‘AP! SIFE- Source inspector Fixed Equipment Notes Guide for Source Inspection and Quality Surveillance of Fixed Equipment 1) Material Verification Program for New and Existing Alloy Piping Systems ‘Ans: APIRP 578 2) Valve Inspection and Testing ‘Ans: API Std 598 3) ipe Flanges and Flanged Fi Ans: ASME B16.5, 4) Structural Welding Code Ans: AWS DLL. 5) AARH is Ans: Arithmetic Average Roughness Height (a measure of surface roughness) 6) A comparison between measurements one of known magnitude or correctness (the standard) compared to the measuring device under test in order to establish the accuracy of a measuring device ‘Ans: Calibration 7) A metal integrally bonded onto another metal (e.g, plate), under high pressure and temperature whose properties are better suited to resist damage from the process fluids than the underlying base metal Ans: Cladding 8) Adeparture from requirements in the contractual agreements or its referenced PO, engineering design, specified codes, standards or procedures. ‘Ans: Deviation 9) The height of any point ona vessel as shown on a vessel drawing e.g. nozzle, manway, or longitudinal weld as measured from a base plate or other reference line such as the bottom. head tangent line, Ans: Elevation 10) The chemical symbol for iron which may appear on an MTR Ans: Fe 11) the base metal area next to the weld that has had its metal structure affected by the heat of welding ‘Ans: Heat Affected Zone (HAZ) 1| Page22) evaluation of a component or equipment for compliance with a specific product specification, code, drawing and/or standard specified in the contractual requirements, which may include the measuring, testing or gauging of one or more characteristics specified for the product to determine conformity is. ‘Ans: Inspection 13) Inspection Agency is Ans: An entity employed to provide competent, qualified and certified source inspection personnel for the purpose of performing source inspection 14) Who is responsible for the development of the source inspection strategy, coordination of the source inspection visits, and implementation of the source inspection activities on a project? ‘Ans: Inspection Coordinator 15) Inspection Waiver is é ‘Ans: Permission to proceed with production/shipment without having a purchaser source inspection representative present for a specific activity 16) Inspection and Test Plan (ITP) is A detailed plan for the source inspection activities which will guide the source inspector in quality assurance activities at the $/V site with. Ans: reference to applicable technical information, acceptance criteria and reporting information 17) The position of a surface of a component or structure that is horizontal (within tolerances) with the base plate and at 90 degrees to the vertical plumb Ans: Levelness 18) The maximum gauge pressure at the top of a pressure vessel allowed by code calculations for a designated temperature. ‘Ans: Maximum Allowable Working Pressure (MAWP) 19) The chemical symbol for magnesium which may appear on an MTR. Ans: Mg 20) The chemical symbol for manganese which may appear on an MTR. Ans: Mn 21) A document that certifies that a metal/material product is in conformance with the requirements (e.g. chemical and mechanical properties) of a specified industry standard—such as ASTM, ASME, etc. Ans: Material Test Report or Mill Test Report (MTR) 22) Areport filled out by the SI detailing an issue that has been discovered to be not in accordance with project contractual agreements such as the PO, engineering design, specified codes, standards or procedures ‘Ans: Nonconformance Report (NCR) 2] Page23) NDE/NDT are ‘Ans: Nondestructive Examination (the preferred terminology) and Nondestructive Testing (the outdated terminology). Note: NDE/NDT is A quality process that involves the examination, testing and evaluation of materials, components or assemblies without affecting its functionality e.g. VT, PT, MT, UT, RT 24) NOT is ‘Ans: Nondestructive Testing—Means the same as NDE, which is now the preferred terminology. 25) The orientation of a nozzle or attachment is the number of degrees off from a vertical centerline (a circumferential degree line} of the attachment or nozzle on the plan view of a vessel. For example, orientation of a nozzle or attachment can be checked with a protractor or smart level Ans: Orientation. 26) PAR is ‘Ans: Procedure Quaitication Record per ASME BPVC Section IX, QW 200.2 27) Anozzle or attachment projection is the length from the nozzle or the attachment face to the vessel shell centerline Ans: Projection 28) A measure of surface finish on flanges. Ans: Root Mean Square (RMS) 29) The term used to describe surface discoloration that occurs on the surface of steel that has been previously blasted e.g. near-white or white metal in preparation for coating ‘Ans: Rust Bloom 30) When rust bloom is found, the surface should generally, be. : ‘Ans: re-cleaned before coating using the same blast cleaning process. 31) The process of providing quality surveillance of materials, fabrications and equipment being supplied by supplier/vendor (S/V) or manufacturer/fabricator (M/F) for use in the oil, petrochemical and gas industry, including upstream, midstream and downstream segments ‘Ans: Source Inspection 32) Whom responsible for performing the actual source inspection act accordance with the applicable inspection and test plan (ITP)? Ans: Source Inspector ies at the S/V facil 33) TEMA. ‘Ans: Tubular Exchanger Manufacturers Association 34) the limit (or limits) of specified dimensions, physical properties or other measured values of a component is, Ans: Tolerance 3] Page35) the deviation from perfect alignment between two pieces of metal welded together. It is important for the SI to measure. Ans: fili@ (weld mismatch) with a hi-lo gauge. 36) WPQ Ans: Welding Performance Qualification Record per ASME BPVC Section IX, QW 301.4, 37) ‘tasked with the responsibility of performing source inspection coordination and/or source inspection activities should develop a management program in order to provide the individuals performing the specific source inspection functions the necessary information to accomplish their duties. ‘Ans: Employers or inspection agencies 38) From the Source Inspection Management Program documents, a Project Specific Inspection Plan should be developed by Ans: the inspection coordinator 39) Effective source inspection for each project begins with, P ‘Ans: a risk-based assessment of the materials and/or equipment to be procured for the project. 40) These risk-based assessments are performed to. Ans: identify the level of effort for source inspection activities during the M&F phase of a project at the S/V facility 41} Development of Inspection and Test Plans (ITP) should be Ans: > specific to the type of equipment to be inspected, the associated risk level for each piece of equipment and identify all the inspection activities necessary to be performed by the assigned source inspector. 42) Dates for source inspection scheduled work process events such as the pre-inspection meeting (fabrication kickoff), key inspection events (factory acceptance, performance testing and final inspection) and anticipated shipping date should be identified in advance, ‘Ans: £0 allow coordination with other project members involved in the activity. 43) Source inspection reports are ‘The amount and type should be. Ans: specified in the ITP. portant deliverables from the SI to the project team or client. 44) If any conflict should arise during the inspection activity, the source inspector should, Ans: notify their supervisor for resolution as soon as possible, 4|Page45) Prior to commencing the quality surveillance specified in the ITP, the source inspector should Ans: > confirm that the $/V has the most current documents, drawings, etc. specified in the engineering design. Later editions of industry codes and standards do not apply if the engineering design has specified an earlier edition of a specific standard. > confirm that that all project documents have been reviewed/approved by the purchaser 46) The SI needs to be familiar with all company and client standards that are specified in the contractual agreements. Company and Client Standards are : Ans: Sijpically augment or Supplement industry standards for issues not sufficiently well covered in industry standards. 47) RP includes a description of the various types of pressure vessels and the materials and standards for their fabrication. Ans: API RP 572, Inspection Practices far Pressure Vessels. 48) provides guidance for the source inspector on welding fabrication inspection. Issues covered include welding processes, procedures, welder qualifications, metallurgical affects from welding, inspection techniques, welding terminology and symbols, how to review a welding procedure, and a guide to common filler metals. ‘Ans: AP! RP 577, Welding inspection and Metallurgy 49) is to provide guidelines for a material and quality system to verify that the nominal composition of piping alloy components is consistent with the material specifications. The primary topics covered include material verification test methods, evaluation of PMI test results, marking and record keeping Ans: API RP 578, Material Verification Program for New and Existing Alloy Piping Systems. 50) standard covers the inspection, examination, and pressure test medium and requirements for vatious kinds of valves utilized in the energy industry. ‘Ans: API Std 598, Valve Inspection and Testing. 51) NDE requirement for valves (body, bonnets, welding, weld preps) will be governed by ‘Ans: The applicable piping code (ASME 831.3 or 831.1) 52) ASME BPVC Section II—Materials. Ans: Part A—Ferrous Material Specifications Part B—Nonferrous Material Specifications Part C—Spenifications for Welting Rods, Electrodes and Filler Metals. Part D—Materials Properties. vvvy 5] Page53) contain requirements and methods for NDE techniques that are specified by other sections of the ASME BPVC and/or contractual agreements. ‘Ans : ASME BPVC Section V Note : For the purposes of S| examination, some of the content covered in ASME BPVC Section V that applicants should focus on include : > All definitions in Subsection A, Article 1, Appendix 1 and Subsection B, Article 30, SE-1316 > Article 1.0m General Requirements for NDE > Atticle 4 on Uttrasonie Examination Methods of Welds > Atticle 6 on Liquid Penetrant Examination > Article 7 on Magnetic Particle Exarnination > Article 10 on Leak Testing > Attiole 23, Section 797 on UT Thickness Testing 54) contains the requirements, specific prohibitions and non-mandatory guidance for standard design unfired pressure vessel materials, design, fabrication, examination, inspection, testing, certification and pressure relief requirements Ans: ASME BPVC Section Vill, Division 1 —Rules for the Construction of Pressure Vessels 55) Rules for the Construction of Pressure Vessels Alternative Rules Ans : ASME BPVC Section Vill, Division 2 56) covers the qualifications of welders, welding operators and the procedures that will be employed during fabrication, ‘Ans: Section IX of the ASME BPVC Part OW Note: ASME BPVC Section IX—Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators 57) Process Piping. ‘Ans: ASME 831.3 58) Recommended practice establishes a general framework for a qualification and certification program for NDE technici Ans: ASNT SNT-TC-1A 59) Procedure for Determining Conformance to Dry Coating Thickness Requirements. ‘Ans: SSPC-PA 2 Coating Applications Standard No. 2 60) SSPC Surface Preparation Guide. Ans: > S5PC-SP1—Solvent Cleaning > _SSPC-SP3—Power Tool Cleaning > SSPC-SP6 or NACE 3—Commercial Blast Cleaning. > _SSPC-SP7 or NACE 4—Brush-Off Blast Cleaning. > $SPC-SP11—Power Tool Cleaning to Bare Met 6| Page61) Near-White Blast Cleaning ‘Ans : SSPC-SP10 or NACE 2 62) Pre-purchase Meeting : ‘Ans : Prior to Contract Placement Note: > The source inspector may or may not participate in a pre-purchase meeting. > The purpose of 5Pre-purchase Meeting is to cover some specific design, fabrication, and/or QA/QC requirements expected of the $/V to make sure that their bid does not inadvertently overlook them and result in unanticipated surprises during fabrication and source inspection activities. 63) Pre-inspection Meeting, e Ans: Prior to Start of Fabrication Note: > The source inspector assigned to the S/V facility should participate in the pre-inspection meeting. > The purpose of Pre-inspection Meeting is to enisuré that everyone at the S/V who will be involved in manufacturing, fabrication and monitoring the quality of the equipment fully understands specific requirements and details of the job, especially those requirements that may be non-routine or different relative to normal S/V quality surveillance. 64) Photographs are common place in inspection reports as they assist in the description of the inspection results, The SI should request permission from, ‘Ans: The S/V prior to taking any photographs 65) Reports should be submitted to for review of content and technical clarity before they are distributed to the purchaser unless otherwise instructed Ans: the inspection coordinator 66) When deviations to the contractual agreement or its referenced specifications, drawings, codes or standards are identified, the source inspector should identify them as nonconformances. The source inspector should notify as soon as practical once a nonconformance has been identified ‘Ans: the inspection coordinator. 67) In general, deviations from specifications must be approved by ‘Ans: the responsible engineer/technical personnel 68) At the completion of the source inspection activities at an S/V, the source inspector, inspection coordinator, and all others involved in the “planning and doing” processes should Ans: review the entire planning and doing part of the “Plan-Do~Check-Adjust” continuous improvement (Cl) cycle 7) Page69) Ensuring that the S/V is using the correct material during the fabrication or manufacturing of the equipment is a critical element of quality surveillance. Typical reviews should consist of the following, Ans: Material Test Reports (MTRs) 70) Confirming that the construction materials proposed are the actual materials used during, construction is, Ans: atypical source inspection activity 71) Verify that the material complies with specific chemical and/or mechanical properties as specified in Ans: the contractual documents 72) Before Visual Examination procedure performance, the visual acuity requirements Ans: Personnel are required to demonstrate annually completion of a I-1 Jaeger-type eye vision test, 73) The primary source for the specific NDE techniques to be applied during M&F by the S/Vis included in the applicable project specifications. Those documents should reference other appropriate codes/standards for NDE methods such as, Ans: ASME BPVC Section V and NDE technician qualifications such ag ASNT SNT TCA 74) covers most of what the source inspector needs to know about material verification and PMI. Ans: API RP S78, 75) Tensile testing is performed to determine Ans: yeld strength (point at which elastic deformation becomes plstic/permanent deformation) and ultimate tensile strength (fracture point) of an item. Note: Tensile testing is used to determine a metals ultimate tensile strength, yield strength, elongation and reduction in area. A tensile test is performed by pulling a test specimen to failure with increasing load, 76) is commonly performed on weld coupons to check the ductility and integrity of welds. Ans: Bend testing. ™ is performed to determine toughness of metals and welds. ‘Ans: Charpy impact testing, 78) For many construction codes, impact testing often becomes a requirement below temperatures of, Ans: S30°F) but the engineering specifications may require impact testing at other temperatures as well. 73) generally not applicable to fixed equipment like vessels and piping and is more related to machinery, instruments, analyzers, and control systems to determine that the equipment will perform as specified in service. Ans: Performance and functional testing. 8|Page80) Coating systems are usually specified in the contractual and engineering documents and likely will involve single or multi coating applications. The method of inspection of these coating. systems is by the use of which the SI should be familiar with, Ans: SSPC-PA 2 81) Reviewing Final S/V Data. It is typical for the SI to perform final review of the contractually required S/V data upon the completion of the manufacturing/fabrication and prior to shipment of the materials or equipment. This review is to determine that all documents are complete, with the as built item with all supporting documents as identified in the contractual agreement. Such documentation may include but is not limited to: Ans: inal fal MTR’s Pressure test documentation NDE results Product specific OC checks NCR close outs Certification documents Code compliance documentation tion drawings vvyvvY vv 82) Rework and repair should be x ‘Ans: approved by the purchaser and verified by the Sl 83) Typical defects associated with the casting process that the SI should be aware of include: Ans: > Shrinkage voids > Gas porosity > Trapped inclusions 84) Grade symbols are required such as WCB, WC9, CF8M in order to indicate the type of Ans: casting material (valve castings) 85) Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping ‘Components—Visual Method for Evaluation of Surface Irregularities is the standard that is generally used to perform visual evaluation of surface irregularities that may have occurred during the casting process. ‘Ans: MSS-SP-55, 86) The vast majority of metallic materials used for the fabrication of refinery and chemical plant equipment are used in the, form. Ans: Wrought. 87) grain flow follows the general shape of the component and results in improved strength and toughness characteristics by ‘Ans: forging process 9|Pag88) Standard Specification for Steel Forgings, General Requirements covers a group of common requirements that may be applied to steel forgings for general use Ans: ASTM A788 89) are the principal machine tool used in turning Ans: Lathes 90) Examples of physical properties of a metal are Ans: 7 the melting temperature, the thermal conductivity, electrical conductivity, the coefficient of thermal expansion, and density. vvvy 91) property of a ferrous alloy that determines the depth and distribution of hardness induced by quenching. Ans: Hardenabilty 92) Hardness of a material is defined as the resistance to, \ Ans: plastic deformation by indentation 93) Hardness depends primarily on Ans: the carbon content of the material Note: hardenability is strongly affected by the presence of alloying elements, such as chromium, molybdenum and vanadium, and to a lesser extent by carbon content and alloying elements such as nickel, copper and silicon. 94) heating of the weld and surrounding base metal to a predetermined temperature prior to the start of welding. Ans: Preheating 95) The primary purpose for preheating carbon and low-alloy steels is ‘Ans: to reduce the tendency for hydrogen induced delayed cracking 96) According to B31.3, the pre-heat zone for welding of new process piping should, Ans: extend at léastlonelindh beyond the edge of the weld for piping. 97) When PWHT is required by code, typical normal holding temperatures for carbon and some alloy steels is, Ans: 00°F for one hour per inch of thickness with 15 minute minimum. 98) For Heat Treatment of A-516. If approved by the purchaser, cooling rates faster than those obtained by cooling in air are permissible for improvement of the toughness, provided the plates are subsequently tempered in the temperature range, : Ans: 1100 to 1300°F (595 to 705°C] 10| Page99] When PWHT is required by code, typically heating rates for pressure equipment and piping above 800°F must be controlled to, ‘Ans: idiot than 400Fper hou with no variation permitted of More than 2S0"Fin anv as #88 segment of the equipment. 100) A pressure vessel is a container designed to withstand internal or external pressure. The pressure vessels are typically constructed in accordance with Ans: ASME BPVC Section Vll or other recognized international pressure vessel codes, or as approved by the jurisdiction, 101) For pressure vessel, codes typically limit design basis to an external or internal operating pressure, : ‘Ans: no less than 15 psig (103 kPa). 102) The primary difference between a tank and a vessel is that. Ans: tanks generally operate at lower pressures, often ator just above atmospheric pressures, 103) Austenitic stainless steels (type 300 series) come in a variety of. Ans: Cr/Mo/Ni/Fe contents. 104) Type 321 and 347 are stabilized grades that will avoid, Ans: SHIRSBGRIGPEREIHAY during welding and therefore retain most oftheir corrosion resistance during fabrication 105) Type 321 and 347 are stabilized grades that will avoid sensitization of the HAZ during welding and therefore retain most of their corrosion resistance during fabrication. Type 321 is stabilized with small amounts of, ; while type 347 is stabilized with small amounts of ‘Ans: Type 321 is stabilized with small amounts of Ti; while type 347 is stabilized with small amounts of Nb. 106) Some type 300 stainless steels also come in “L” grades like 3041, 3161, and 3171. The “L” stands for. ‘ Ans: low carbon. 107) Some type 300 stainless steels also come in “H” grades like 304H, 316H, and 317H. The “H” stands for Ans: high carbon. 108) All materials used for the construction of pressure vessels should have traceability. For example, acceptable methods of traceability for plates used in the fabrication of vessels include: Ans: Plate number Lot number > Heat number o me 11| Page109) FRP can be made with different resins as the matrix material and typically use glass fiber as the reinforcement. area type of FRP that is more rigid due to the use of a thermoset resin for the matrix rather than a thermoplastic. Ans: Reinforced thermoset plastics 110) ASME Section Vil, Division 3 provides alternative rules for construction of high-pressure vessels with design pressure ‘Ans: generally, above 10) [70 MPa), 111) The SI should conduct dimensional checks of pressure vessels to ensure they are within the required tolerances of the specification. At a minimum these checks consist of the following: Ans: Mill under-tolerance of plates and pipes Tolerances for formed heads Out-of-roundness of shell Nozzles and attachments orientation vv vv > Weld mismatch > Weld reinforcement 112) Heat Exchangers are used to Ans: reduce the temperature of one fuldby transferring heat to another fluid without mixing the fluids 1113) In Heat Exchangers, an impingement baffle plate or rod baffle is located below the shell inlet nozzle to Ans: prevent impingement of the incoming fluid on the adjacent tubes. 114) In the U.S., Heat Exchangers and condensers are designed and built in accordance >. P| 661—Air-Cooled Heat Exchangers for General Refinery Services 115} Valve pressure testing is normally required for per API Std 598, Ans: the shell, seat leakage, back seat and packing 116) NDE requirements for valves will be governed by the applicable piping code_ . Ans: ASME 831.3 or B31.1, and/or the purchase order documents, 1117) What is the difference between the Weld Neck Flange and Ring Type Joint (RT!) Flange? Ans: Weld Neck Flange is circumferentially welded into the system at its neck which ‘means that the integrity of the butt-welded area can be easily examined by radiography and Ring Type Joint (RTJ) Flange has A metal ring compressed into a hexagonal groove on the face of the flange to make the seal | Page118) Marking on valves at a minimum shall comply with the requirements of . ‘Ans: MSS-SP-25, Standard Marking System for Valves, Fittings, Flanges and Unions unless ‘otherwise specified in the purchase order documents 1119) Gaskets have proven to be reliable in most applications, and allow lower clamping forces than solid gaskets Ans: Spiral wound gaskets 120) The welding of structural steel generally falls under the requirements of. Ans: AWS DLL 121) Galvanizing should be in accordance with unless otherwise specified in the purchase order documents Ans: ASTM A123 o A153 122) Power Boilers Stamp Ans :S LS) 123) Multi-purpose welding inspection gage that can be used to verify angles of welded preparation, excess weld cap size, undercut depth, fillet throat size and surface misalignment. Ans : Bridge Cam Gages 1124) instrument used to measure outside diameters/dimensions. Typically used for close tolerance ‘dimensions on machined parts. ‘Ans : OD Micrometer + “Sle 125) Measures the depth of weld undercut or other surface discontinuities. Ans: Pit gage 1126) Tool for measuring surface temperature. ‘Ans: Laser Thermal Gun 127) Tool designed to measure electric current in amperage and voltage. May be used for checking welding machine settings ‘Ans: Clamp on Amp Meter128) Tool designed to measure the surface roughness for material that is about to be coated. ‘Ans : Digital Surface Profile Gage 128) Tool designed to replicate surface profile and measure surface roughness. Ans : Surface Profile Replica Tape 130) Tool designed to verify or measure chemical content. Ans : Positive Material Identification Too! =—— a 131) Tool for measuring surface hardness. Ans: Portable Brinell Tester 1132) Used for calibration of precision measurement equipment. ‘Ans: Precision Gage Blocks 577 - Welding Proces: ind_Metallur: 133) A nonmetallic product resulting from the mutual dissolution of flux and nonmetallic impurities in some welding and brazing processes. Ans: slag, 134) A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal Ans: undercut. 135) Which of the following defects not the common in all welding processes? ‘Ans: tungsten inclusion. 14| Page136) Welder performance qualification expires if the welding process is, ‘Ans: not used during a six-month period. 137) reduce the number of welding procedure and performance qualifications by. ‘Ans: F-numbers (Electrodes and welding rods) 138) a volumetric examination method capable of examining the entire specimen rather than just the surface. Ans: RT. 1139) tools used in industrial radiography to establish the quality level of the radiographic technique. Ans: IQs (penetrameters) Note: Standards for industrial radiography require the use of one or more image quality indicators (IQs) to determine the required sensitivity is achieved. 140) fect visual examination is conducted when access is sufficient to place the eve within. : ‘Ans: 6 in. through 24 in. (150 mm through 600 mm) of the surface to be examined and at an angle not less than 30 degrees to the surface. 141) An interruption of the typical structure of a material, such as a lack of homogeneity in its mechanical, metallurgical, or physical characteristics Ans: Discontinuity. Note: A discontinuity is not necessarily a defect 1142) The response or evidence from the application of a non-destructive examination. Ans: Indication, 1143) A flaw (imperfection or unintentional discontinuity) of such size, shape, orientation, location or property, which is rejectable Ans: Defect. 144) Tensile testing is used to determine. ‘ ‘Ans: a metals ultimate tensile strength, yield strength, elongation and reduction in area. Note: A tensile test is performed by pulling a test specimen to failure with increasing load. 145) the force acting in a given region of the metal when an external load is applied. Ans: Stress. Note: } The nominal stress of a metal is equal to the tensile strength. > The ultimate tensile strength of a metal is determined by dividing the external load applied by the cross-sectional area of the tensile specimen. 146) the amount of deformation change in shape, a specimen has experienced when stressed. Ans: Strain, Note: Strain is expressed as the length of elongation divided by the original length of the specimen prior to being stressed 15| Page147) stress applied above the yield point produces a permanent increase in specimen length and the yielding is considered Ans: plastic deformation. 148) curve for a material gives the relationship between stress and strain. Ans: A stress-strain curve. 149) The hardness of a material is defined as Ans: the resistance to plastic deformation by indentation. Note: Indentation hardness may be measured by various hardness tests, such as Brinell, Rockwell, Knoop and Vickers 150) the ability of a metal to absorb energy and deform plastically before fracturing. Ans: toughness. Note: An important material property to tank and pressure vessel designers is the “fracture toughness” of a metal which is defined as the ability to resist fracture or crack propagation under stress. 151) The primary purpose for preheating carbon and low-alloy is to, ‘Ans: reduce the tendency for hydrogen induced delayed cracking. 152) If preheat is specified in the WPS it is important that the inspector confirms that the required temperature is maintained by using several methods ‘ns: thermocouples, EBRIEEBWFSREEE, infrared temperature measuring instruments, or temperature indicating crayons. 153) Preheat should be applied and extend to. Ans: at least 2 in. (50.8 mm) of either side of the weld to encompass the weld and potential heat affected zone areas. 154) The primary reason for postweld heat treatment is to, Ans: relieve the residual stresses in a welded fabrication, 155) Typically, steels with a CE less than 0.35 require, . ‘Ans: no preheat. 156) Steels with a CE of 0.35 to 0.55 usually require ‘Ans: preheating. 157) steels with a CE greater than 0.55 require. ‘Ans: both preheating and a PWHT. 158) provides an in-depth review of the safety aspects to be considered when hot tapping or welding on in-service piping or equipment Ans: AP/ 2201. 16 | Page159) Hot tap and in-service welding operations should be carried out. : ‘Ans: only with low-hydrogen consumables and electrodes (e.g. E7016, £7018, and £7048), 160) = Meat, eco eats ee a ec a p Smee fee eee ue sh oc arspe i es ee notes Sees nae mee meee Figure: A4—Standard Weld Symbots a |Page161) key 1. RoouOpening: | 2 RootFace: _Thatgorion of he groove face ocr tobe ro SmeeaKeaES The suface ofa joint monberincaod he gone 4. BevelAngle: The angle gre between he ropares espe a member snd 2 flan prpeniciar'o he suse of AKO fermenter 5. Goove Ange: The tallest angio he grove Dotween workpiece 6. Groove Weld Size: The joint penetration ofa groove weld 7, Plate Thickness (7): Thickness ofthe base metals to be welded Figure A.5—Groove Weld Nomenclature = EXXXX Figure A.6—SMAW Welding Electrode Identification System Chemical Strength ‘composition et Ta ERXXS-X Figure A.7—GMAWIGTAWIPAW Welding Electrode Identification System 18| PageAPIRP 578 - Guidelines for a Material Verification Program (MVP) for New and Existing Assets 162) A certified document that permits each component to be identified according to the original heat of material from which it was produced and identifies the applicable material specification (including documentation of all test results required by the material specification). Ans: mill test report (MTR). 163) As per API578, PMI Test Methods Ans: ©) Chemical laboratory chemical analysis 4d) Other qualitative Tests (chemical spot, resistivity spot testing) > Other technique (Eddy-current sorters, electromagnetic alloy sorters, triboelectric devices (e.g, ferrite meters) and thermoelectric tests) 164) Recommended Practice for Color Coding of Piping Materials is, ‘Ans : Fabrication Institute (PFI) Standard £522. 165) If the material verification program procedure established by the owner/user requires a visual identification such as color coding or marking, the owner/user should maintain a record of the alloy material/color code combinations. Recommended Practice for Color Coding of Piping Materials is. ‘ Ans : Fabrication Institute (PFI) Standard E522. 166) Shoiild not be considered a substitute for PMI testing, Bilt may be an important part of an overall quality assurance program. Ans: Material certifications, mill test reports, or certificates of compliance. API RP 572 “Inspection Practices for Pressure Vessels 167) A metal integrally bonded onto another metal under high pressure and temperature whose properties are better suited to resist damage from the process than the substrate material. Ans: dadding. 168) A nonmetallic or metallic material installed on the interior of a vessel whose properties are better suited to resist damage from the process than the substrate material. Ans lining. 168) Strips of metal plates or sheets that are welded to the inside of a vessel wall for the purpose of protecting the vessel construction material from interaction with process fluids. Normally, the strips are of a more corrosion-resistant or erosion-resistant alloy than the vessel wall and provide additional corrosion/erosion resistance. Ans: strip lining. 19| Page170) The use of weld metal of a composition different than the base metal to provide corrosion and/or erosion resistance to the base meta Ans: weld overlay. API STD 598 Valve Inspection and Testing 171) A pressure test used to verify leakage past the stem or shaft to bonnet seal. Ans: backseat test 172) What is the duration of backseat test for valve NPS 4? Ans: 60 second Table 4—Duration of Required Test Pressure Valve Size Minimum Test Duration (Seconds) * Backseat (forvaives | Check | closure DN Me Shel | ganith |. | Valves, | Other Valves ckseat | (api 594) Feature) | ( <50 <2 15 15 60 15 6510150 | 2%nto6 60 60 60 60 20010300 | 81012 120 60 120 120 2 360 214 300 60 120 120 > The test curation is the period of inspection after the valve is fuly prepared and is under ful pressure ASME B16.5 Pipe Flanges and Flanged Fittings 173) ASME B16.5 covers NPS's Ans: from %" to 24” Note: ASME 816.47 covers NPS's from 26" to 60" 174) Pipe Flanges and Flanged Fittings. Ans: ASME B16.5 Note: > B16.5 covers flange class designations for 150, 300, 400, 600, 900, 1500 and 2500 systems for sizes from NPS 4 to NPS 24 made from cast or forged materials. 175) covers blind flanges and reducing flanges ‘Ans: ASME 816.5, 20|Page176) covers piping line blanks (blinds). ‘Ans: ASME 816.48 177) Special techniques, such as controlled bolt tightening, are described in, ‘Ans: ASME PCC-1 ASME SECTION Vill Rules for Construction of Pressure Vessel 178) when determining the permissible out-of-roundness of cylindrical shells under internal pressure where the cross-section does not pass through a nozzle vessels, the difference between the maximum and minimum in: cross section under consideration shall not. Ans: exceed 1% (29610) 179) What is the range for a dial gage used during a hydrostatic test? Ans: minimum 1% and maximum 4 times that pressure, 180) All gages shall be calibrated against, E Ans: a Stiidad @@a@-WeighERESHetor a calibrated master gage. 181) When vessels are to contain substances, either liquid or gaseous. Who is responsible to determine if itis lethal? Ans: owner/user and/or his designated agent. 182) when itis deemed necessary the Weld metal and heat affected zones may be pened by manual, electric, or pneumatic means. Peening Ans: helpful to control distortion, to relieve residual stresses, or to improve the quality of the weld. 183) When PWHT is required by code, typically cooling rates for pressure equipment and piping above 800°F must be controlled t Ans: no more than SOO°F per hour. ASME B31.3 Process Piping 184) Which the following code/ standard cover the requirements for materials and components, design, fabrication, assembly, erection, examination, inspection, and testing of piping and applies to piping for all fluids, including raw, intermediate, and finished chemicals, petroleum products gas, steam, air, and water, fluidized solids, Pafrigerants & cryogenic fluids? Ans: scope of 831.3. 185) mechanical or electromechanical device to examine the inside diameter of inaccessible welds ‘Ans: borescopic examination 21| Page186) What is the action to be taken if a spot or random RT examination on a sample reveals a weld defect? ‘Ans: RT two additional samples of the same kind by the same welder 187) What would be the usual extent of examination for butt welds in normal class fluid service piping? Ans: Not less than 5% of circumferential butt and miter groove welds shall be examined fully by random radiography or ultrasonic examination 188) nominal pipe size (followed, when appropriate, by the specific size designation number without an inch symbol). ‘Ans: NPS 189) Throat of a fillet weld: > theoretical throat: the perpendicular distance from the hypotenuse of the largest right triangle that can be inscribed in the weld cross section to the root of the joint > actual throat: the shortest distance from the root of a fillet weld to its face > effective throat: the minimum distance, minus any reinforcement (convexity), between the weld root and the face of a fillet weld AWS 01.1 Structural Welding Code 190) Prequalification of WPSsis allowed by, : Ans: AWS D1.1 ‘ASME IX Welding, Brazing, and Fusing Qualifications 191) For the short-circuiting transfer mode of the gas metal-arc process, when the qualification test coupon thickness is less than 1/2 in. (13 mm), the maximum range of thickness of Base Metal is. : Ans: 1.1 times that of the qualification test coupon 192) For the short-circuiting transfer mode of the gas metal-arc process, when the qualification test coupon thickness 1/2 in. (13 mm) and greater, the maximum range of thickness of Base Metal is Ans: 2 times that of the qualification test coupon 22| PageRecommended Practice No.SNT-TC-1A personnel qualification and certification in nondestructive testing 193) individual should have sufficient technical knowledge and skills to be qualified to properly perform specific calibrations, specific NDT, and specific evaluations for acceptance or rejection determinations according to written instructions and to record results and should receive the necessary instruction and supervision. Ans: NDT Level |. SSPC-PA 2 procedure for determining conformance to Dry coating thickness requirements cness requirements by 194) As per SSPC-PA 2, determining conformance to Dry coating ‘Ans: Magnetic Pull-Off and Electronic Gages. 23| PageReminder &Recall of point RMS Root Mean Square—Almeastire ofisurface finishron flanges) Ferrous Materials Alloys that are iron based, including stainless steels, Ferrous content of ferrous metal 50% 77? Inspection Agency An entity employed to competent, qualified and certified Tor the purpose of performing source inspection. For example and inspection agenoy can be an EPC company, an owner-user, or an inspection service company, Inspection Waiver Permission to proceed with production/shipment without having a purchaser source inspection raprésantati present fora specfc roi MAWP —Aoximum Alowable Working Press ue SRIRTESUGS SSS [atthe topos presse VeRselalonied by code cations fora cesignated temperature. Normalizing Heat Treatment A heat treating pracess in which a ferrous material or alloy is heated to’ specified temperature above the transformation range of the metal and subsequently cooled in still air at room temperature. Typically normalizing heat treatments will refine the grain size and THORS ESA CSTE NPS. Nominal Pipe Size—A’standard for designating pipe sizes (inches) and decoclated wal tnloess che) og te ior ope ee 0" 6 four inch pipe & nornaly shown as NPS 4 MSH MeRNBS SOD isang Orientation The onertal6Rt a haza rettachert is the umber of degrees of from a vertical centerline (a circurrferential degree line) of the Ainafvert or soca hte plan ow ofa vest Por carpe orientation of a nozzle or attachment can be checked with a Saar Projection _ Anozzle or attachment projection is the Outof-Roundness A deviation from perfect roundness e.g ovality ina vessel circumference. ASME BPVC Section VIII, Division 1, UG 80 Goals wil ot of roundness of vesos! shel. The maximum mitted ovality tolerance (Dmax —Dmin) "2 % of the opening ofa long as the ut of founcess portion les wilin inside da of he opening Pressure Vessel A cortainee dovigned to vithetand a spociios amount st rer or external pressure generally BBBVEMIS BBIg. Ths definition includes heat exchangers, air-coolers, columns, towers, unfired steam generators (boiers) ard other vapar genetaling Vessels, 24 | Page2 5 Quality Assurance—A proactive quality process that aims to prevent defects and refers to a program of planned, systematic and preventative activities implemented in a quality system that is intended to provide a degree of confidence that a product will consistently meet specifications, Itincludes the systematic measurement, comparison with a standard, monitoring of processes and an associated feedback loop that is, intended to avoid deviations fram specication. Qualification required for personnel to perform the duties of specific job e.g, ¢ certified source inspector. uments filled out by the S| indicating concerns or other factual descriptions of what was noticed during the course of product surveillance, but not necessarily issues that my be considered defects or requiring NCR's. Tolerance _ Engineering tolerances refer to, or other measured values of 2 ‘component. Weld Reinforcement — The height of the weld cap, The longitudinal joint weld reinforcement limit is more stringent than that for UW 35 citcumferential joints. This is because longitudinal joint bears double stress, and itis required that the stress concentration be minimzed. Maximum weld reinforcement is specified in ‘ASME BPVC Section Vill, Division 1 25|Pageinvolve company specific activities ike what activities are to be performed, who is responsible for each activities ie personal titties, the training & competency required for SI, freq of st, acceptance criteria , specific work procedure, Interfacing with Jurisdictional authorized inspector Pre pection meeting is called fabrication kick off RISK INSPECTION CATAGORY 1) Lowest Risk: Fully depend on S/V Quality programme : No Source Inspection 2) lower to medium risk material or equipment Final Source Inspection (final acceptance) only just prior to shipment, rely primanly on S/V quality with minimum source inspection), 3)medium to medium high-risk equipment; Intermeciate Source Inspection level (mixture of reliance on SIV quality with some source inspection activities et the more critical hold points). The number of shop visits may go up or down based on the performance level of the S/V, 4)Higher risk equipment: Advanced Source Inspection level (, significant amount of source inspection e.g, weekly to provide higher level of quality assurance). The number of shop visits may go up or down based on the performance level of the SIV. 5) Highest risk equipment: Resident Source Inspection level [, full time shop inspectors) assigned, possibly even on all shifts] Dates for source inspection pre-inspection meeting, key inspection events (acceptance, performance testing and final inspection) and anticipated shipping date should be identified in advance to allow coordination with other project members involved in the activity SI should give Source inspection reports to Project team or Client If any conflict in inspection activity, the source inspector notify their supervisor for resolution ASAP. Additionally, the source inspector should confirm that that all project documents have been Feviewediapproved by the purchaser. Reports should be subrmitted to the inspection coordinator for review of content and technical clarity before they are distributed to the purchaser unless otherwise instructed Nonconformance/Deviations. When deviations to the contractual agreement are identified, the source inspector should identify them as nonconformances. and should be notified inspection coordinstor asap ‘Source Inspection Project Continuous Improvement. Any such improvements should be documented and made available to source inspection managers and coordinators to implement the improvements. This should include an evaluation of the performance of the SIV The SI needs to be familiar with all SSFTBBRVPaRgIGIENEStERGERES that are specified in the contractual agreements. These stancards typically augment or supplement indusity standards forlissUes not sufficiently well covered in industry standards, ‘All mandatory requirements ie. “shallimust’ statements, included in the company spectfications must be met or become an issue for an NCR ther issues contained in the specified standards such as those suggested or recommended ie “should” statements which are expectations of the S/V, but not necessarily requirements may become an issue to be reported in Supplier Observation Reports (SOR’s) and handled in accordance with standard purchaser management systems. 26 | Page© SSPC-SP5 or NACE 1—White Metal Blast Cleani ° 8.3 Performing the Source Inspection Qualified and certified, as specified in the ITP or other contractual documents. or welder log books or ASNT SNT TC-1, EPRI, of API Industry Qualified Examiners teow siege nent guesesswmiarn Pre-purchase Meeting (Prior to Contract Placement) ‘The source inspector may or may not participate in a pre-purchase meeting. Pre-inspection Meeting (Prior to Start of Fabrication) The source inspector assigned to the S/V facility should participate in the pre-inspection meeting ‘Advance preparation by the source inspector is important for the pre-ingpection meeting The purpose of this meeting is to ensure that everyone at the SIV fully understands specific requirements and details of the job, especially those requirements that may be non-routine or different relative to normal S/V quality surveillance Photographs can be used in ins, ion reports: ‘The Sf shoul tecuest permission fom te SIV prt taking ary photoraphs. Care ‘should be exercised to ensure that an appropriate number of photos are attached Reports should be submitted to the inspection coordinator for review of content and technical clarity before they are distributed to the purchaser unless otherwise instructed Nonconformance/Deviations. When deviations to the contractual agreement are identified, the source inspector should identify them as nonconformances. and should be notified Inspection coordinator asap MIR : Material test report Or MIL Report PM| is retrospective Casting Process ‘+ Anadvantage of the casting process is that 2 single step process can be used to produce components that are characterized by one of more of the following attributes: Complex shapes e.g. fitings, anges, valve bodies. Hollow sections or internal cavities Imtegular curved surfaces Very large sizes Materials that are difficutt to machine + BiSadWE Toughness may be inadequate Typical defects - Shrinkage voids, (1 Gas porosity Trapped incisions 27 | Pagecovers the minimum requirements for design, materials, fabrication, inspection, testing, and preparation for delivery of air coolers. ‘As with all fixed equipment items, the WF is responsible for ensuring that the fabricated heat exchanger complies with the TEMA Standard when it is specified in the contractual documents. ASME B31.6 Chemical plant piping But it was folded to 31.3 ‘When the shape or size does not permit inclusion of all the required markings, some markings may be omitted starting with the least important information such as size. ie. sealing surfaces for diferent services, such as raised face, fiat face, ring joint and lap joint Reisec-face is the most common type. Manufacturing tolerances for widely used + A703 / A703M «Standard Specification for Steel Castings, General Requirements, for Pressure-Containing Parts. 4 ASTMAT7E8 / A788M + Standard Specification for Stee! Forgings, General Requirements. 4 pwHr ‘© PWHT is the most common form of fabrication heat treatment applied to fixed equipment. When PWHT is required by code, typical normal holding temperatures for carbon and some alloy steels is 11100" F for one hour per inch of thickness with 15 minutes minimum. * Typically, heating rates for Pressure equipment and piping above 800°F must be controlled to no more ‘than 400°F per hour with no vatiation permitted of more than 250°F in any 15 foot segment of the equipment. + Design Cotes ‘© Some high-pressuire vessels are designed and built in accordance with the specifications of Section Vill, Division 2. + Section Vill, Division 3 provides alternative rules for construction of high-pressure vessels with design pressure generally above 10 ksi (70 MPa). 4 Valve pressure testing is normally required for the * shell, seat leakage, back seat and packing. * Hydrostatic testing is normally applied per API Std 598. 4 Marking on valves at a minimum shall comply with the requirements of. ‘ MSS-SP-25, Standard Marking System for Valves, Fittings, Flanges and Unions unless otherwise specified in the purchase order documents. ‘+ Markings shall be applied to the body of a valve or an identification plate. 28| PageASME B16.5 covers NPS's from %" to 24” and © Each specification further delineates flanges into pressure classes: 150, 300, 400, 600, 900, 1500 and 2500 psi ASME B16.47 covers NPS's from 26" to 60". © ASME 816.47 delineatesits flanges into pressure classes 75, 150, 300, 400, 600, 900. Materials for flanges are usually covered in ASME d ‘* SA-105 (Specification for Carbon Steel Forgings for Piping Applications), *# $A-266 (Specification for Carbon Steel Forgings for Pressure Vessel Components), or # SA-182 (Specification for Forged or Ralled Allay-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service), Manufacturing tolerances for widely used wrought fittings may be found in # ASME B16.9 for butt welding fittings and # ASME B16.11 for socket weld and threaded fittings. Dimensional tolerances are generally in accordance with * AISC 303 unless specifically shown on the shop drawing. Galvanizing should be in accordance with * ASTM A123 or A153 unless otherwise specified in the purchase order documents 29| Page