7.

What is the relation between brinell hardness

No and Rockwell hardness No?
22 HRC (Rockwell hardness)=238 BHN
(Bridnell Hardness No)
8. What is mean by PWHT? Why it is required?
POST WELD HEAT TREATMENT this is done to
remove residual stress left in the joint, which
may cause brittle fracture.
9. What is the minimum thickness of pipe that
requires stress relieving to be done as per
B31.3?
18 mm thk

10 Which fluid is used in heat exchanger in side

and tube side?
Generally corrosive fluid is used from the tube side
(as tube can be easily replace) and cleaner fluid is
used from shell side. sometimes hot fluid is also
11 What
Reynlod
number and what is value of
used
fromisthe
shell side.
Reynolds number unto which the flow is
laminar? (ANS FULLY NOT COMPLETED)
it,s a dimensionless number toclassify the
nature of flow.
Re= pvd/u
Whre : Re= Raynolds no
p= as density of fluid
d = diameter of pipe
v =average velocity of fluid
u=viscocity of fluid
flows is laminar up to Re=2100

12. Where do you provide Anchor and slotted

support of heat exchanger?
Anchor support of heat exchanger is provide on the
sdefrom which tube bundle will be pulled out for
the purpose of maintenance work also it is based
on the growth of the connecting piping as
exchanger should greow with the piping.
13. What do you mean by hoop stresses and how
do you calculate it?
Stresses which are generated circumferentially
due to the action of internal pressure of pipe are
called as hoop stress.it is calcucalted by
Hoop stress (Sh)- Pdo/4t
Where P =force acting from inside
Do = OD of pipe
t=pipe thickness

14. How does hoop stress affect system?

As per membrane theory for pressure design of
cylinder, as long as hoop stress isless than yield
stress ofmoc. The design safe. Hope stress
induced by thermal pressure is twice the axial
stress (SL). This is widely used for pressure
thickness
calculation
for pressure
vessel.
15. Define
corrosion
and various
type of
corrosion?
Corrosion is a chemical / electrochemical reaction
between metal/alloyand environment that
produces deterioration of the material or its
properties. The cathodic reaction is liberation of
hydrogen gas or formation hydroxide and the
anodic reaction is dissolution of material forming
its ions.

The corrosive can be classified as:

Acids, alkalies and neutral solution depending on PH
Oxidizing agents,reduting agents
Specific depolarizing ions like chloride, fluoride etc
In acids the catodic reaction controls and the in
neutral solutions and alkalies the anodic reaction
control the rate. In addition the diffusion rates of
ions, velocity, mixing temperature etc control the
rate of corrosion.
The piping materials are subject to internal and/or
external corrosion,internal corrosion can usually
predicted and is controlled since the nature of fluid is
known. External corrosion is the more difficult to
foresee due to variety of atmosphere and soil
conditions, which may exist around a single pipeline.

The important type of corrosion piping enginer

should consider are :
Uniform corrosion :
Localized corrosion,which may again be subdivided
into
Galvanic or bimetalluc corrosion
Crevice corrosion
Pitting corrosion
Intergranular attack
Stress corrosion cracking
Uniform corrosion is themost common form of
corrosion and accounts for the greater proportion of
metal deterioration in terms of both mass of metal
converted to corrosion product and cost. It is
normally
characterized
by
a
chemical
or
electrochemical reaction, which proceeds uniformly

Galvanic corrosion: is enchanced corrosion of one

material when the material is joined to another
nobler material ( at higher potential in galvanic
series which is evolved from emf series given in
table 4.1.1 and nature of corrosive) and is exposed
to corrosive,even though the normal corrosion of the
materialis low. Remedies for this type of corrosion
are avoiding contact of dissimiliar materials,
providing large anode to cathode area ratio,
increasing the distance between the materials, or by
providing cathodic protection by impressed current
or by sacrificial anode.
Pitting : is a localized attack,which occurs,in passive
materials. At some week locations in material either
due to mechanical factoraremetallurgical factors
passivity is lost and it becomes anodic and severe
corrosion takes place by autocatalycit action.it

Crevice corrosion : occurs in creavices oropenings

which are large enough to corrosive medium but not
capable of communicate the changes in concentration
of bulk solution. This corrosion occurs due to
differential concentration cells formed at crevices.
Remedies for crevice corrosion are the same as for
pitting.
Intergranular attack : occurs in stainless stel due to
depletion of chromium oxide (which gives passivity) at
grain boundaries in heat-affected zone of weld due to
formation of carbide. The remedies are toreduce
carboncontent, or to add small amount of stabilizer like
Ti, Nb, or to generate ferrite islands in austenite by
modifying Ni and Cr contents.
Stress
corrosion:
cracking
occurs
when
the
combination of three factore tensile stress,corrosivity
and suspectiblity to crack occurs. It may be
transgranular or intergranular depending on type of

Corrosion resistance materials like stainless steels

nickel, copper,tin,lead and their alloys are usually
best adapted to specific uniform conditions,which can
be predicted. Protective coating, cladding,lining
plating and painting may be adapted to internal and
external protection of less expansive base materials.
Coating include asphalt, tar and waxes.lining with
glass, cement, rubber, porcelain, plastic, and
synthetic elastomers orplating with carrion resisting
metals offer many possible solutions to corrocion
resistance. The corrosion resistance of construction
material is given table 4.1.2.

The rate if corriosion may be economically reduced

by :
Selection of costlier corrosion resistance material
Application of protective coatings
Deactivation of the corrosive medium by adding

Deactivation of corrosive fluid may be econimically

justified inmany process applications like dearating
of boiler feed water.
Cathodic protection of piping has been succesfuly
applied
to underground
What is design
pressure? installiton and in mildly
corrosive
system.
The design
pressure of each component in a piping
system shall be not less than the pressure at the
most severe condition of coincident internal or
external pressure and temperature ( minimum or
maximum) expected during service.
What is design temperature?
The design temperature or each components in a
piping system is the temperature at which, under the
concident pressure, the greatest thickness or highest
component rating is required.
What is minimum temperature?
The design minimum temperature is the lowest

16. What is the consideration generally adopted for

the strength calculation by piping designer?
Considerations generally adopted for the strength calculation
by piping designer. Based on the process parameters
furnished by the process engineer are as below:
Design pressure as 10% higher than the anticipated
maximum operating pressure.
Design temperature 25 degreeC above the anticipated
operating temperature.
When operating temperature is 15 degreeC and below, the
design temperature as the anticipate minimum operating
temperature.
If ASTM materials are used ASME/ANSI should be preferred.
The selection ofmaterials shall follow the norms below
a. carbon steel shall be used up to 4250 C
b. low temperaturesteelshall be used below 200 C
c. alloy carbon steel shall be used above 4250C
d. for the corrosive fluids recommendation from the process
licensors to be followed.

FEW TIPS FOR THE PREPARATION PIPING

SPECIFICATIONS

The approach should be minimize the number of

different elements and thus simplify and rationalize
stock facilities.
A. Material
- Carbon steel shall be used for the temperatu up to
4250 C
- Low temperature steel shall be used for temperature
below-290 C
- Alloy steel shal be used for temperature above 4260
C
- Stainless steel shall be ued for corrosive fluids.basic
material of construction specified by process licensor
to be referred for the type.
- Galvanized steel piping shall be used for service such

B. Piping joints
- Butt-welded connection shall be used for all
alloy/carbon steel piping 2 NB and larger
- Alloy/carbon steel piping 1.5 NBand below shall
be socket welded.
- Threaded connections shall be avoided except in
galvanized piping.
- Flanged joints shall be minimized, as it is a point
of potential leakage. It may be used to connect
piping to equipment or valves. Connecting pipe
lines of dissimilar materials, where spools pieces
are required to permit removal or servicing of
equipment of where pipe sand fitting are with
flanged connections.

17. What is the difference between brazing and

soldering?
BRAZING:
- A process where base metals do not melt
- Filler material has a temperature above 4500 C
- Filler metal wets the base metal and drawn into joint
by capillary action.
- Most often used for joining of coppers amd
combination of metals, which cannot be welded.
- Brazing procedure and personel have to be qualified
as per ASME section IX.
SOLDERING:
- Similar to brazing but filler metal melting point is
between 2350 C to 2600 C.
- Used for aluminium.
- Organis fluxes are used to prevent oxidation.
- No requirements for qualification of procedure and
personnel given in ASME.

18. What is the different position for pipe welding?

- Pipe weld joints are identified as test positions.
They are normally grove welds and are indicated by
the letter G
-Test position1G is roll welding eith the axis of pipe
horizontal, welding done in flat position and the pipe
rotating under the arc.
- Test position 2G is known as horizontal welding
with pipe axis vertical, but the weld axis in
horizontal position.
- Test position 5G is known as horizontal fixed
position. Axis of the pipe is horizontal, pipe is not to
be turned or rolled during welding.
- Test position 6G for pipe welding has the axis of
the pipe at 450 and the pipe is not turned while
welding.

19. Why preheating is ruquired?

In a weld , the problems of
Hydrogen getting dissolve in the weld metal.
Stresses due to weld shrinkage.
Thermal shock from heat of welding in thick
walled pipes.
Preheating the bass metal of the welding prior to
welding process can minimize theze.
Preheating reduces the cooling rate of the weld
joint and results in a more ductile structure in
weld metal and heat affected zone (HAZ).

20. What is Oxy-fuel gas cutting and plasma gas

cutting?

Oxy-fuel gas cutting is a procedd where severing of the metal is

effected by the chemical reaction of the base metal with oxygen
at an elevated temperature. In the cutting torch, a fuel such as
acetylene, propane or natural gas is used to preheat the base
metal to cutting temperature. A high velocity stream of oxygen is
then directed at the heated area resulting in an exothermic
reaction and severing of the metal. This method is used for
carbon steel and low alloy steels.
Plasma Arc Cutting is frequently used method for high alloy
steels. The cutting torch generates an arc, which is forced to
pass through a small diameter orifice and concentrate its energy
on a small area to melt the material generating extremely high
temperatures. Simultaneously a gas such as argon, hydrogen or
a mixture of nitrogen and hydrogen is intruduced at the orifice
where it expands and accelerates through the orifice. The melted
metal is removed by the jet like action of the gas stream.
Thermal cutting methods are used for edge preparation also
after the cutting operation is over.

What is cold spring

Intentional stressing and elastic deformation of piping system during
the erection process to permit the system to attain more favourable
reactions and the stresses during the operating conditions

System dimensions are fabricated short by an amount equal to some

percentage of the calculated expansion value in each direction
System is then erected with a gap at some final closure weld,equal to
the cut shorts in each direction
Forces and moments are then applied at both ends as necessary to
bring the final joint into allignment
Once this is done , anchours and fixtures are provided on both sides of
the joint to preserve the allignment during welding, examination and
PWHT
When the restraints are removed, the reactions are absorbed in to the
terminal points and the piping is in stress.
During start up the piping expands as the temperature increases and
levels of stress and terminal reactions resulting from the initial cold
spring will decrease.
Higher stress in the piping at cold temperature is justified by the
increased strength of the material at low temperatures.
It is difficult to achieve 100% cold spring, where the piping in the
operating condition will have zero stress theorerically
Applied to high temperature systems such as stream lines and not

What are pressure piping codes?

B31.3Power piping
B31.3process piping
B31.4pipeline transportation systems for liquid
hydro carbons and tother liquids
B31.5refrigerantion piping
B31.8gas transportation and distribution piping
systems
B31.9building services piping
B31.11 slurry transportation piping systems
IN B 31.3 HOW FLUID CATEGORY IS FORMED?
CATEGORY D
a. The fluid handled is non flammable, non toxic,
and not damaging to humas tissues
b. The desaign gauge pressure does not exceed
150 pressure and temperature is from -29*C to
186*C

CATEGORY M
A fluid service in which the potential for personnel
exposure is judged to be significant and in which
single exposure to a very small quantity of a toxic
fluid, caused by leakages, can produce serious
irreversible harm to persons on breathing or bodily
contact, even when prompt restorative measures
are taken.
HIGHER PRESSURE FLUID SERVICE-K CATEGORY
A fluid service for which the owner specifies the
use of chapter ix (B.B1.3 For piping design and
construction.
NORMAL FLUID SERVICE
A fluid service pertaining to most piping covered
by this code. I.e not subject to the rules for
category D, category M, or high pressure fluid
service