Type 2.

1
Document issued by the manufacturer, stating compliance with the order
Type 2.2
Test report issued by the manufacturer
Type 3.1
Inspection document endorsed by the manufacturer's authorized representative
stating compliance with the order
Type 3.2
Inspection document endorsed by the manufacturer's authorized representative and
either an inspection representative named by the purchaser or an independent third-
party inspection body

API 1104
Welding of Pipeline & Related Activities
API 1105
Construction Practices for Oil & Products Pipelines
ASME B 31.4
Pipeline Transportation System for Liquid Hydrocarbon
ASME B 31.8
Gas Transmission and Distribution Piping System

MECHANIZED WELDING:
Welding in which the welding parameters are controlled mechanically or electronically
and may be manually varied during welding to maintain the required welding position.

AUTOMATIC WELDING:
Welding in which all of the welding parameters are controlled. Manual adjustments
may be made between welding operations but not during welding.

MANUAL WELDING PROCESS:

Electrode travel as well as Welding Holder travel both are controlled manually.
Example: Arc welding.

SEMI-AUTOMATIC WELDING:
Electrode travel is automatic (spool feed) whereas the welding holder travel is manual.
Example: MIG and TIG welding.

AUTOMATIC WELDING:
Both electrode travel (spool feed) and holder travel is automatic.
Example: submerged Arc Welding

PIPELINE LAYING ACTIVITIES:

ROU Survey
Rou Clearing And Grading
Stringing
Trenching
Bending
 Welding
Field Joint Coating
Lowering
Backfilling
Crossing
Tie-Ins
Hydro testing
Pipeline Markers, Clean Up & Restoration
Station Works
Magnetic Pigging & Pre Commissioning Activity

ROU SURVEY
Installation of Bench Marks, Turning Points
Stake markers in center line of pipeline at a distance of max.100m for center line and
for horizontal bends10 m. and reference point for same
Stake two ROU markers at least at every 100m, Painted in red and numbers in white
in direction of flow.
Chainage markers at every 250 m

ROU CLEARING & GRADING

All obstacles causing hindrance in construction / laying pipeline are removed.
Entire ROU is graded for movement of equipments and vehicle.
Temporary approaches/bridges, if required, are constructed for movement of
equipments, vehicles & personnels

STRINGING
Stringing shall be done after blasting & trenching when ROU is in rocky area.
Coated Pipes shall be strung on approved soft earth/sand filled bag and wedge in such
a way that bottom of coated Pipe remain above ground
Pipes shall be supported at minimum two locations
Pipe number, Heat number, coat number & length shall be transferred and recorded
in serial order

TRENCHING
Trench excavation is carried out along staked centerline of Pipeline
The width of excavation for trench shall be minimum (pipe diameter plus 200mm
either side)
Depth of trench shall be as specified (Normal= 1M; Road= 1.2M; River= 1.5M; Rly. =
1.7M etc.)
In case of trenching in rocky areas, blasting is performed with the guidelines /Safety
Rules of Chief Controller of explosives, Nagpur.
In case where rock/gravel or murrum/hard soil is encountered in the bottom of trench,
padding material (minimum compacted thickness of 150 mm) shall be provided.
When up-floating of the pipeline after backfilling is anticipated, ant buoyancy
measures are provided in such areas e.g. weighing by applying continuous concrete,
installing saddle weights etc.
BENDING
For changes in vertical & horizontal alignment, pre-fabricated cold field bends are
provided
Over-bends are made in a manners that Centre of bend clears the highest point of
trench bottom. Sag bends shall fit the bottom of the trench. Side bends shall have
specified clearance to the outside wall of trench.
The radius of cold field bends shall not be more than 40 times the dia. of pipe (for
18inch and above) and 30 times the dia. of pipe (for 18inch below).
Pipes with longitudinal welds are bent a way that weld lies in the plane passing
through the neutral axis of bend

WELDING
Welding Procedure Specification (WPS) to be followed for the welding is qualified and
the Procedure qualification record (PQR) is approved before start of welding.
Approved brand of electrodes are used for welding. Physical properties of the weld
produced by an electrode shall not be less than minimum value of base metal.
Electrode qualification and batch record are maintained. Each pipe shall be thoroughly
checked internally & externally for visual defect/ damage and cleaned internally by
compressed air blowing.
Damaged end shall be cut and re-beveled with beveling machine. All new bevels shall
be 100% dye penetrant /MPI tested and ultrasonically tested for any lamination.
Use of internal clamp is mandatory for pipe dia.> 10. Except tie in joints, fitting etc.
In such case external clamps are used.
Each joint shall bear an identification number which shall be followed for NDT
The number of welders, and welding sequence, speed etc. should be similar to that of
adopted in approved welding procedure
Radiography examination of 100 % girth weld is carried out. Weld shall meet the
requirement of API 1104. In addition 100% ultrasonic inspection is required for critical
weld joints i.e. tie in, welding of valves etc. joints which have not undergone pressure
testing i.e. GOLDEN Tie-Ins.
Repair is limited to maximum 30% of the weld length. Weld containing cracks shall be
cut and re-bevelled to make a joint.
Destructive testing of weld joints are done for 0.1% of the total numbers of welds
completed.

FIELD JOINT COATING

The cut-back areas of Coated Pipes where weld joints are made are to be coated by
Field Joint Coating.
Field joint coating material is heat shrinkable wraparound sleeve used as anticorrosion
coating of buried onshore pipeline.
Sleeve consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semi-
rigid polyolefin backing with a uniform thickness of high shear strength
thermoplastic/co-melt adhesive
The joint coating system shall consist of a solvent free epoxy primer applied to the
pipe surface prior to sleeve application. The surface area is blast cleaned to SA-2.5
followed by Pre-heating of pipe surface, application of epoxy primer and application
of sleeve by heat shrinking.
 Each sleeve joint is inspected by means of a full circle holiday detector set to DC
voltage at 25 KV (Pipe surface temperature below 50 degree Celsius) and thickness of
sleeve checked.
One out of 50 joints coating or one coating out of every day production shall be tested
to establish peel strength on steel and factory applied coating.

LOWERING
Lowering shall commence after inspection of trench. Trench bottom shall be free from
pipe supports, stones, roots, debris, stakes, and rigid material. Padding shall be
provided in rocky/ murram area.
Lowering shall commence as soon as possible after completion of joint coating, Before
lowering in, complete check by a full circle holiday detector for pipe coating and field
joint coating at 15 KV is carried out (Speed 300mm /sec). Any damage shall be
repaired. Support/ skid points shall be thoroughly checked.
The pipeline must be laid without interruption for the whole or the length of section
available
Ends of the lowered pipeline section shall be closed with night cap to prevent ingress
of water, mud etc.

BACK FILLING
Backfilling shall be carried out immediately after pipeline lowering in trench after
inspection, so as to provide a natural anchorage for the pipeline, thus avoiding long
exposure of coating to high temperature, damaging action of adverse weather
conditions, sliding down of trench sides and pipeline movement in the trench.
Backfill material shall not contain any extraneous material or hard lumps of soil which
can damage pipeline or coating or leave the voids in backfilled trench.
After placing of initial backfill, proper compaction shall be done. The surplus material
shall be crowned (300 mm) directly over trench and adjacent excavated area on both
side of trench.
If trench are excavated in steep area where the slope is more than 10%, slope breakers
shall be installed to prevent erosion of backfill. Stabilization of backfill shall be done in
sandy area to have consolidated cover over the pipeline.

CROSSINGS
Cased & Un-cased crossings for Roads & Railways
Open cut & Horizontal Directional Drilling (HDD) for Minor & Major River Crossing

TIEINs
The unconnected sections of the lowered pipeline sections at various locations have
to be welded, coated and backfilled to make the sections ready for post installation
hydro test.
If a pup piece cannot be avoided for tie in, the minimum 1.0 m length shall be added.

HYDRO-TESTING
Hydrostatic test is performed on entire length of the pipeline. The maximum
permitted length is 50 Kms. Hydrostatic test diagrams indicating number of test
 sections and minimum and maximum test pressure in each test section are prepared
before performing hydrostatic test.
Hydrostatic test commence only after completion of all welding works so as to avoid/
minimize untested hydro-test joints/ Golden joints.
Hydro test includes all those sections which are tested earlier for Road, rail road
crossings, major water crossings etc.
Duration of hydrostatic test is minimum 24 hours after thermal stabilization. Hydro-
static test pressure for pipeline handling hydrocarbon in gaseous phase is 1.25 times
the design pressure in pipeline located in Class-1 & 2 locations and 1.4 times the design
pressure if pipeline located in Class-3 & 4 locations.
Before water filling, pipeline shall be cleaned with air driven pigs with spring loaded
brushes and chiseled to remove all mill scale, rust, sand etc. from the internal pipe
section.
After successful cleaning and acceptance, gauging is carried out using gauging pig.
After acceptance of gauging operation, un-inhabited water is pumped into the section
using four cup batching pigs which are launched at specific intervals.
After water filling operation, thermal equilibrium between pipeline and environment
shall be checked with thermocouples installed on the pipeline. After thermal
stabilization pressurization is carried out in cycles of 50% test pressure & 75% test
pressure and held for 1 hour at each test pressure and depressurized to zero pressure
and then pressurized to final test pressure. During each test pressure, two test shall
be carried out for calculation of air volume in the pipeline under test and on
acceptance of air volume test the section is held for 24 hours at Final test pressure
and pressure and temperature recorded on chart.
The hydrostatic test shall be considered positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. The
pressure value thus added shall be compared with initial value and the test shall be
considered as acceptable if the difference is less than or equal to 0.3 bar.
After positive test results, test shall be terminated. The pipeline shall be depressurized
at constant rate. Dewatering shall be carried out by using four cup pigs driven by
compressed air. Foam pigs shall be passed to complete the dewatering.

PIPELINE MARKERS, CLEAN-UP AND RESTORATION

Following type of markers shall be fabricated and installed along the pipeline route
such that they do not cause any hindrance to the regular land user or traffic
Aerial Markers: At every 5 Kms.
Kilometer Markers: At every 1 Km. & as per Alignment sheet
Pipeline Warning Markers: At Road / Railway / River Crossings & Stations / Terminals
ROU Boundary Markers: At every 750 Mtrs. & as per Alignment sheet
Direction Markers: At significant turning points
Navigational Markers: At bank of Navigational Course
OFC Markers: At OFC Joints
ROU and all sites used for construction of pipeline, water crossing and other structures
shall be restored as per satisfaction of authority having jurisdiction over it.
Damages to roads, bridges, fences etc. damaged during construction shall be restored
to original.
 The bed of water course shall be restoring to the original level. The banks and any
excavated area shall be restored to original levels. The banks shall also be stabilized.
On completion of clean-up, the ROU shall be restored to such stable and usable
condition as may be reasonably consistent with the condition of the ROU prior to
laying the pipeline. The release note from the land owner s regarding satisfactory
indemnification and restoration of land shall be obtained from land owner.

SV / IP / DT / PS & RT STATION WORKS

Sectionalizing Valve (SV) is installed at regular intervals (around 25 to 40 Kms.) to
isolate pipeline section during emergencies like leakage in pipeline as per statutory
requirements. An SV station is installed at such locations having a unmanned control
room with a guard room and boundary wall. A lockable grill cage is provided over the
Sectionalizing Valve installation including piping and instrumentation to prevent
tampering by unauthorized persons and ensuring safety of pipeline operations.
Intermediate Pigging (IP) stations are installed at regular intervals (as per design ~ 150
Kms.) having a Pig Launcher and a Pig Receiver with Control room, Sump tank, Basket
Filters, guard room, boundary wall etc. to facilitate pigging of pipeline during routine
Operation and Maintenance.
Dispatch Terminal (DT), Pump Station (PS) & Receipt Terminals are provided at start,
intermediate & end locations of the Pipeline to facilitate handling and pumping of the
product through the pipeline. It comprises of Pig Launcher / Pig Receiver with Control
room, Mainline & Booster Pumps (DT/PS), Sump tank, Basket Filters, guard room,
Firewater system, boundary wall etc.

LINEPIPE COATING AT YARD

TYPES OF EXTERNAL YARD COATING
3 Layer Polyethelene (3LPE) Coating / FBE Coating
Coal Tar Enamel (CTE) Coating

3LPE COATING / ONE LAYER FBE COATING

1st Layer: Fusion Bonded Epoxy 50 Microns (200 To 300 Microns - FBE Coating)
2nd Layer: Side Extrusion Adhesive (LDPE) 200 To 300 Microns
3rd Layer: Side Extrusion Polyethelene (LDPE / MDPE / HDPE) - > 2 mm

CTE COATING (HOT APPLIED)

1st Coat: Coal Tar Primer 50 To 75 Microns
2nd Coat: 1st Hot Coal Tar Enamel Layer With Inner Wrap > 1 mm
3rd Coat: 2nd Hot Coal Tar Enamel Layer With Inner Wrap > 1 mm
Final Coat: Coal Tar Impregnated Outer Wrap 600 To 750 Microns

F NUMBER
The F number grouping of filler metals refers to their similarity on their usability
characteristics. The usability determines the ability of a welder to deposit a sound
weld metal with a certain filler metal.

P NUMBER
 The P number in welding assigned to the material by ASME Code Section IX to reduces
the number of welding procedure qualification. Why we do want to reduce the
numbers of PQR? because this part is expensive part, for each PQR you need to
produce a test sample and sent to metallurgical lab for mechanical testing (two
tension tests, two root bend tests and two face bend tests).

A NUMBER
A number gives a similar chemical composition in a as weld condition.

ESSENTIAL VARIABLE IN WELDING PROCEDURE SPECIFICATION (WPS)

Essential variables are conditions in which a change, as described in the specific
variables, is considered to affect the mechanical properties of the joint". In most of
welding process, The P number, F number, A number PWHT, thickness (out of
specified range) are essential variable.

NONESSENTIAL VARIABLES
The code defines it as Nonessential variables are conditions in which a change, as
described in the specific variables, is not considered to affect the mechanical
properties of the joint". Normally, joint designs, filler metal diameter, the minor
change in the electrical characteristics, welding positions, welding technique (some of
them) are nonessential variable in welding procedure specification.

PAINTING

Formula:

INDUCTION TIME / STAND TIME / LOAD TIME ARE;

Length of time after mixing
BGAS period at 20 to 30 Minute

POT LIFE ARE;

After mixing paint must be used
BGAS period at 6 to 8 hours

MEASURE DFT;
Eccentric Wheel
Comp Gauge
What is the function of valves?
Answer: -
Isolation.
Regulation.
Non-Return.
Special purpose.

How the valves are classified based on their function?

Answer:-
A. Isolation:-
Gate valve.
Ball valve
Plug valve.
Piston valve.
Diaphragm Valve.
Butterfly valve.
Pinch valve.
B. Regulation:-
Globe valve.
Needle valve.
Butterfly valve.
Diaphragm valve.
Piston valve.
Pinch valve.
C. Non- Return:-
Check valve.
D. Special purpose
Multi- Port valve.
Flush Bottom valve.
Float valve.
Foot valve.
Line blind valve.
Knife Gate valve.

How the valves are classified based on its method of operation?

Answer: -
Valves are classified based on its method of operation as: -
Self- operated valves.
Operated valves.

Name the Self operated & operated valves?

Answer:-
Mainly the check valves are self-operated and all other valve types comes under
operated valves.

How the valves are classified based on end connection?

Answer: -
 Valves are classified based on end connection as: -
Screwed ends.
Socket ends.
Flanged ends.
Butt weld ends.
Wafer type ends.
Buttress ends.
End connection means arrangement of attachment of the valve with the
equipment or the piping.

What are the types of check valves?

Answer: -
Check valves are divided into two types based on check mechanism as: -
Lift check valve.
Swing check valve.

What do you mean by special purpose valves?

Answer:-
Valves that perform duties other than the two-way isolation, control and check are
called special Purpose valves.

What are Glandless piston valves? Where these are used?

Answer:-
Glandless piston valves are regulating valves used in steam services.

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Questions related to Pipe Fittings:

1. How can flanges be classified based on Pipe Attachment?

Answer:
Flanges can be classified based on pipe attachment as:
Slip On
The Slip-on type flanges are attached by welding inside as well as outside.
These flanges are of forged construction.
Socket Weld
The Socket Weld flanges are welded on one side only. These are used for small
bore lines only.
Screwed
The Screwed-on flanges are used on pipelines where welding cannot
be carried out.
Lap Joint
The Lap Joint flanges are used with stub ends. The stub ends are welded with
pipes & flanges are kept loose over the same.
Welding Neck
The Welding neck flanges are attached by butt welding to the pipe. These are
used mainly for critical services where the weld joints need radiographic
inspection.
Blind
The Blind flanges are used to close the ends which need to be reopened.
Reducing
The reducing flanges are used to connect between larger and smaller sizes
without using a reducer. In case of reducing flanges, the thickness of flange
should be that of the higher diameter.
Integral
Integral flanges are those, which are cast along with the piping Component or
equipment.

How can flanges be classified based on Pressure- temperature ratings?

Answer:
Flanges are classified based on pressure temperature ratings as:
#150
#300
#400
#600
#900
#1500
#2500
Pressure temperature rating carts in the standard ASME16.5 specify the non-shock
working gauge pressure to which the flange can be subjected to at a particular
temperature.

How can flanges be classified based on facing?

Answer:
Flanges are classified based on facing as:
Flat face. (FF)
Raised face. (R/F)
 Tongue and groove. (T/G)
Male and female. (M/F)
Ring type joint. (RTJ)

How can flanges be classified based on face finish?

Answer:
Flanges are classified based on face finish as:
Smooth finish.
Serrated finish.

Where the smooth finish flange & serrated finish flange finds its use?
Answer:
The smooth finish flange is provided when metallic gasket is provided and serrated
finish flange is provided when non-metallic gasket is provided.

What are the types of serrated finish provided on flange face?

Answer:
Concentric or
Spiral (Phonographic)

How the serration on flanges is specified?

Answer:
The serration on flanges is specified by the number, which is the Arithmetic Average
Rough Height (AARH).

Where the concentric serration is insisted for face finish?

Answer:
Concentric serration are insisted for face finish where the fluid being carried has very
low density and can find leakage path through cavity.

How the Gaskets are classified based on the type of construction?

Answer:
Based on the type of construction, gaskets are classified as:
Full face.
Spiral wound metallic.
Ring type.
Metal jacketed.
Inside bolt circle.

What is the most commonly used material for Gasket?

Answer:
Compressed Asbestos Fibre.

Which type of gasket is recommended for high temperature & high-pressure application?
Answer:
Spiral Wound Metallic Gasket.
What are the criteria for selection of MOC of Spiral Wound metallic Gasket winding material?
Answer:
The selection of material of construction for Gasket winding depends upon:
The corrosive nature and concentration of fluid being carried.
The operating temperature of the fluid.
The relative cost of alternate winding material.

What are the most common materials used for spiral wound metallic gasket winding?
Answer:
The most commonly used material for spiral wound metallic gasket winding is:
Austenitic stainless steel 304 with asbestos filler.
Austenitic stainless steel 316 with asbestos filler.
Austenitic stainless steel 321 with asbestos filler.

Which material is used as filler material for spiral wound gasket in case of high
temperature services?
Answer:
For very high temperature services, graphite filler is used.

What is centering ring in connection to spiral wound gasket?

Answer:
Spiral wound gaskets are provided with carbon steel external ring called centering
ring.

What will be the AARH finish on flange face for using spiral wound gasket?
Answer:
125-250 AARH finish.

On which type of flanges the use of spiral wound gasket are restricted?
Answer:
Rating spiral wound gasket on flanges other #ASME B16.5 does not recommend the
use of 150 than welding neck and lapped joint type.

Up to what temperature limits the low strength carbon steel bolts should not be used
for flanged joints?
Answer:
C.C or below 28Flanged joints using low strength carbon steel shall not be used
above 200

How the pipe fittings are classified based on end connections?

Answer:
Pipe fittings are classified based on end connection as:
Socket weld fittings.
Screwed end fittings.
Bevelled end or Butt weld fittings.
Spigot socket fittings.
Buttress end fittings.
Up to what temperature the carbon steel materials shall be used?
Answer:
Carbon steel materials shall be used for temperature up to 425C

Which material is used for temperature above 426C?

Answer:
Alloy steel materials shall be used for temperature above 426 C

Which type of material is used for corrosive fluid?

Answer:
Stainless steel materials shall be used for corrosive fluid.

Which type of piping materials are used for drinking water, instrument air etc.?
Answer:
Galvanized steel materials shall be used for drinking water, instrument air and NI lines
(LP).

What is the difference between Pipe and Tube?

Answer:
Pipe is identified by NB and thickness is defined by Schedule whereas Tube is identified
by OD & its thickness as BWG (Brimingham wire gauge or 1/100 inch).

From which size onwards NB of pipe is equal to OD of Pipe?

Answer:
From the size 14 and onwards NB = OD of pipe.

What should be the radius of long radius elbow?

Answer:
1.5D (Where D is the diameter of the pipe.)

What should be the radius of short radius elbow?

Answer:-
1D(Where D is the diameter of the pipe.)

What is the basis of using of short radius & long radius elbow?
Answer:-
Long radius elbow are used for small pressure drop whereas short radius elbow are
used for high pressure drops. For catalyst flows vary long radius elbows are used.

Normally where do we use the following?

(1) Eccentric reducers. (2) Concentric reducers.
Answer:
Eccentric reducers = Pump suction to avoid Cavitation, to maintain elevation (BOP) in
rack.
Concentric reducers = Pump discharge, vertical pipeline etc.
Concentric reducer is used in pump suction. (Yes / No). Explain.
Answer:
No. Air pockets may form if concentric reducer is used at pump suction, which results
in cavitation and cause damage to Pump. To avoid this problem, Eccentric Reducer
with flat side up (FSU) is used in Pump Suction.

Where the ERW spiral & longitudinal pipes are used?

Answer:
Use depends upon the availability of pipes. Nothing functional difference.

Where the ERW & Seamless pipes are used?

Answer:
Above 18 ERW pipes are used. Below 18 seamless pipes are used. Seamless pipes
can sustain higher temperature & pressure.

What is the main use of ASTM A53 & A106 Gr. B pipes?
Answer:
ASTM A53 pipes are mainly used for utility services whereas A106 Gr. B pipes are used
for high Pressure & high temperature services.

From which side of pipe will you take a branch connection?

Answer:-
When fluid is Gas, Air or Steam and Cryogenic Service Topside.
When Fluid is Liquid Bottom Side.

Why dont we take a branch for Cryogenic Service from bottom side though the fluid is
in liquid state?
Answer:
There is the chance of ice formation during normal operation and since ice flows from
the bottom of the pipe it will block the branch pipe connection.

Why do we provide High Point Vent (HPV) and Low Point Drain (LPD) in piping?
Answer:
HPV For removing Air during Hydro-test.
LPD For draining water after conducting Hydro-test.

What do you mean by Jacketed Piping?

Answer:
Piping which is recognized as providing the most uniform application of heat to the
process, as well as maintaining the most uniform processing temperatures where
steam tracing is not capable of maintaining the temperature of fluid constant. Usually
used for molten sulphur, Polymers service.

What is the minimum distance to be maintained between two welds in a pipe?

Answer:
The thumb rule is that the minimum distance between adjacent butt welds is 1D. If
not, it is never closer than 1-1/2. This is supposedly to prevent the overlap of HAZs.
 Minimum spacing of circumferential welds between centerlines shall not be less than
4 times the pipe wall thickness or 25 mm whichever is greater.

What do you mean by IBR and which lines comes under IBR purview?
Answer:
IBR: Indian Boiler Regulation Act.
Steam lines with conditions listed bellow comes under IBR purview :
Lines for which design pressure is 3.5 kg/sq. cm and above.
Line size above 10 having design pressure 1.0 kg/sq. cm and above.
Boiler feed water lines to steam generator, condensate lines to steam generator and
flash drum.

What are Weldolet and Sockolet? And where they are used?
Answer:-
Weldolet and Sockolet are basically self-reinforced fittings.
Weldolet is used for Butt weld branch connection where standard tee is not available
due to size restrictions and the piping is of critical / high-pressure service.
Sockolet is used for socket welding branch connection, which require reinforcing pad.

What is the MOC for Superheated high pressure Steam Lines?

Answer:-
A 335 Gr. P I / P 11, Composition: Cr. Mo (P1) / 1 Cr. Mo (P11)

What is the normal upstream and downstream straight length of orifice flow meter?
Answer:
Upstream 15D
Downstream 5D

Questions related to Materials:

What is the ASTM code for the following?
Pipes
Carbon Steel
Alloy Steel
Stainless Steel
Nickel Steel.
Tubes
Carbon Steel
Alloy Steel
Stainless Steel
Nickel Steel.
Wrought Iron Fittings
Carbon Steel
Alloy Steel
Stainless Steel
Nickel Steel.
Forged Fittings
Carbon Steel
 Alloy Steel
Stainless Steel
Nickel Steel.
Cast Fittings
Carbon Steel
Alloy Steel
Stainless Steel
Nickel Steel.
Plates
Carbon Steel
Alloy Steel
Stainless Steel
Nickel Steel.

Answer:
Pipes:-
Carbon Steel
ASTM A53 Gr. A/B
ASTM A106 Gr. A/B/C
ASTM A333 Gr.1/Gr.6
Alloy Steel
ASTM A335 Gr.P1/P2/P5/P7/P9/P11/P12/P22.
Stainless Steel
ASTM A312TP304/TP304L/TP304H/TP308/TP310/TP316/TP316L/TP316H/TP3
17/TP321/TP321H/TP347/TP347H/TP348/TP348H.
Nickel Steel
ASTM A333Gr.3/ Gr.8.

Tubes:-
Carbon Steel
ASTM A178/179/192, ASTM A334 Gr.1/6.
Alloy Steel
ASTM A161T1, ASTM A213T1/T2/T5/T7/T9/T11/T12/T22.
Stainless Steel
ASTM A213 TP304/TP304L/TP304H/TP310/TP316/TP316L/TP316H/
TP317/TP321/TP321H/TP347/TP347H/TP348/TP348H/ASTM A608 HK40.
Nickel Steel
ASTM A334Gr.3/Gr.8

Wrought Iron fittings

Carbon Steel
ASTM A234Gr.WPA/B, ASTM A420 Gr.WPL6.
Alloy Steel
ASTM A234 WP1/WP5/WP7/WP9/WP11/WP12/WP22.
Stainless Steel
ASTM A403 WP304/WP304L/WP304H/WP309/WP310/WP316/
WP316L/WP316H/ WP317/WP321/WP321H/WP347/WP347H/WP348.
 Nickel Steel
ASTM A420WPL6/WPL8.

Forged Fittings
Carbon Steel
ASTM A181. ASTM A105, ASTM A350 LF1/2.
Alloy Steel
ASTM A182F1/F2/F5/F7/F9/F11/F12/F22.
Stainless Steel
ASTM A182F6/F304/F304L/F304H/F310/F316/F316L/F316H/F321/
F321H/F347/F347H/F348.
Nickel Steel
ASTM A350 LF3, ASTM A522.

Cast Fittings
Carbon Steel
ASTM A216, ASTM A352 LCB/C.
Alloy Steel
ASTM A217 WC1/WC6/WC9/C5/C12.
Stainless Steel
ASTM A217 CA15, ASTM A296 CA15, ASTM A351 CF8/CF3/CH20/
CK20/CF 8M/CF 3M/CF 8C/HK40.
Nickel Steel
ASTM A352LC3.

Plates
Carbon Steel
ASTM A285, ASTM A515, ASTM A516.
Alloy Steel
ASTM A387 Gr.2/Gr.5/Gr.7/Gr.9/Gr.11/Gr.12/Gr.22.
Stainless Steel
ASTM A240 TP410/TP405/TP430/TP304/TP304L/TP309/TP310S/
TP316/TP316L/TP317/TP321/TP347/TP348
Nickel Steel
ASTM A203 Gr.D/Gr.E, ASTM A353.

What is the basic difference between Pipe specification A106 Gr. A / Gr. B/ Gr. C.?
Answer:
Difference is due to the Carbon content.
% of carbon content in:
ASTM A106 Gr. A 0.25 %
ASTM A106 Gr. B 0.30 %
II ASTM A106 Gr. C 0.35 %.

What is the difference between pipe specifications ASTM A312 TP 304 & ASTM A312 TP304L,
ASTM A312 TP 316 & ASTM A312 TP 316L?
Answer:
Difference is due to the Carbon content. The Letter L denotes lower percentage of
carbon.
% of carbon content in:
ASTM A312 TP 304 0.08 %
ASTM A312 TP 304L- 0.035%
ASTM A312 TP 316 0.08 %
ASTM A312 TP 316L- 0.035%

What is the standard for Process (or) Plant piping systems?

Answer: ASME B 31.3

What is the standard for Power Piping systems?

Answer: ASME B 31.1

What is the standard for liquid Petroleum Transportation piping systems?

Answer: ASME B31.4

What is the standard for Gas Transmission and Distribution piping systems?
Answer: ASME B31.8

What is the Code for Welding of Pipelines and Related facilities?

Answer: API 1104

What is the standard for welding rods Electrodes and filler metals?
Answer: ASME Sec-IIC

What is the standard for Non-destructive Examination?

Answer: ASME Sec-V

What is the standard for welding and Brazing Qualifications?

Answer: ASME Sec-IX

Which type of process we are using in field/fabrication shop?

Answer: Fusion welding

What is the specification/classification for carbon steel filler wire?

Answer: AWS 5.18/ER70-Sx

What is the specification/classification for carbon steel Electrode?

Answer: AWS 5.1/E-XXXX

Where we can use E-6010 type electrode?

Answer: we can use at root pass for deep penetration

What is the meaning for ASME?

Answer: American Society for Mechanical Engineering
Which type of electrode we are using in GTAW process?
Answer: Non-Consumable Tungston Electrode

How Many times we can dry the electrodes?

Answer: Only one time

Why we are baking the electrodes?

Answer: To remove the moisture content from the Electrodes.

What is the standard for Structural steel fabrication?

Answer: AWS D1.1

What is the standard for Welding symbols?

Answer: AWS A2.4.

What is the hydrotest pressure?

Answer: 1.5 Times of design pressure.

What is the drying temperature for Stainless Steel electrodes?

Answer: 120 to 250 degree temperature.

What is the drying procedure procedure for Low hydrogen electrodes?

Answer: 260 to 430 degree temperature.baking for two hours

What are the defects we can find in visual Inspection?

Answer: Porosity,Undercut,Surface crack (HIC),Side wall fusion on fusion boundary.

What is the Procedure for Fit-Up inspection?

Answer: Base metal classification,cleaning,Alignment,root gap,root face,bevel angle &
mismatch (or) overlap.

What is the internal overlap (or) mismatch for piping?

Answer: 1.5 mm.

How much root face are allowed?

Answer: As per WPS (or) 0.8 to 1.6 mm

What is meaning for F Number?

Answer: F- is filler metal grouping Number.

What is meaning for P Number?

Answer: P is base metal grouping Number.

What is meaning for A Number?

Answer: A is electrode chemical analysis number.
How much bead width we can allow?
Answer: Max 3 times of electrode diameter.

How much area is required for Pre-heat?

Answer: 75 mm minimum from both end of the Joint.

Which section we are using for NDT?

Answer: ASME Sec-V

What are the essential variables for SMAW process?

Answer: In base metal thickness, P-number, dia of pipe, pre, post weld heat treatment
In filler metals F,A-numbers, dia

What are the essential variables for GTAW process?

Answer: In Base Metal thickness, P-number, dia of pipe, pre, post weld heat treatment In
Filler Metals F, A-numbers,dia of filler metal

If welder made test by 2 dia, what is his range qualified?

Answer: He has qualified 1-dia and above.

If welder made test by 14 mm thickness, what is his thickness range qualified?

Answer: He has qualified unlimited thickness.

What is carbon % in low carbon steel?

Answer: Max 0.30 %

What is the interpass temperature for carbon steel materials?

Answer: Max 315C

What is meaning for SAES,SAEP and SAMSS?

Answer: Saudi Aramco Engineering Standards Saudi Aramco Engineering Procedures Saudi
Aramco Materials System Specification.

How much under cut depth allowed in piping?

Answer: 0.8 mm

How much area is required for Pre-heat?

Answer: 75 mm minimum from both end of the Joint.

How much percentage is allowed more than test pressure in Pressure relief device?
Answer: Test pressure plus10% (10% should be lesser than 50Psi).

How much gap is allowed in socket weld?

Answer: 1.5 mm minimum before welding.

What is the minimum fillet size in socket weld?

Answer: Minimum 3 mm fillet size.
Hydro test.
1. Piping Internal Cleaning
a. Air compressor
b. Air blower
c. Electrical cable
d. Generator
c. Wire brush
d. cotton waste cloth
e. water tanker water with pump

Testing
a. Pressure gauge-(30days calibration valid, range 1.5 to 2 times test pressure)
b. Test manifold (calibration validity)
c. Pressure relief valve (Set to 5% above test pressure)
d. Test pump
e. Water tank
f. Hoses
g. Test blind
h. Test water (refer as per project specification)

Test package
1. Calibration Certificates of Gauges, relief valves
2. P&ID and ISO Drawing
3. Test Package Control sheet
4. Marked up P&ID
5. As built Drawing
6. Welding log
7. NDE report
8 .Punch list all punch list cleared (category one)
9. Pressure test Check sheet
10. Safety check lists

CHARPY IMPACT TEST

AIM:
To determine the impact energy of given specimen by using charpy impact tester.
APPARATUS
: Charpy impact testing machine, specimen, magnifying lens, annealed sampleof steel.
THEORY
: This test uses charpy bar specimen with a square cross-section and a notch of 5mm depth.
It is simply supported beam and loaded behind the notch by impact of pendulum.The
specimen is forced to bend and fracture at a high strain-rate order. The
principlemeasurements from impact test in the energy absorbed in fracturing the specimen.
After breaking, the test bar the pendulum is rebounded in a height which decreases as the
energyabsorbed in the fracture energy measured by charpy test is only a relative energy and
cannot be used directly in design equation.Another common measurement obtained from
charpy test results from examinationfracture surface to whether the fracture surface is
fibrous, granular or a mixture of both. Thedifferent distinguishable zones of fracture surface
helps in judging mode of fracture. A notch is supplied on specimen because it ensures that
the specimen will break as aresult of impact load to which is subjected without notch many
materials would simply bendwithout breaking, so it would therefore impossible to determine
their ability energy.
DIFFERENT HEAT TREATMENTS GIVEN TO DIFFERENT SPECIMENS OFSAME MATERIAL
ARE:ANNEALING:
It is one of the most important and widely used heat treatment as it isrestores the ductility to
metal that has been severely strain-hardened. It involves heating of steel to 900 and cooling
in furnace.
NORMALISING
: It involves heating of steel to 900c, soaking for one hour and cooling instill air.
HARDENING (WATER QUENCHED):
This operation is applied to all tools and someimportant machine parts intended for especially
heavy duty services. It involves heating of steel to 900c followed by soaking for one hour and
quenched in water or any liquid medium.
TEMPERING:
Here steel which is quenched component is reheated to a temperature belowthe
transformation range followed by cooling at a desired rate. It restores the ductility
andreduces brittleness due to quenching. The material can be heated to either 200 c, 500c,.
PROCEDURE
:1)Specimen and swinging hammer are fixed in either position.2)Pendulum is brought up and
fixed at a particular position 3)Centre of specimen notch is aligned to centre of support by
means of charpysetting gauge.4) Pointer is adjusted to zero.5)Pendulum is release from top,
giving an impact blow to the specimen.6)Energy absorbed is noted, through a magnifying
glass lens to note extent of typeof fracture surface.
ADVANTAGES
:1)It is simple and utilizes simple and cheaper, small specimen.2)This can be carried out over
a range of sub-ambient temperatures.3)This test can be used for comparing influence of alloy
studies and heat treatmenton notch toughness.4)Used for quality control and material
acceptance purpose.
DISADVANTAGES
:1)The results of charpy test are difficult to use in design.2)There is no correlation of charpy
data with below size.3)The large scatter inherent in test may make it difficult to determine
welldefined transition temperature curves.
PRECAUTIONS
: 1)Notch configuration should be carefully prepared as it affects notch-
toughnessvalue.2)Centre of specimen notch should be aligned with centre of
support.3)Impact energy reading should be taken without parallax error.
RESULT
:The impact energy absorbed by annealing specimen isThe impact energy absorbed by
normalizing specimen isThe impact energy absorbed by tempering specimen is