Pressure Test Witness

1) What is the minimum hydrostatic test pressure according to ASME VIII, Div 1?
Answer:
 Test Pressure (psig) = 1.3 x MAWP x Lowest Stress Ratio (LSR) for the material which
the vessel is constructed

2) Why the pneumatic test is more hazardous compared to the hydrotest?

Answer:
 Air - because pressurized air contains more energy than pressurized water, hence
increasing the risk of explosion.

3) A stainless steel Type 304 pressure vessel is due for a pressure test. What kind of
water is the most preferred choice for the hydro test?

Answer:
 Low chloride water ( i.e. Demineralised water)

4) List down three (3) parameters to be considered prior to perform the pressure
test.

Answer:
 1. Test pressure
 2. Acceptance criteria
 3. Temperature
 4. Pressure test graph
 5. Procedure
 6. Type of test medium

5) What is the difference between a pressure test and a leak test?

Answer:
 The primary purpose of performing a pressure test is to verify the integrity of a
pressure system. especially when welded repairs or alterations have been
performed on the pressure boundary.

 Pressure or tightness tests can be used to check for pressure system leakage,
especially in flanged joints. Tightness tests may be performed in conjunction with
the pressure test.

6) List four (4) common pressure test apparatus.

Answer:
 1. Pressure gauge
 2. Pressure relief valve
 3. trapped air vent
 4. Pressure pump
 5. Liquid test media
 6. Pressure Hoses and Fitting

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  7. Chart Recorder
 8. Bleed Valve

7) What are the information should be recorded and included in test report?
Answer:
 1. Testing date
 2. Testing condition (temperature, pressure, test time)
 3. Leak location
 4. Leakage rate
 5. Test fluid
 6. Tester details

Mechanical Test Witness

8) List three (3) types of Bend Test.
Answer:
 1. Side bend test
 2. Face bend test
 3. Root bend test

9) List three (3) mechanical test bother than Bend Test and describe their purpose.

Answer:
 1. Tensile test - to determine yield &
 tensile strengths
 2. Charpy / impact test - to determine fracture toughness
 3. Burst test for marine hose or piping - to determine yield strength
 4.Nick break test for fillet weld - to check weld discontinuity

10)Which section of ASME BPVC states the acceptance criteria of mechanical test for
qualifying a welding procedure? (2)
Answer:
 ASME Section IX

Hardness Test Witness

11)List three (3) types of hardness measurement method.

Answer:
 I. Vicker
 II. Rockwell
 III. Brinell

12)Briefly describe the stages of performing hardness testing from material receiving
until completion of reporting.

Answer:
 I. Perform calibration
 II. Perform hardness test

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  III. Refer table for conversion
 IV. Refer material hardness value ASME Sec II
 V. Convert hardness value to tensile strength
 VI. Provide sketch and report

Leak Test Witness

13)Explain three (3) reasons for performing leak testing.

Answer:
 I. To check the presence of leakage rates exceed acceptance standards.
 II. To ensure equipment integrity
 III. To avoid any product leak/spillage during operation

14)What is the minimum and maximum range of the gauges to be used during leak
test?
Answer:
 Gauge Range.
 When dial indicating and recording pressure gauge(s) are used in leak testing,
they should preferably have the dial(s) graduated over a range of approximately
double the intended maximum pressure, but in no case shall the range be less
than 1 ½
 more than four times that pressure. These range limits do not apply to dial
indicating and recording vacuum gages. ( ASME V Article 10)

15)Name two (2) possible locations for leakage may be happened.

Answer:
 I. Flange connection
 II. Welding joint
 III. Fitting

Turnaround Preparation

16)List three necessary information for an inspector to demonstrate his credential to

qualify him to work during scheduled plant shutdown
Answer:
 Competency certificate for inspector & NDT personnel
 Resume & working experience
 Inspector specialty

17)During Turnaround, there is a plan to perform internal inspection on a in-serviced

vessel. The vessel is constructed using carbon steel. List 3 inspection activities
normally applicable for that vessel. For each activity, give the coverage area
Answer:
 Visual Inspection, 100% coverage or accessible area.
 Dye Penetrant Testing on weldment, 100% coverage or potential area or accessible
area.
 Magnetic Particle Testing on weldment, 100% coverage or potential area or accessible
area.
 Corrosion Under Insulation inspection, 10% strip at potential location.

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 18)In three months’ time, your plant will be having a turnaround. You have been
assigned the following jobs:

i. Carry out magnetic particle inspection on 20 carbon steel pressure vessels. Some
vessels require access via scaffolding and insulation removal.
ii. Carry out liquid dye penetrant inspection on 20 stainless steel pressure vessels. Some
vessels require access via scaffolding and insulation removal.
iii. Carry out eddy current testing on 3000 heat exchanger tubes.
iv. Carry out repair & replacement on 50 carbon steel & stainless-steel piping joints. All
joints require DPT or MPT, and radiography examinations.

List down the type, and the number of equipment, tools, and consumables, and other
resources, that you plan to acquire to carry out these four jobs, assuming you are given
a total of 14 days during the turnaround, to complete all jobs. Briefly explain your
answer.
Answer:
 MPI team (20 vessel + 50 piping joints) = (2+1) teams. Assuming max handover is 4
vessels/day and 5 joints/day. Add manpower if equipment loading increase.
 DPT team (20 vessel + 50 piping joints) = (2+1) teams. Assuming max handover is 4
vessels/day and 5 joints/day. Add manpower if equipment loading increase.
 ECT team (3000 tubes) = 2 teams. Assuming ECT can complete 300tubes/day, max
handover 600 tubes/day.
 RT Team (50 jts) = 1 team. Assuming 10 joints/day.

19)Briefly explain the purpose and contents of the following documents.

i. Scheme Of Examination
ii. Job Method Sheet
Answer:
i. Inspection activity to be carried out and points of interest
ii. Overall activity to be carried out on individual equipment involving all related parties

Scheme of Examination
20)List ten (10) information should be available in SOE document.
Answer:
 Tag No
 PMT No
 Equipment description
 Equipment drawing
 Design data
 Process fluid
 NDT requirement
 Test pressure
 Material specification
 History

21)What kind of NDT inspection is recommended for checking welds in Deaerator?

Answer:

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 Visual inspection, DPT & RT, UT, MPT,

22)What type of document is required in order for you to develop SOE?

Answer:
 Equipment drawing, PFD and Equipment history.

23)Name code and standard for in-service vessel, piping and tank inspection?
Answer:
 API 510 for vessel, API 570 for piping and API 653 for tank.

24)List internal components for the following equipment and specify type of
inspection for each of them?
i. Fired Boiler
ii. Column
Answer:
i. Fired Boiler
 Burner – visual, Refractory – visual, Tube - visual, profile RT, UT, MPT/DPT
 Steam &
 Water drum - visual, DPT

ii. Column
 Tray – visual, Cap – visual, Shell - Visual, MPT, DPT

25)Explain THREE (3) items in JMS

Answer:
 Job steps
 Job sequence
 Manpower and manhour resources required for a work
 Equipment specification

Piping/Pipeline Corrosion Survey Execution

26)Identify three (3) location that is susceptible to degradation mechanism on

piping/pipeline.
Answer:
 Bend area
 Damage insulation
 Soil-to-Air area
 Intermittent service area
 Dead leg
 Injection point
 Pipe support

27)What is the term for piping/pipeline with no flow or stagnant and give three (3)
location where is normally no flow occurs on piping system? Deadlegs Location:
Answer:
 Blanked branches
 Lines with normally closed block valves
 Lines with one end blanked
 Pressurized dummy support legs

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 Stagnant control valve bypass piping
 Spare pump piping
(Source API570)

28)Where does erosion-corrosion most probably to happen on plant piping?

Answer:
 High-velocity and high-turbulence areas e.g. downstream of control valves,
downstream of orifices, downstream pump discharges
 Bend area eg: elbow
 Injection point
(Source API570)

29)Briefly explain on how to perform piping/pipeline corrosion survey (1 – 7)

Refer to API 574
Answer:
 Develop inspection plan
 Develop RBI plan
 Interval – based inspection plan
 Classify piping service
 Perform monitoring piping

30)What is the recommended NDT for checking Microbiological Induced Corrosion?

Answer:
 Radiographic Testing
 Corrosion mapping
 Radiographic Testing
 Corrosion mapping

31)Why it is important to have a proper reporting system for piping/pipeline

corrosion survey?
Answer:
 Maintaining the Integrity of the Pipe or Piping
 CORROSION CONTROL
 For referencing and guideline

32)Why dissimilar material is not recommended to have direct contact to each other?
Answer:
 To avoid galvanic corrosion

Piping/Pipeline Corrosion Under Insulation Survey Execution

33)Give three (3) locations where water can ingress into insulation?
Answer:
 Insulation termination point
 Aluminum clad gap
 Damaged insulation

34)Why CUI is negligible or low susceptibility for insulated piping operates above 200
220 deg C ?

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Answer:
 Water evaporates quickly

35)Recommend NDT method which can be utilize for detecting CUI on piping.
Answer:
 Profile radiography / Computerized Radiography
 Long range UT
 Neutron back scattered

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