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 1, 2, 3 & 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 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 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
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, 12sch 40/40s, 12sch 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 80NB 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?
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/ mm
48,000 Psi min.
Grade B-416 N/mm
60,000 Psi min
Grade C-485 N/mm
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
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.)
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.
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.
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 nonferrous 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 800f (425* c)
-How temperature steel shall be used below 20f (-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-. This is supposedly to prevent the overlap
of HAZ s.
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/cm
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 through 24. Sizes NPS 26 to 60 refer
BS 1560
for fabricated flanges.
ANSI B 16.9
Steel butt weld fittings.
Size NPS 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
ANSI B 16.21
Non metallic gaskets

B 16.47.

2.Why screwed and socket welded fittings are expensive?

These fittings are manufactured from solid forging. Hence its expensive. These fittings are bulky in nature. Hence it is used up to 1 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. Olets 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 lowpressure 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.
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 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 1 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
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 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)
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 liquids 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 thei
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 200 0 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.
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 coldwater 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?
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
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
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?
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).
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 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?
31.1Uts/4---2/3 Y S
31.3---Uts/32/3 Y S
31.40.72
6.What is fluid?
Fluid is a liquid but it can vapor also.
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 Reynolds number and what is value of Reynolds number unto which the flow is laminar? (ANS FULLY NOT COMPLETED)
Its a dimensionless number to classify the nature of flow.
Re= vd/
Where: Re: Raynolds 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 exchanger should grow 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 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:
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 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.
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
c) Alloy carbon steel shall be used above 4250 C.
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.
- 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 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 jet like action of the gas stream removes the melted
metal. 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.
-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

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