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Piping Inspector's Guide
Piping Inspector's Guide
1) WHAT IS WPS?
2) ANSI/ASME CODES :
a) Asbestos gasket
d) Titanium gasket
4) E – 7016 is a type of welding rod. What does under lined number indicate?
5) What is FF elevation?
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6) Five Types of Non Destructive Examination :
c) Radiographic Test
d) Ultrasonic Test
e) Visual Test
a) Impact Test
b) Bend Test
c) Tensile Test
STPG 42
Limit fluids Resistance and minimize choak of pipe due to foreign material.
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15) What is the role of Venturi?
Spring support, Hanger support, and 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 %.
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c) Detail phase – All design are finalized, the design used such checked
Data as steel and concrete, drawings, hydraulic and certified vendors
Drawings for equipment valves and Instruments.
25) Open system: Is one in which the content of a line are discharged and not
Recovered.
26) Closed system: Is one which the contents of relief system or steam trap
Condensates are recovered.
27) Steam Turbine: Are used where there is a readily available source of steam
And are also used to drive stand by process pumps in critical
Service in the event of an electrical power failure and
Emergency stand by equipment such as fire water pumps and
Electrical generators.
28) Turbine: Is a machine for deriving mechanical power (rotating shaft) from the
Expansion of a gas or Vapor (usually air or steam in industrial
Plants).
29) Diaphragm: These forms of diaphragm valve are popular for regulating the
Flow of slurries and Corrosive fluids and for vacuum.
31) Safety Relief Valve: Relieves excess pressure of either gas or liquid which may
Suddenly develop A vapor phase due to rapid and
Uncontrolled heating from Chemical reaction in liquid
Laden vessel.
32) Butterfly Valve: Used for liquid, slurries, powders and vacuum. The usual
Resilient plastic seat has a temperature limitation but tight
Closure at high temperature.
33) Check Valve: Designed to permit flow of liquid or gas in a one direction and
Close if flow reverses.
34) Gate Valve: Use for water, gas, steam, slurries line suitable for throttling and
Full flow use.
34) Globe Valve: Use for regulating flow should be from seat stem side, assist
Closure and to Prevent the disc chattering against the seat in
The Throttling position
.
35) Carbon Steel: Lose strength at high temperature; electric resistance welder
(ERW) pipe is not considered satisfactory for service about
750*F and furnace butt Welded (FBW) pipe above about 650*F.
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36) Steam Tracing: To prevent fluid from congealing, forming hydrates,
Condensing, interfering with Operation or causing any
Damage to piping, equipment and instrument.
39) In Horizontal runs: The taps are located at the tops of the flanges in gas,
Steam and vapors Lines, an approximately horizontal
Position avoids vapors locks in Liquid lines.
40) Vents: Are needed to let gas usually air in and out of service. Basically remove
The air pocket from the line.
41) Break Flange: Piping connected to channel head nozzle should be furnished
With break flange to facilitate the removal of the channel head.
43) Temporary strainers: Used for start – up operations on the suction side of
Pumps and Compressors, after start – up the screen
Usually are removed.
45) Steam Traps: The purpose of fitting traps is to obtain fast heating of system
And equipment by Freeing the steam lines of condensates and
Air.
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51) Gas Turbines: Are used in various application including gas transmission
Gas lift, liquid pumping, gas re injection and process
Compressor.
52) Inter Coolers: Are primarily used to reduce the operating temperature with in
A compressor Circuit which allows the use a smaller machine
With fewer cylinders
54) Condensate Pump: The condensate pump is usually vertical removes the
Condensates from the hot well in the surface condense.
Condensates form during Liquefaction in the condenser
And are collected in the hotwell.
55) Drums: Collects liquids from vapors circuits and pump it to other process
Groups, disposal or product storage. Used in process plant as
Intermediate containers that Received liquid from distillation and
Condensing equipment
58) Reactor: Are used in processing facilities to contain catalyst that promote
Chemical reaction of feeds. Reactor is generally vertical steel
Hallow Vessels and often operate under very high temperature and
Pressure.
59) Tower: Are cylindrical steel vessel that are used for distillation of materials
In the production of such products as gasoline, diesel and heating oil.
60) Non- Destructive: Knowing the internal defect of weld without changing the
Appearance of the Material.
61) Inconel: A High Nickel Alloy containing chromium and Iron, resistant to
Oxidation and Corrosion.
61) Knock out Drum: A stream of gas containing drops of liquid is passed
Through a knock out Drum in order to slow down the flow
And allows the liquid to separate and collect.
62) Pump Suction: Eccentric reducers are used in lines 2 ½” and larger and
Arranged to avoid Creating a vapor space and creating a
Pocket which would need to be drained.
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63) Valves are used for these purposes:
64) Venturi meter: Instrument for measuring of gas or liquid measuring the
Decreased pressure so caused.
65) Slip on flange: Has poor resistance to shock and vibration easier to align
Than the welding neck Flange, calculated strength under
Internal pressure is about one third that of the corresponding
The weld neck flange.
66) Weld Neck Flange: Suitable where extreme temperature shear impact and
Vibratory stresses Apply primarily use for vessel and
Equipment nozzle.
68) Seal Welds: may be used only to prevent leakage of threaded joints and not to
Be considered as contributing any strength to the joints.
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69) Threaded joints checklist:
( 1.1/2” )
( 1” )
70) How many threads can be visible after seal welding threaded joints?
71) What is the gap requirement for socket welds for new construction?
73) What is the minimum fillet weld size for a socket welded connection?
74) What are common failures in the quality system during fit up that leads
To hydro test failures?
Failure to properly clean, de burrs and degreases fittings and piping prior to
Welding. Oil residue from cutting causes through weld porosity and leakage
During hydro tests.
b) Have the tell- tale holes for air testing been drilled, tapped, de
burred and oil removed by cleaning ( sand blasting ).
c) Has the branch to header weld been welded flush. NDT performed,
accepted prior to fit up of reinforcement pad.
d) Has the repad been properly cold worked and radiuses to meet the
piping OD and assure good fit up. No hammer marks.
e) Do not allow flange tack welding above the branch connection until
the repad fit is acceptable. Maximum gap is 1.6 mm.
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f) A 6 mm gap maximum is allowed between repad and branch for
root opening.
g) Follow preheat tables and W – 011 requirements for GTAW &
SMAW process on welding.
Fit up, elevation and slope per AFC drawings, this checked by
survey or level
( String line ) in accordance with PIPS and procedures.
79) Give Examples of unique support details that allow piping freedom of
Movement for thermal Expansion:
80) Clearances:
a) 50 mm rule between all piping and supports.
81) Serrated Finish: Is used with asbestos and other gaskets. The regular smooth
Finish is used with Gaskets made from hard materials and
With spiral wound gaskets. Cold water finish is normally
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Used without gaskets.
82) Gaskets: Are used to make a fluid resistant seal between two surfaces.
d) Cost.
84) Drip legs: Often made from pipe and fittings, the drip leg is an inexpensive
Means of collecting Condensate. Removal of condensates from
Steam lines.
85) Hanger Support: Device which suspends piping (usually a single line) from
Structural steel, or Steel and concrete. Hanger is usually
Adjustable for height.
86) Saddle: A welded attachment for pipe requiring insulation and subject to
Longitudinal or rolling
Movement (resulting from temperature changes)
88) Dry Steam: Is a gas, consisting of water vapor only. Placed in contact with
Water at the same
Temperature, dry steam will not condense, nor will more steam form –
Liquid and vapor are in equilibrium.
89) Wet Steam: Consists of water vapor and suspended water particles at the
Same temperature as the vapor. Heating ability ( quality ) varies
With the percentage of dry steam in the mixture ( the Water
Particles contain to latent heat of Vaporization ) Like dry steam,
Wet steam is in equilibrium with water at the same temperature.
90) Super heated steam: If heat is added to a quantity of dry steam, the
Temperature of the steam Will rise and the number of
Degrees rise in temperature is the degrees of super
heat.
Thus Super Heat is sensible heat – that is it can be
Measured by a thermometer.
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91) Condensate: What it is & how it forms: Steam in a line will give up heat to the
Piping and surroundings, and will gradually become Wetter, its
Temperature remaining the same. The change of state of part of
The vapor to liquid Gives heat to the piping without lowering the
Temperature in the line. The water that forms is termed
‘Condensate’ of the line initially contains super heated steam,
Heat loss to the piping and Surroundings will first cause the
Steam to lose sensible heat until the steam temperature drops
To that of dry steam at the line pressure.
93) What are the common type of valves and its function?
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Check valve – non return valve
94) Where will you place the level gauge of a kettle type reboiler?
A mandatory item in the quality plan that guides and assures quality in a
Specific type of work in Basic sequence of QC activity steps.
A document that details the specific steps needed to fulfill the QC activity in
The ITP.
100) what types of inspection action points are found in the ITP?
Piping and instrument diagram will show the piping layout and detailed notes
Relating to piping and instrumentation.
Safety Instruction Sheet that gives full design details related to a piping
System or Line.
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A specific name in alphanumeric designation describes features of a piping
System.
ICS1P3 = 150# class, Carbon Steel, 1/16” CA, General hydro carbon.
a) How do you verify the material, and mention several items to check?
Mill Certificate, heat number, color coding and PMI, schedule, rating,
Carbon equivalent
Value for PREHEAT, diameter, class, grade.
d) What are the tolerances for physical piping straightness and defects?
87 ½ % (all) to 115% (greater than 2”), 120% (2” & less) of nominal.
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CMTRs & trim during Valve testing (Visual inspection)
Check the Gasket material as per the drawing and specification, size, rating
And visual Inspection of surface damages.
116) what are Jack Screws and when are they required?
Flush Grinding of butt welds of the orifice flange inside and seal welding of o
Orifice tapping Pipes.
118) what are the NDT methods are required during orifice flange
Installations?
No!
# Check that correct bolts and gaskets are installed at all reinstated joints
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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.
# Check that all valves are functioning properly and that spindle has been
Coated with copa-slip Are equaled there specified.
# Check that all pump suction strainers have been correctly installed.
# checks that correct flow through filters, and strainers, traps, check valves
And globe valves.
5) Ensure all line listed in test package are identified and test
pressure is correct as per LDT.
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2) The test medium and pressure.
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TABLE FOR GASKET:
NOTE : This is calculated as following condition. ASTM A 53 SCH. 40. Full water,
continuous beam.
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Table – 1
A285 GR.
B
LOW ALLOY STEEL
A387 GR.1 A335 – P1 A182-F1 A213-T1 A217- E-7018- ER-80S-G
WC1 A1
A387 A335 – P12 A182- A213- A217- E-8018- ER-80S-B2
GR.12 F12 T12 WC4 B2
A387 A335 – P11 A182- A213- A217- E-8018- ER-80S-B2
GR.11 F11 T11 WC6 B2
A387 A335 – P22 A182- A213- A217- E-9018- ER-90S-B3
GR.22 F22 T22 WC9 B3
STAINLESS STEEL
A240- A312- A182- A213- A351-CF3 E 308L- ER-308L
304L TP304L F304L TP304L 16
A240- A312- A182- A213- A351- E 316L- ER-316L
316L TP316L 316L TP316L CF3M 16
904 L A790 A789 FOX CN
20 / 25M
SAF 2205 A790 A789 E2209- ER-2209
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SPECIALITY ALLOYS
316L U.G. 316L U.G. 316L 316L - Thermanit
U.G. U.G. 19 / 15H
310MoL 310MoL 310MoL 310MoL E310LMo Thermanit
25 / 22H
Alloy 20 Inconel Inconel 625
112
Incoloy Incoloy Incoloy Inconel Inconel 617
800HT 800HT 800HT 117
HK-40 HK-40 E310 H ER-310H
25-35- 25-35-Cb Inconel Inconel 617
Cb Mod. 117
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Mod.
2) Welding Completed.
3) NDE Completed.
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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.
5) Holding time is 10 minutes minimum. The test pressure is attained until all
welds and connection have been examined. (shall not over pressurize the
system)
6) After the test, the system was drained to minimize standing water in the line. Air
blowing to be performed to remove the remaining water.
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VALVE INSPECTION AND TESTING: (API 598)
a) Shell Test.
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.
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Valve should not be positioned with their stem pointing down ward below
horizontal with following exceptions:
b) Butterfly valves shall not be installed with the spindle in the vertical
position for services where collection of dirt in the lower shaft bearing
could occur.
c) Gate valves installed around safety / relief valves and in flare lines shall
be positioned with the stem pointing horizontally.
A Process Wherein the lighters fluid is separated from the heavier fluid.
Saddle support.
Skirt support.
300 lbs.
300 lbs.
300 lbs.
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133) What is the common material use for pipe, fittings, valves, flanges,
gasket & bolts?
134) What is the position of the reducer in the suction side of pump and
its purpose?
It must be position top flat not to create bubbles of Air that will corrode
the surface of the blade.
2.1 meters.
1 meter.
2.1 meters.
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1) To sense 2) to transmit 3) to indicate 4) to record 5) to control
Usually comprises four service lines carrying Steam, Utility Air, Service
Water and Nitrogen.
a) Variable Load.
b) Constant Load.
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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.
149) While GTAW welding at what wind speed do you have to install wind
protection.
0.5 m / sec.
Fe – Cr – Ni.
152) What should be the Internal Gap of the socket weld joint and what is
the reason for
Leaving the gap?
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155) Four main parts of Spiral wound Gasket:
Is 1/16” high for 150 and 300 lbs flanges, and ¼” high for all other
pressure classes.
250 psi cast iron flanges and flanged fittings also have the 1/16” raised
face.
Most common uses are for mating with non – steel flanges on bodies of
pumps, etc. and for mating 125 psi cast iron valve and fittings. Flat faced
flanges are used with a Gasket
Whose outer diameter equals that of the flange- this reduces the danger
of cracking a cast iron, bronze or plastic flange when the assembly is
tightened.
Most efficient for high temperature and high pressure service. Ring joint
facing is not prone to damage in handling as the surfaces in contact with
the gasket are recessed. Use of facing of this type may increase as hollow
metal O- ring gain acceptance for process
Chemical seals.
c) Stud bolts in the less frequently used sizes and materials can
be readily made from round stock.
a) Serrated
b) Smooth
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Is usually specially ordered and is available in two qualities. The
smoother surface is termed “ cold water “ finish. The regular smooth
finish shows no tool marks to the naked eye.
Is a flat disc with a precisely made hole at its center, it offers a well
defined obstruction to flow when inserted in a line. The resistance of the
orifice sets up a pressure difference in the fluid either side of the plate,
which can be used to measure the rate of flow.
Where flanges of different rating are bolted together, the rating of the
joint shall not exceed that of the lower flange. Bolting torque shall be
limited so that excessive loads will not be imposed on the lower rated
flange in obtaining a tight joint.
Basically required two nos. pressure gauges. One in the top side, and the
other in the down side. Test pressure should be monitored only in the
Top side pressure Gauge.
Every 10 meter height, 1 barg head pressure to be added with the top
Side pressure Readings.
To control the accuracy of the readings, the pressure gauge range should
be 1.5 times to 3.0 times of the test pressure. It is mandatory to use only
the calibrated gauges.
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b) To allow venting during welding and heat treatment.
a) A335 Gr.P5………………0.5%
b) A335 Gr.P9………………0.9%
c) A335 Gr.P11……………..1 ¼ %
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