PIPING QUESTIONNAIRE

Scope: This piping questionnaire is to be referred along with piping

presentation MFF.Module.1 PART I. It deals with piping, piping components
including valves and pressure testing of piping.
PIPE
1.Why 1¼”, 2½”, 3½” & 5” are called non-prepared sizes in ONGC
specification?
These sizes are not readily available and manufacturer find difficult to
manufacture. Use of the sizes should be avoided in new constructions. Hence
ONGC recommends not to use this size.

2.What is the difference between Std wall / extra strong & Schedule 40 /80
thickness?
From ½” to 10” Std wall & schedule 40 thickness will match together.
Above 10”(i.e. 12 “) Std wall thickness will remains same. Where as Sch. 40
thickness will be keep on increasing.

Extra strong & sch .80

From ½” to 8” Extra strong and Sch 80 thickness will match together.
Above 8” (i.e. 10” onwards) extra strong thickness will remain same where as
sch 80 thickness will be keep on increasing.

3.what are the schedule available for Stainless Steel and Carbon Steel
(5 S, 10 S, 40 S, and 80 S) SS are suffixed by S letter along with schedule.
10,20,30,40,60,80,100,120,140,160, Std Wall, Extra strong, Double Extra
Strong.

4.What are the various tolerance specified on pipe?

Incase of thickness it can deviate by ± 12.5 % of its thickness.

Incase of outside diameter

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Incase of Inside diameter

Incase of length

5.Is STD Wall, Extra Strong, Double Extra Strong? Thicknesses are
available in Stainless Steel also?
No. It is available on Carbon Steel only.

6.Name the Carbon Steel and Stainless Steel pipe Standards. What is the
information it can furnish?
ANSI B 36.10 Welded and Seamless Wrought Steel pipes upto NPS 80 sizes
are available.
ANSI B 36.19 Welded and Seamless Austenitic Stainless steel pipes.
Both these standard gives information on sizes of pipe, tolerance, material details
etc.
Some time one may need to refer ASTM A 530 for general requirements of
pipes.

7.Compare ANSI B 36.10, ANSI B 36.19 standards.

Generally the schedule number of both the STD will match,
Except the following,

10” sch 80/80 s, 12”sch 40/40s, 12”sch 80, /80s, 14” sch 10/10s
16” sch 10/10s, 18” sch 10/10s, 20’ sch 10/10s, 22” sch 10/10s

ANSI B 36.10 covers pipe size up to 80”NB and ANSI B 36.19 covers pipe size
up to 34” NB.

8.Name commonly used C.S, SS and non-ferrous Pipe and pipe fittings?

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A 53, for general service, commenly used pipe.
ERW Grade A
ERW Grade B
Seamless Grade A
Seamless Grade B
Furnace butt welded (100 NB & Smaller) pipes are less expensive, but cannot be
used for the same working pressure as ERW & Seamless pipe. The latter are
recommended for all higher-pressure application.
Under these specifications, piping up to extra strong wall thickness only can be
procured. For pipes with heavier wall thick, A 106 specification to be used.

A 106 for high temperature & high-pressure pipe

Grade A-333 N/ mm² 48,000 Psi min.
Grade B-416 N/mm² 60,000 Psi min
Grade C-485 N/mm² 70,000 Psi min
Although the physical & chemical properties for Grade A & B are Comparable to
those for A-53 pipe and the types of testing required by both specifications are
similar, the tests prescribed for A106 are more stringent and are applied to
smaller lots of pipe. Therefore pipe procured to specification A 106 is preferred
for exacting services.

A 120.galvanized pipe

This pipe are black or galvanized welded and seamless steel pipe in sizes 300NB
and smaller, for ordinary uses in handling steam, water, gas or air.
This pipe is not intended for use at medium or high temperature nor close coiling
and bending. No need to test the pipe for chemical and physical properties
except hydro test.

A 312 STAINLESS STEEL PIPE

This specification covers seamless and automatic welded (without the addition of
the filler material) chrome nickel pipe and is generally available in sizes 200 NB

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and smaller. The steel is made by electric furnace process, and the pipe is
furnished in pickled and passivated condition.

Fifteen grades of austenitic stainless steel (identified as grades TP 304, TP304 H,

TP304 L, TP309, TP310, TP316, TP316 H, TP316 L TP317, TP 321, TP 321H,
TP 347, TP 347H, TP 348 AND TP 348 H) are available.

CHROME NICKEL ( STAINLESS STEEL ) PIPE

Special consideration must be given to the ordinary 18% chrome – 8% nickel

steels when they are to be welded, hot formed or used for corrosion resistance.
At temperature from 425* c to 815* c, chromium carbides are formed along the
grain boundaries with a consequent reduction of corrosion resistance properties.
This, however, can be minimized by the addition of such as titanium and
columbium.

Two grades of stainless steel pipe are in common use –regular grade and L grade.
Regular grade, having a maximum carbon content of 0.08% has a higher strength
at elevated temperatures, but is susceptible to intergranular corrosion.
Consequently the second grade, L, is developed in which the carbon content is
limited to 0.03%. This serves to reduce intergranular corrosion; however, the low
carbon content of the L grade decreases the tensile strength at elevated
temperatures.

A new grade, H, has subsequently been introduced. This grade, having a carbon
content of 0.04% to 0.10%, is also susceptible to intergranular corrosion, as is
the regular grade, but its higher range of carbon content assures the required high
temperature strength which would not be obtainable with the lower carbon range
of the regular grade.

A-358
This specification covers electric fusion welded chromium nickel steel pipe and
is sizes 200 NB and larger. The pipe is made from ASTM A-240 chromium
nickel plate in seven grades. . (Type 304, 309s, 310s, 316,321, 347, and 347.)

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A-376
Seamless austenitic steel pipe for high temperature services.

LOW TEMPERATURE SERVICE PIPE.

A-333
For steel pipe low temperature service three nickel grades normally available.
NON-FERROUS PIPE
Non-ferrous pipe is used for many extreme conditions, i.e. for low temperature,
for very high temperature, for corrosive conditions beyond the abilities of ferrous
materials. The most common non ferrous pipe materials are nickel, copper,
aluminum and their many alloyed compositions such as monel, inconel, hasteloy,
red brass, yellow brass, cupro-nickel.

Welded fittinings
The following ASTM specifications govern materials, methods of manufacture,
quality controls and marking of factory made, wrought steel welding fittings.
A-234 - Carbon steel and ferritic alloy steel fittings
A-403 - Stainless (austenitic) steel feetings.
A-420 – Carbon and alloy steel fittings for low temperature service.

All the three specifications follow the same pattern, modified only to the extent
necessary for the particular material or service involved.
A-234 This specification covers three grades of carbon steel, one grade of
carbon molybdenum and four grades of low to medium (1% through 5%)
chromium molybdenum steels.
This specification requires that:
A fusion-welded seam in a fitting must be welded and qualified under
section IX of ASME B&PV code;
A minimum of 4% of all fittings (randomly selected) in standard and extra
strong wall thickness and every fitting heavier than extra strong, in any lot must
be radiographically examined throughout the entire length of each weld and
approved in accordance with Sec VIII of the ASME code;
The fittings be normalized to refine the grain resulting in better
combination of mechanical properties when the fittings are formed at
temperature above 980 degree C.

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A-403 this specification establishes fourteen grades of austenitic steels, including
the more popular grades of 304,316 and 347. These steels are used for their
properties of strength at high temperature, excellent and resistance to many
corrosive fluids.
This specification requires that;
A fusion-welded seam in a fitting must be welded and qualified under
section IX of ASME B&PV code;
All fittings in any lot must be radiographically examined throught the entire
length of weld and approved in accordance with Section VIII of the ASME code;
The fittings must be subjected to a carbide solution treatment to inhibit
intergranular corrosion.
A-420 This specification covers four grades for low temperature service up to –
100 degree. In the range between –100 degree C and –200 degree C, the
materials specified in A403 are more suitable.
This specification requires that:
A fusion-welded seam in a fitting must be welded and qualified under
section IX of ASME code.
A minimum of 4% of all fittings (randomly selected) in standard and extra
strong wall thickness and every fitting heavier than extra strong, in any lot must
be radiographically examined throughout the entire length of each weld and
approved in accordance with Section VIII of the ASME code;
The fittings be normalized to improve low temperature impact properties,
regardless of forming temperatures.
Forged Steel Flanges
The following ASTM specifications given the manufacture of forged steel
flanges. Each specification covers forged or rolled steel pipe flanges, forged
fittings, and valves and parts.

A-105 - Carbon steel, for high temperature service.

A-181 - Carbon steel, for general service.
A-182 - Alloy steel, for high temperature service.
A-350 - Carbon and alloy steel, for low temperature services.
A-404 - Alloy steel, specially heat treated for high temperature services.

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A-105 – Covers two grades of carbon steel material and is generally applied to
flanges having primary pressure ratings of 400# and more.
A-181 – covers two grades of carbon steel, but is intended for lower pressure
with primary pressure ratings of 150# and 300#.
A-182 – covers twenty-four grades of alloy steel, ten grades of ferritic steel and
fourteen grades of austenitic steel flanges.
A-350 – covers four grades of carbon steel and alloy steel flanges for low
temperature in addition to permitting the use of austenitic alloys covered in A-
182 for low temperature installations.
A-404 – contains a single grade of ferritic alloy steel, which must be specially
heat-treated for high temperature use.

9.Why outside diameter is kept constant for varying schedule Number?

(Why not inside diameter).(EXACT ANS. NOT KNOWN)
Wall thickness varies with the schedule number but the outside diameter
remains constant for the various sizes, as the thickness changes, the inside
diameter changes.

10.Up to what percentage Stainless Steel & special alloys comes under
ferrous group?
If alloying element is within 50 % then it will be comes under ferrous group. If
alloying element exceeds by more than 50 % then it will be comes under non-
ferrous group. And that alloy will name it.
Ex. Nickel alloy. (In conal 32% nickel & 20% Cr).

11. What are the Limitation based on selection of material?

-C.S shall be used up to 800’f (425* c)
-How temperature steel shall be used below –20’f (-29*c)
-Alloy steel shall be used above 800*f
- For corrosive fluid recommendation.

12.What is the min. distance to be maintained between two welds in a pipe.?

The rule of thumb is that the minimum distance between adjacent butt welds is
1D. If not, it is never closer than 1-½”. This is supposedly to prevent the overlap
of HAZ s.

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Minimum spacing of circumferential welds between centerlines shall
Not be less than 4 times the pipe wall thickness or 25 mm whichever is greater.

13.What is desired life cycle for piping in operation?

Desired life cycle for piping in operation is 20 years (7000 cycles).
The normal no. of cycles for which the displacement or thermal stresses are
designed is 7000 cycles.

14.what is the allowable stress range for CS pipes?

2070 kg/cm²

15.what are the insulation materials used for piping systems.

Fibrous –Rock & Glass wool
Rigid- Calcium silicate, polyisocyanurate, cellular Glass

16. What is DN in pipe?

DN (Nominal Diameter) is a dimensionless designator used in the SI (metric)
system to describe pipe size.

FITTINGS
1.Name few pipe fitting standards?
ANSI B 16.5 Steel and nickel pipe flanges and flanged fittings.
size NPS ½” through 24”. Sizes NPS 26 to 60” refer B
16.47.
BS 1560 for fabricated flanges.
ANSI B 16.9 Steel butt weld fittings.
Size NPS ½” through 48’’
ANSI B 16.11 Forged steel socket welding and threaded fittings
ANSI B 16.25 Butt welding ends.
ANSI B 16.28 short radius elbows and returns
ANSI B 16.1 Cast iron flanged fittings tees, elbows, laterals, etc.
In pressure classes 25,125,250 and 800 are used.
ANSI B 16.20 Metallic gaskets

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ANSI B 16.21 Non metallic gaskets

2.Why screwed and socket welded fittings are expensive?

These fittings are manufactured from solid forging. Hence it’s expensive. These
fittings are bulky in nature. Hence it is used up to 1½” sizes.
Screwed class ratings 2000,3000,6000
Socket class ratings 3000,6000,9000
Normally Butt-welded fittings schedule is matched with connecting pipes.
Flange fittings are rated as ratings. O’lets are generally as per MSS-SP

3.What are the advantage of using tongue & groove or ring type joint?
Because of the small gasket contact area a tight joint may be made using low
bolting loads. There by resulting in lower flange stresses. These joints are widely
used in high temperature and pressure.

4.What is spigot joint?

Spigot /socket ends specified when lead caulked cemented joint are provided
between pipes and, between pipes & fittings. These are recommended only for
low-pressure application.

5.Why miter bend are not used on critical service?

Because of its design limitation (pressure drop, joint in the bend may cause
leakage) miter bends are not subjected to high pressure and temperature. Hence it
is not used on critical service.

6.How do you decide the number of flange bolt holes?

The more pressure existing, the more bolts, required bolts holes are always added
in quantities of 4,8,12,16,20,24 etc bolting is always equally spaced on the bolt
circle.

7.What is the purpose of maintaining 1/16” gap in socket weld fittings?

Socket weld joints 1/16” gap is maintained to prevent weld from cracking under
thermal stress.

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Brief about Forged steel thread and socket welded fittings as per ANSI B16.11

The std covers pressure temperature rating dimension, tolerance, marking and
materials requirements for forged carbon and alloy steel fittings, although these
fittings are available in sizes up to NPS 4, size limitation may be imposed by
certain course acceptable material forms are forgings, bars, seamless pipe, etc
which conform the chemical composition, melting processes and mechanical
property requirements of ASTM A105, A182, or A 350,
Limitation
A maximum allowable pressure of the fitting is equal to that computed for
straight seamless pipe of equivalent material, and considering manufacturing
tolerance, corrosion allowances and mechanical strength allowances. Also for
socket welding fittings the pressure rating must be matched to the pipe wall
thickness to assure that the flat of the band can accommodate the size of fillet
welded required by the applicable code.
The recommended fittings pressure class for the various pipe wall thickness is as
follows.

Pipe sch threaded socket welded

80/xs or less 2000 3000
160 3000 6000
XXS 6000 9000

Brief about Forged steel thread and socket welded fittings as per ANSI B16.9
and B 16.28.

Wrought fitting materials conforms ASTM A 234, A 403 or A 420, the grade of
which have chemical and physical properties equivalent to that of mating pipe.
ANSI B 16.9 require that the pressure temperature ratings of the fittings equal or
exceed that of the mating pipe of the same or equivalent material, same size and
same nominal wall thickness,
The pressure temperature rating may be established are rated at 80% of the rating
calculated for seamless straight pipe of the same size and nominal thick and same
or equivalent material therefore both standard require that in lieu of specifying

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any pressure rating, the pipe wall thickness and pipe material, type with which
the fittings are intended to be used be identified. On the fitting
Pressure testing of the fitting is not required.

B16.9 & B 16.28 gives the dimensional and manufacturing tolerance.

National standard does not govern lateral. Working pressure is rated at 40 % of
the allowable working pressure established for pipe from which laterals are
made. Where full allowable pipe pressure must be made, the laterals are
generally made from heavier pipe.

Brief about Flanged end fittings

ASTM 216 Carbon steel castings
ASTM B351 SS castings
A 352 alloy steel castings

Welded piping is usually specified for sizes 2” and above.

Screwed and socket welded piping is for sizes 1½ and smaller.
Piping system for refineries usually are 1”-24” screwed & socket welded fittings
have 90’ ell s.45’ ells tees, caps. Etc.

8.What is Weld cap?

The weld cap terminates a pipe.

9.What is Swage nipple?

It is a reducer. But it is longer in sizes .it is available in eccentric or concentric
and come in the welded sizes and threaded it is most commonly used in sizes 2”
and smaller instead of using reducer.

10.What is Couplings?
Coupling joins two pieces of pipe or male connections it also stub in a small pipe
or male connections it also stub in small pipe or connection in to a larger one

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11.What is Union?
Union joins screwed and socket weld pipe and male connection. When they may
need to be broken apart in the future, the union is a possible leak joint and should
be used where the break away future is necessary.

12.Brief about Flange and flange facings

Flange comes in all sizes and materials. The forged steel flange comes in seven
basic ratings, which the ANSI set 150, 300, 400, 600, 900,1500 & 2500.

Cast iron flange come in two ratings the 125 rating has a flat face while the 250#
ratings usually has a raised face

Flange joint are expensive.

Raised face 1/16” for 150# 300#
Raised face ¼” for other series.
Flat-faced flanges have no raised face and require a fully faced gasket.

Groove in RT (ring type joint) flange fits a metallic ring which is compressed
the groove is oval or octagonal
Ring type joint could also be specified for welded neck and slip on flange.
Slip-on flange may be substituted for welded neck flange in 150# & 300# ratings
(cost effective and less space & less load.)

The raised face, the lapped and the large male and female facing have the same
dimension, which provide a relatively large contact area. Where metal gaskets
are used with these facings, the gasket area should be reduced to increase the
gasket compression.
7.How can flanges be classified based on facings?
a)Flat face
b)Raised face
c)Tongue and groove
d)Ring type joint

13.What do you mean by AARH( flange finish)

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Arithmetic Average Roughness Height

14.Which are the different types of gasket?

Full face, spiral wound, octagonal ring type, metal jacketed and inside bolt circle.

15.What should be the relative hardness between the RTJ gasket and flange
groove.?
For a RTJ flange, the joint ring should have 30-40 Vickers hardness less than
that of the mating face of flange. (Brinnel hardness for RTJ groove shall be 20-
50 BHN more than the corresponding gasket hardness)

16.What do you mean cavitation in pump?

A pump is designed to handle liquid, not vapour.Vapour forms if the pressure in
the pump falls below the liquid’s vapour pressure. The vapour pressure occurs
right at the impeller inlet where a sharp pressure drop occurs. The impeller
rapidly builds up the pressure which collapses vapour bubbles causing cavitation
and damage. This is avoided by maintaining sufficient NPSH.
(Cavitation implies cavities or holes in the fluid we are pumping. These holes can also
be described as bubbles. So cavitation is really the formation of bubbles and their
collapse. Bubbles form when ever liquid boils. It can be avoided by providing
sufficient NPSH.)
17. Flanges
- Rating shall be based on the pressure temperature conditions. However 150 lb
flanges are not permitted beyond 2000 C
- Socket welding flanges may be used for all pressure ratings upto 1.5” NB size
except on steam lines subjected to 1 BR regulations.
- Screwed flanges shall be used for galvanized steel/cast iron piping.
- Slip on flanges are used in 150 lb and 300 lb rating upto a maximum of 2000 C
welding neck flanges shall be used for higher pressure ratings.
- Raised face is used for flanges upto 600 lb rating. For flanges 900 lb rating and
above RTJ is recommended. Tongue and groove facing shall be used selectively.
- Depending on pressure and temperature gasket shall be either CAF., spiral
wound metallic for raised face flanges or to be selected based on the corrosive
nature of fluid.

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- Use flat face flanges to mate with cast iron valves and equipments.

Bellows exp. Joints

17.Why bellows are thinner?
To provide the requisite flexibility, the metal bellows is considerably thinner
than the associated piping thus these exp. Joints are especially susceptible to
rupture by over pressure.
Exp joints are used in piping system to absorb thermal expansion where use of
exp. Loops are undesirable or impractical. Exp. Joints are available in slip, ball,
metal bellows and rubber bellows configurations.

18.What is purpose of Rubber expansion Joints?

Are similar in design to metal bellows exp joints except that they are constructed
by fabric and wire reinforced elastomers. There are most suitable for use in cold-
water service where large movements must be absorbed e.g. (condenser
circulating water).

19.What is the maximum expansion in loops in normal design?

10 inches

20.What are weldolet and sockotlet? And where they are used?
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.

Valves

1.What is the purpose of valve?

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Valves are used to close or open or control flow. Valves are designed to perform
any of the below functions.

Classification of based on function

Isolation (gate, ball, plug, butterfly etc.)

Regulation (globe, butterfly etc.)
Non return (check valves, SDNR, etc.)
Special purpose (foot valves etc.)

Valves can be further classified based on the end connection screwed, socket flanged, and
butt weld.

Pr. Temperature ratings of valves

Pr temperature rating is the maximum allowable sustained non shock pressure at the
corresponding tabulated temperature.

Class
Valve the specified by the pressure rating of the body of the valves. Classes are.

150 # 300 # 400 # 600 # 900 # 1500 # 2500 # class 800 #

2. What is Trim?
The trim is comprised of stem seat surface and other small internal parts that normally
contact the surface fluid.

3.What is Wire drawing?

The term is used to indicate the premature erosion of the valves seat caused by excessive
velocity between seat and seat disc
Velocity at a rate of sonic

4.Brief about Globe valve

It is used for throttling purpose. Ex. Wash basin Valve v named after its globular body.

Higher pressure drop – 270’ turn before reaching orifice

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 270’ turn after reaching orifice

Angle valve
It is used for throttling purpose Similar to globe valve; it can replace one elbow joint.
Less pr. Drop

5.Brief about Plug valve (also called cocks)

Ball valves are similar to plug valve
Quarter turn can open/close the valve

6.Brief about Check valve

It is used admit flow in one direction.
It works on the principal of pressure difference.

SDNR-This valve is also one type of non return valve.

Brief about Gate valve (isolation valve)

-Mostly used on industrial piping
-Not recommend for throttling of flow. To be used for isolation (throttling means erosion at
bottom of gate).
-Flow is axial to piping.
-Lower pr. Drop.
Valve can be identified by welded shaped body line.

7.Is gate valves are used high temp also?

Yes.

Brief about Ball valve (isolation)

It is named after ball shaped disc located with in the body.
Normally positive shut off valves. Positive shut off is attained because of the soft seats.
(Nylon, synthetic rubber, imparts excellent sealing ability.

-Lower pr. Drop. Services.

Quarter turn or handle will open /close valve.

-Suitable for gas, compressed air, liquid and slurry hence used on off shore /onshore,
petrochemicals, widely.
-Metals seats ball valves are used for high temperatre service. (With fluorinated polymer
seats, can be used for temp from –450 degree Fahrenheit

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To 500 Fahrenheit, with graphite seats temp up to 1000 Fahrenheit.

8.Brief about Butterfly valve

These are low pressure valves may be control or regulate flow.
Thee are available with metal to metal seats and soft seats.
Flanged type.
Wafer lug type.
Water type.
Positive shut off valve
Quarter shut off valve.
Occupies less space.
Wafer lug and wafer type body design. Is that former has provision for all the studs to pass
through the body. Whereas the latter has provision for only locating bolts. Can be used for
corrosion service by selecting proper disc. Material. (Nitrile. rubber. PTFE) etc.

Needle valve

Generally used for instrument gauge, and meter line service. Very accurate throttling is
possible and therefore extensively used in high pressure and high temperature services.

9.Difference between B16.5 and B 16.34

The pressure temperature rating of B16.34 parallels that of ANSI B 16.5 except
that B 16.34 provides for an increase in pressure rating for welding –end valves
that receive additional prescribed Non destructive examination.
ANSI B 16.1 cast iron flange.
B 16.34 steel/ nickel flange.

10.What is Relief valve?

The main purpose of are relief valve is to protect an equipment or pipe line by
relieving excess pressure, and is the only valve which is continuously closed
position.
.

11.What is the difference between Safety relief valve and pressure relief
valve?

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Safety relief valve
These are designed for gases; in this case the valve seat pops up to open the
valve where ever set pressure is crossed. These valve reseats below the initial set
pressure. There by reducing the system pressure. To a safe level prior to
reseating.

Pressure relief valve

These are designed for compressible fluids like water etc. in this case the valve
seat does not pop up but gradually opens up proportionally to the over pressure
margin, after the operating pressure crosses the set value.

12What is the permissible leakage while testing the valve?

HYDRO TEST
1 When leak test can be substituted for hydro test?
As for as possible hydro test should be conducted, incase of any damage
expected due hydro test then it may be substituted.
(Damage to the piping linings or internal insulation, or contamination,
corrosiveness or moisture present during hydro test may affect the system. Or
would present the danger of brittle fracture due to low metal temperature. During
the test. )

2 What is the limitation for pneumatic test?

It would present an undue hazard of possible release of energy stored in the
system.
It would present the danger of brittle fracture due to low metal temperature
during the test.

3 What should be done incase of hydro test & leak test cannot be carried out
condition. ?
The joints should be checked for its 100% NDT requirements (100% RT or
100% UT).

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4 What is the purpose of carrying out preliminary pneumatic test?
Normally pneumatic test is conducted not more then 25 psi gauge pressure prior
to hydro test to locate major leaks. (May be from blanks.)

5 Can heat treatment be conducted after hydro test?

No, heat treatment should be conducted before hydro test.

6 Why the visual examination is carried out at during 90% hydro test of test
instead of 100% in case of higher pressure?
Although job has been pressurized for 100%. Hydro test, any leakage developed
during 100 %, .the traces will be available even at 90%.
By doing examination at 90 %, the possible danger at 100% to human kind is
avoided.

7 How much should be the pressure for hydro –test? No.

Hydro test pressure should be calculated as follow except as provided against

point no-D
A. 1.5 Times of Design pressure.
B. For a design temperature above the test temperature, minimum test pressure
can be calculated as:
pt=(1.5 x p x St) / S
Where: -
Pt: Minimum Test pressure
P:Internal design pressure.
St: Allowable stress at test temperature
S: Allowable stress as design temperature

C If a test pressure as per above would produce a stress in excess of the yield
strength at test temperature. The test pressure may be reduced to maximum
pressure that will not exceed the yield strength at test temp.

D. If the test pressure of piping exceeds the vessel pressure and it is not
considered practicable to isolate piping from vessel, The piping and
vessel may be tested together at test pressure of the vessel when

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 approved by owner and provided the test pressure for vessel is not less
than 115% of piping design pressure adjusted for temperature as per
point no B.

Miscellaneous
1. What are Codes and standards?
A group of general rules or systematic procedures for design, fabrication,
installation & inspection prepared so that if can be adopted by legal jurisdiction
made in to law.

2.Standard
Recommended practices –without specific recommendation or requirements.
from the process licensor to be followed.

3.What are the common available software for piping?

C A E S A R –II For pipe stressing.
PIPENET For fluid flow analysis
S T A A D III For stress analysis
X steel, struCAD, steel CAD For steel detailing
4.What is piping class?
Document indicating the dimensional and material specification of pipe fittings
and valve types is called a piping class.

5.What are the allowable stress in various code?

Allowable stress in various codes?
31.1—Uts/4---2/3 Y S
31.3---Uts/3—2/3 Y S
31.4—0.72

6.What is fluid?
Fluid is a liquid but it can vapor also.

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7.What is the relation between Brinell hardness No and Rockwell hardness
No?
22 HRC (Rockwell Hardness)=238 BHN(Brinell 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?
19 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
replaced ) and cleaner fluid is used from shell side. Sometimes hot fluid is also
used from the shell side.

11.What is Reynold’s number and what is value of Reynold’s number unto

which the flow is laminar? (ANS FULLY NOT COMPLETED)
It’s a dimensionless number to classify the nature of flow.
Re= vd/
Where: Re: Raynold’s no.
ass Density of fluid.
d: diameter of pipe.
V: average velocity of fluid.
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 provided on the side from 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 exxhanger should grow with the piping.

13.What do you mean by Hoop stresses and how do you calculate it?

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Stresses which are generated circumferentially due to the action of internal
pressure of pipe are called as Hoop stress. It is calculated 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
is less than yield stress of Moc. The design is safe. Hoop 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/alloy and
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 solutions depending on pH,
• Oxidizing agents, reducing agents,
• Specific depolarizing ions like chloride, fluoride etc.

In acids the cathodic reaction controls and in neutral solutions and alkalies the
anodic reaction controls 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 types of corrosion a piping engineer should consider are:

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Uniform corrosion:
Localized corrosion, which may again be subdivided into
i) Galvanic or bi-metallic corrosion
ii) Crevice corrosion
iii) Pitting corrosion
iv) Intergranular attack
v) Stress corrosion cracking.

Uniform corrosion is the most 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 over the entire
exposed surface.

Galvanic corrosion: is enhanced corrosion of one material when the material is

joined to another nobler material (at a 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 material is low.
Remedies for this type of corrosion are avoiding contact of dissimilar 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 the material either due to mechanical factor or metallurgical factors
passivity is lost and it becomes anodic and severe corrosion takes place by auto-
catalytic action. It occurs in gravitational direction. It can be prevented by
impressed current or by sacrificial anodes or by adding pitting inhibitors like
molybdates.

Crevice corrosion: occurs in crevices or openings 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 aeration or differential

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concentration cells formed at crevices. Remedies for crevice corrosion are the
same as for pitting.

Intergranular attack: occurs in stainless steel 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 to reduce carbon content, or to add
small amounts of stabilizers like Ti, Nb, or to generate ferrite islands in austenite
by modifying Ni & Cr contents.

Stress corrosion: cracking occurs when the combination of three factors tensile
stress, corrosivity and susceptibility to crack occurs. It may be transgranular or
inter granular depending on type of corroding medium. The remedy to the
problem lies in modifying the nature of medium by addition of inhibitors pr
avoiding tensile stress or by cathodic protection.

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 coatings, cladding, lining plating and painting may be
adapted to internal and external protection of less expensive base materials.
Coatings include asphalt, tar and waxes. Lining with glass, cement, rubber,
porcelain, plastic, and synthetic elastomers or plating with corrosion resisting
metals offer many possible solutions to corrosion resistance. The corrosion
resistance of construction materials is given in table 4.1.2.

The rate of corrosion may be economically reduced by:

• Selection of costlier corrosion resistance material.

• Application of protective coatings.
• Deactivation of the corrosive medium by adding suitable inhibitors or by
removing aggressive component.
• Cathodic protection of base material.

Deactivation of corrosive fluid may be economically justified in many process

applications like deaerating of boiler feed water.

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Cathodic protection of piping has been successfully applied to underground
installation and in mildly corrosive systems.

WHAT IS DESIGN PRESSURE?

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 coincident pressure, the greatest thickness or
highest component rating is required.

WHAT IS MINIMUM TEMPERATURE?

The design minimum temperature is the lowest component temperature expected
in service.

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:

a) Design pressure as 10% higher than the anticipated maximum operating

pressure.
b) Design temperature 25 degree C above the anticipated operating
temperature
c) When operating temperature is 15 degree C and below, the design
temperature as the anticipated minimum operating temperature.

If ASTM materials are used ASME/ANSI should be preferred.

The selection of materials shall follow the norms below

a) Carbon steel shall be used up to 4250 C.
b) Low temperature steel shall be used below 200C

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 c) Alloy carbon steel shall be used above 4250 C.
d) For corrosive fluids recommendations from the process licensors to be
followed.

FEW TIPS FOR THE PREPERATION 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 temperature upto 4250 C
- Low temperature steel shall be used for temperature below –290 C
- Alloy steel shall be used for temperature above 4260 C.
- Stainless steel shall be used 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 as drinking water,
instrument air, nitrogen (LP) etc.
- Selection of Non-ferrous and Non-metallic piping shall be as per the
recommendation from the process licensor.

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’’ NB and 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 spool pieces are required to permit removal or
servicing of equipment and where pipes and fittings are with flanged
connections.

17. What is the difference between Brazing and soldering?

Ans.
BRAZING:
- A process where base metals do not melt.
- Filler material has a temperature above 4500 C.

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- Filler metal wets the base metal and drawn into joint by capillary action.
- Most often used for joining of coppers and combination of metals, which
cannot be welded.
- Brazing procedure and personnel 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.
- Organic 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?

Ans. - Pipe weld joints are identified as test positions. They are normally grove
welds and are indicated by the letter ‘G’
- Test position ‘1G’ is roll welding with 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 required?

Ans. 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 base metal of the welding prior to welding process can minimize
these.
- 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?

Ans. Oxy-fuel gas cutting is a process where severing of the metal is effected
by the chemical reaction of the base metal with oxygen at an elevated

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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 a 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 introduced 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 alignment

-Once this is done, anchors and fixtures are provided on both sides of the joint to
preserve the alignment 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.

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-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 theoretically

-Applied to high temperature systems such as steam lines and not reheat lines

-Care should be exercised when working with cold spring lines. If the line has to
be cut, it should be anchored on either side of the cut to prevent any possible
accident.

WHAT ARE PRESSURE PIPING CODES ?

B31.3 Power piping

B31.3 Process piping

B31.4 Pipeline transportation systems for liquid hydro carbons and

other liquids

B31.5 Refrigeration piping

B31.8 Gas transportation and distribution piping systems

B31.9 Building services piping

B31.11 Slurry transportation piping systems

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IN B 31.3 HOW FLUID CATEGORY IS FORMED?

CATEGORY D
a)The fluid handled is non flammable, non toxic, and not damaging to
human tissues
b)The design 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 a 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

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