16)
3.0 (1/8)
4.0 (5/32)
5.0 (3/16)

Table 341.3.2 Acceptance Criteria for Welds and Examination Methods for Evaluating Weld Imperfections (Contd)
NOTES:
(1) Criteria given are for required examination. More stringent criteria may be specified in the engineering design. See also paras. 341.5 and 341.5.3.
(2) Longitudinal groove weld includes straight and spiral seam. Criteria are not intended to apply to welds made in accordance with a standard listed in Table A-1 or
Table 326.1. Alternative Leak Test requires examination of these welds; see para. 345.9.
(3) Fillet weld includes socket and seal welds, and attachment welds for slip-on flanges, branch reinforcement, and supports.
(4) Branch connection weld includes pressure containing welds in branches and fabricated laps.
(5) These imperfections are evaluated only for welds 5 mm (316 in.) in nominal thickness.
(6) Where two limiting values are separated by and, the lesser of the values determines acceptance. Where two sets of values are separated by or, the larger
value is acceptable. T w is the nominal wall thickness of the thinner of two components joined by a butt weld.
(7) Tightly butted unfused root faces are unacceptable.
(8) For groove welds, height is the lesser of the measurements made from the surfaces of the adjacent components; both reinforcement and internal protrusion are
permitted in a weld. For fillet welds, height is measured from the theoretical throat, Fig. 328.5.2A; internal protrusion does not apply.
(9) For welds in aluminum alloy only, internal protrusion shall not exceed the following values:
(a) for thickness 2 mm (564 in.): 1.5 mm (116 in.);
(b) for thickness > 2 mm and 6 mm (14 in.): 2.5 mm (332 in.)
For external reinforcement and for greater thicknesses, see the tabulation for Symbol L.

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