1. What is dead leg ?

 Piping sections that are potential for internal corrosion due to flow stagnation
 Dead legs are created mainly by flow stagnation enhanced with presence of settled
water and solid deposits.
2. What is the different ASME 31 code for pressure piping
 ASME B31. 1 – Power Piping
 ASME B31.2 – Fuel Gas Piping
 ASME B31.3 – Process Piping
 ASME B31.4 – Pipeline Transportation system for fluid hydrocarbon & other liquid
 ASME B31.5 – Refrigeration Piping
 ASME B31.8- Gas transmission & Distribution piping system
 ASME B31.9- Building Services Piping
 ASME B31.11- Slurry Transportation Piping System
3. What is the factors in a mill certificate
 Heat numbers
 Chemical composition
 Mechanical properties ( tensile strength, hardness, elongation, reduction area,yield
strength.
4. Which rope using for lifting of coated pipe.
 Nylon
5. What is the minimum clearance between pipe and structure
 2 inches
6. What is the hydrotest holding time for A/G piping
 30 minutes minimum
7. What is the importance activities to be checked during flange alignment fit up.
 Misalignment
 Rotation of flanges ( ± 2.4mm )
 Tilt of the flange ( shall not exceed to ±1.6mm from the square position )
 Flange face thickness, gasket thickness is ±1.6mm
 Combination of vertical and horizontal rotational offset ±3.2mm
8. What are the piping inspector responsibilities.
 Material receiving inspection
 Ensure that approved procedure and ITP are used by construction
 Pipe fit up activities
 Retention of QC reports and records
 Line checking
 Hydrotest activities
 Reinstatement activities
9. How can identify an ISO in a P&ID.
 Line number,service fluid,instrument, equipment, and slope.
10. What is the isolation kit.
 To isolate between aboveground and underground piping.
11. What is insulation kit.
 Isolation of dissimilar metal flanged joints ( electrical insulation )
 Insulating joints for cathodic protection
 EG. Pikotek gaskets
12. What are the pikotek gasket and what are their limitation.
 It is non metallic gasket made of self energized Teflon seal supported by glass reinforced
epoxy laminated to 316 stainless steel core
 The minimum required gap shall be 3.2mm
 It is shall not be used in service temp. more than 154°C
 It shall not be used in hydrocarbon gas service in which flange rating is 300 or higher
 It shall not be used in chemical incompatibility of non metallic component with the
service media.
13. What are the general points to be checked prior to hydro test ( pre pressure checklist )
 Seal weld threaded nipples from headers to 1st block valve ( hydrocarbon service )
 Guides are in direct contact with piping horizontal run at 3 locations ( 6mm gap require )
 Check valve is oriented in the wrong direction
 Piping clearance to structural bracing is 2 inches spacing required.
 Install permanent gasket at flange sets 1,4,5,6 on iso drawings per approved torque
table and install spectacle blind as per drawing.
 Completely remove all water and debris from low point/valve cavity for the in line
valves, do immediately after test. Clean with dry compressed air and relubricate sealing
surfaces.
 Indicate NO punch items, reviewed/initialed/date.
14. What is NCR,CAR and DR.
 Non conformity report: a record reporting the variation from the specified req’t.
 Corrective action report: a record reporting the action taken to eliminate the effect and
causes of an existing NCR.
 Deviation report: a record of the concessions granted by the client or owner to certain
deviation from project specification.
15. What are the specification.
 Specification are guideline details for construction requirement to assure minimum
quality standards are listed and met.
16. What is schedule Q.
 Schedule Q stands for owner minimum quality requirement for contractor and
subcontractor quality system.
17. What is SIS
 Safety instruction sheet
18. What are the points to be checked before pipe fit up.
  Oil, moisture, sand, scale, paint, metallic coating, or other foreign matter shall be
removed from the weld surface and at least 25mm of adjacent base metal prior to
welding, including any such coating on temporary attachments and supports.
 Pipes and fittings for fit up will be placed on temporary pipe bedding and will make sure
that supports are secured properly.
 After end preparation, the alignment, fit up and tack weld activities shall be carried out
for the purpose of exact pipe spool fabrication.
 Line no., component heat no., joint no. fit up inspection signature, welder no, visual
inspection signature and date of welding will be marked near to the joint with metal
paint marker.
 Use markers with free lead , sulfur, and water soluble chloride not more than 50ppm for
SS and alloy materials.
19. There is damage in the received material, what will you do.
 All damage material shall be placed in quarantine area with visible identification,
material (OSD) over, short and damaged report shall be issued. A non conformance
report shall be raised for material with severe damages.
 QC inspector shall monitor all OSD and NCR issued and their corrective action and
preventive action taken.
 Non conforming materials shall be clearly marked, segregated and controlled so that
their unauthorized use is prevented and their final disposition formally documented and
recorded.
20. How will you store the material In the storage area?
 All materials shall be handled with care during fabrication and installation to prevent
damage.
 End protectors on pipes, flanges, weld bevels, threads, socket ends shall be firmly
attached.
 Pipe shall not be rolled or dropped off trucks
 End bevels protectors shall be remain on pipes and fittings while in storage, protectors
shall not damage internal coating.
 Flange face and threads shall be protected from rust by applying suitable rust
preventives.
 After completion of pre fabrication, the spool shall be cleaned and free from weld
spatters, arc strikes and foreign materials on outside and inside of pipes.
 Lined and coated pipes and fittings shall be lifted with wide fabric or rubber covered
slings and padding shall be used to prevent damage to lining or coating. Wire rope slings
shall not be used.
 SS materials shall be covered and protected from water splash and other contamination
during storage.
21. What are the ASME code for flanges?
 ASME B16.5 pipe flanges and flange fitting ( up to 23” )
 ASME B16.47 large diameter flange 24” above
22. What standard for color code for piping materials?

 PFI ES 22 ( piping fabrication institute )

23. How to inspect the flush grinding?
 Any distortion resulting from the butt weld shall be removed and ground flush with
the inside diameter of the pipe, PT shall be done.
 The inside surface of welded joints at orifice flanges shall be ground or machined
smooth.
24. What things are found in a piping isometric?
 Line condition, reference to drawing, continuation, BOM, orientation, approval, revision
control, piping and drawing details.

25. What kind of inspection required during gasket installation?

 Ensure the cleanliness of gasket surfaces and the flanges condition, care shall be taken
during this operation to prevent entering debris in the pipe or equipment.
 Qc inspector shall verify at site during installation, each gasket has the proper material
size and rating according to drawings and line class. Gasket will have individual painted
color mark, which will identify the rating number.
 For gasket 24” and above, will be mark in two locations each.
 Spiral wound gasket should have three colors, which identify the particular material
spec, rating and gasket with inner ring respectively.
26. What is difference between bolt torquing of CS and SS?
 Yield strength of CS is greater than SS
27. Explain spectacle plate?
 Blind flange is used to isolate equipment or other piping during the leak test.
28. How many threads can be visible after seal welding of threaded joints?
 Zero
29. What is the basic difference between pipe specification of A106 Gr.A,B,C?
 Difference is carbon content
 Gr. A = 0.25 %
 Gr.B = 0.30 %
 Gr.C = 0.35 %
30. What is WPS?
 WPS is a written document that provides direction to the welder or welding operator for
making production welds in accordance with code requirement.
31. What is PQR?

 PQR is documents what occurred during welding the test coupon and the result of
testing of the test coupon.
32. What is PMI?
  Verification of the chemical composition of alloy material.
33. What are the gauges used for fit up inspection?
 Bridge cam, high -lo gauge
34. What material used for drinking water?
 Galvanized steel material
35. What the types of bolts and specs?

 A193 B7, A320 B8

36. What is color coding?
 Marking of piping materials to identify each.
37. What are different sections of ASME code?
 ASME section I : Rules of construction of power boiler
 ASME section II : Materials
Part A- Ferrous materials
Part B- Non Ferrous materials
Part C- specification for electrode & filler wire
Part D- properties.
 ASME section IV : Rules of construction of heating boiler
 ASME section v : non destructive examination
 ASME section VI : recommended rules for care & operation of heating boiler
 ASME section VII : recommended guidelines for care of power boiler
 ASME section VIII : rules of construction of pressure vessels.
 ASME section IX : Welding and brazing qualification
38. What types of PMI machine are available
 X-ray Flourescence
 Optical emission spectrography
39. For sour service and NACE which material is used
 HIC carbon resistant material
40. What type of cutting used for SS?
 Plasma arc cutting and grinding wheel
 SS grinding wheel
 Identification by color coding
41. Name the different types of service condition?
 Temperature, pressure and fluid type.
42. What are the branch connection and fittings?
 Branch connections on any fittings are not allowed
 Branch connection is not dead leg with any internal corrosion concerns.
 Branch connection 4 inch and smaller ( drain and vent valves and drip legs of all sizes
excluding dummy legs ) are space a minimum horizontal distance of 24” from fixed
supports/obstruction.
43. Which American standard is reffered for selection of following piping element?
  Flanges:
Asme B16.1 : cast iron pipes flange & flange fittings
Asme B16.5 : carbon steel pipes & flanged fittings ( up to 24” )
Asme B16.47 : large diameter steel flange ( above 24” )
 Butt welded fittings :
Asme B16.9 : Steel butt welding fittings
Asme B16.28 : Butt welded short radius elbows & return bends
 Gasket :
Asme B16.20/API-601 : Metallic gasket for pipe flanges –spiral wound,octagonal ring
joint,jacketed flanges.
Asme B16.21 : Non metallic gasket

 Socket and threaded fittings:

Asme B16.11 : Forged steel socket welding & threaded fittings.
 Valves :
Asme B16.10 : face to face & end to end dimension of valves.
Asme B16.34 : falnged and butt welded ends steel valves ( pressure temp. rating )
except ball, plug & butterfly valves.
 Pipes :
Asme B36.10 : welded and seamless wrought iron pipes.
Asme B36.19 : stainless steel pipes.
44. What is the ASTM code for the following materials?
 Pipes :
A. carbon steel ASTM ( A53 Gr.A/B, A106 Gr.A,B,C, A333 Gr.1/6 )
B. alloy steel ASTM ( A335 Gr.P1, A335 Gr.P2, A335 Gr.P5, A335 Gr.P7, A335 Gr.P9,
A335 Gr.P11, A335 Gr.P12, A335 Gr.P22 )
C. stainless steel ASTM ( A312
TP304/304L/304H/308/308L/310/316/316L/316H/317/321/321H/347/
347H/348/348H )
D. nickel steel ASTM ( A333 Gr.3/8 )
 Tubes :
A. carbon steel ASTM ( A178/179/192/A334 Gr.1/6 )
B. alloy steel ASTM ( A161T1/A213T1/T2/T5/T7/T9/T11/T12/T22 )
C. stainless steel ASTM ( A213
TP304/304L/304H/308/308L/310/316/316L/316H/317/321/321H/347/347H/348/3
48H )
D. nickel steel ASTM ( A334 Gr. 3/8 )

 Wrought Iron fittings:

A. Carbon steel ASTM ( A234 Gr. WPA/B, A420 Gr.WPL6
B. Alloy steel ASTM ( A234 WP1/WP5/WP7/WP9/Wp11/WP12/WP22.
 C. Stainless Steel ASTM ( A403
WP304/304L/304H/309/310/316/316L/316H/317/321/321H/347/347H/348)
D. Nickel Steel ASTM (A420 WPL6/8
 Forged Fittings :
A. Carbon steel ASTM ( A181/A105/A350 LF1/2)
B. Alloy Steel ASTM ( A182F1/F2/F5/F7/F9/F11/F12/F22)
C. Stainless Steel ASTM (
A182F6/F304/F304L/F304H/F310/F316/F316L/F316H/F321/F321H/F347/F347H/34
8)
D. Nickel Steel ASTM ( A350 LF3/A522 )
 Cast fittings :
A. Carbon Steel ASTM ( A216/A352 LCB/C )
B. Alloy Steel ASTM ( A217 WC1/WC6/WC9/WC5/WC11/WC12/WC22 ).
C. Stainless steel ASTM ( A217 CA15/A296 CA15/A351
CF8/CF3/CH20/CK20/CF8M/CF3M/CF8C/HK40.)
D. Nickel Steel ASTM ( A352 LC3)
 Plates :
A. Carbon steel ASTM ( A285/A515/A516
B. Alloy steel ASTM ( A387 Gr.2/5/7/9/11/12/22 )
C. Stainless Steel ASTM ( A240
TP410/405/430/304/304L/309/310S/316/316L/317/321/347/348 ).
D. Nickel Steel ASTM ( A203 Gr.D/E,A353).
45. What is the basic difference between pipe specification A106 Gr. A/B/C?
 A106 Gr.A – 0.25% carbon content
 A106 Gr. B- 0.30 % carbon content
 A106 Gr. C- 0.35 % carbon content
46. What is the difference between pipe specification ASTM A312 TP 304/304L/316/316L?
( letter “L” denotes the lower percentage of carbon content )
 ASTM A312 TP304 – 0.08%
 ASTM A312 TP 304L – 0.035%
 ASTM A312 TP 316 – 0.08%
 ASTM A312 TP 316L – 0.035%
47. How can classified flanges based on pipe attachment?
 Slip on flanges
 Socket weld flange
 Screwed flange
 Lap joint flange
 Welding neck flange
 Blind reducing flange
 Integral flange
48. How can classified flanges based on pressure temperature ratings?
  150#
 300#
 400#
 600#
 900#
 1500#
 2500#
 Pressure temperature ratings charts in the standard ASME B16.5. specify the non shock
working gauge pressure to which the flange can be subjected to particular temperature.
49. How can classified flanges based on facing?
 Raise face ( RF )
 Flat face ( FF )
 Tongue and groove ( T/G )
 Male female ( M/F )
 Ring type joint ( RTJ )
50. How can be classified flanges based on facing?
 Smooth finish ( for metallic gasket )
 Serrated finish ( for non-metallic gasket )
51. What are the types of serrated finish provided on the flange face?
 Concentric
 Spiral ( phonographic )
52. How the serration on flanges specified?
 The serration on flanges specified by the number, which is AARH arithmetic average
rough height )
53. How the gasket are classified based on the type of construction?
 Full face
 Spiral wound gasket
 Ring type gasket
 Metal jacketed gasket
 Inside bolt circle gasket
54. What is commonly used material for gasket?
 Compressed asbestos fibre
55. Which type of gasket recommended for high tempereature & high pressure piping?
 Spiral wound metallic gasket
56. What are the criteria for selection of material of construction for gasket winding?
 the operating temperature of the fluid
 the relative cost of alternate winding material
 the corrosive nature and concentration of fluid being carried
57. what are the common material used for spiral wound metallic gasket
 austenitic stainless steel 304 with asbestos filler
  austenitic stainless steel 316 with asbestos filler
 austenitic stainless steel 321 with asbestos filler
58. what temperature limits for low strength carbon steel bolts?
 Above 200°C or below -28°C
59. How to classified pipe fittings based on end connection?
 Socket weld fittings
 Screwed end fittings
 Buttress end fittings
 Bevel end or butt weld fittings
 Spigot socket fittings
60. Up to what temperature the carbon steel materials can be used?
 Carbon steel materials can be used up to 425°C
61. Which material used for temperature above 426°C?
 Alloy steel material shall be used for temperature above 426°C
62. Which type of material is used for corrosive fluid?
 Stainless steel material shall be used for corrosive fluid
63. Which type of piping materials are used for drinking water, instrument air and Nitrogen lines?
 Galvanized steel materials
64. What is the difference between pipe and tube?
 Pipe is identified by NB and schedule
 Tube is identified by OD and thickness is BWG ( brimingham wire gauge or 1/100 inch )
65. From which size NB of pipe is equal to OD of pipe
 14” OD and above
66. What is the basis of using short radius and long radius elbow?
 Long radius elbow used for small pressure drop.
 Short radius elbow used for high pressure drops.
67. Where do we use the eccentric and concentric reducer?
 Eccentric reducers- pump suction to reduce cavitation, to maintain elevation ( BOP )
 Concentric reducers- pump discharge, vertical pipeline
68. Where ERW & seamless pipes are used?
 Above 18” ERW pipes are used, below 18” seamless pipes. Seamless pipe can sustain
higher temperature & pressure.
69. What is the main used of ASTM A53 & A106 Gr.B pipes?
 A53 pipes mainly used for utility services
 A106 pipes mainly used for high temperature & high pressure services.
70. From which side of pipe will you take a branch connection?
 When service fluid is gas,air,steam,and cryogenic services- topside
 When service fluid is liquid- bottom side
71. Why don’t we take a branch for cryogenic service from bottom side?
 There is chance of ice formation during normal operation and since ice flow from the
bottom of pipe it will block the branch connection.
72. Why do we provide high point vent and low point drain?
 To remove air during hydro test
 For draining water after hydro test
73. What do you mean by jacketed piping?
 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.
74. What are weldolet and sockolet? Where they are used?
 Weldolet and sockolet are basically self reinforced fittings.
 Weldolet is used for buttweld branch connection where standard tee is not available
due to size restriction and the piping is of critical / high pressure service.
 Sockolet is used for socket welding branch connection, which require reinforcing pad.
75. What is the upstream and downstream straight length of orifice flow meter?
 Upstream is 15D
 Downstream is 5D
76. What material for superheated high pressure steam lines?
 A335 Gr.P1/P11
77. What is the function of valve?
 Isolation
 Regulation
 Non return
 Special process
78. How the valve classified based on their function?
ISOLATION.
 Gate valve
 Ball valve
 Plug valve
 Piston valve
 Diaphragm valve
 Butterfly valve
 Pinch valve
REGULATION
 Globe valve
 Needle valve
 Butterfly valve
 Diaphragm valve
 Piston valve
 Pinch valve
NO RETURN
 Check valve
 SPECIAL PURPOSE
 Multi port valve
 Flush bottom valve
 Float valve
 Foot valve
 Line blind valve
 Knife gate valve
79. How the valve classified based on its method of operation
 Self operated valves ( check valve )
 Manual operated valves
80. How the valves classified based on end connection
 Screwed ends
 Socket ends
 Buttress ends
 Wafer type ends
 Flanged ends
81. What are the types of check valves?
 Swing check valves
 Lift check valves
82. What do you mean by special purpose valves?
 Valves can perform two duties isolation, control and check is called special purpose.
83. What is the content of tig welding set?
 Rectifier
 Gas cylinder, pressure gauge, regulator
 Filler wire
 Collet, ceramic nozzle, tungsten,argon hose
84. Why vent hole req’d. for reinforcing pad and trunnion?
 Venti ng of gas generated during welding
85. What us thumb rule to calculate current required for welding?
 Current (amp)= ( diameter of electrodex40)±20
86. Which electrode or filler wire used for welding of following materials?
 A335 P1 E7018 ER70S-1B
 A335P2 E8018-B1 ER80S-B2
 A335P11 E8018-B2 ER515
 A335P5 E502 ER502
 A335P9 E505 ER505
 A312TP304 E308 ER308
 A312TP304L E308L ER308L
 A312TP304H E16-6-2 ER16-8-2
 A312TP308 E309 ER309
  A312TP310 E310 ER310
 A312TP316 E316 ER316
 A312TP316L E316L ER316L
 A312TP316H E16-8-2 ER16-18-2
 A312TP321 E347 ER347
 A312TP321H E16-6-2 E16-8-2
87. What are the common types of defects?
 Lack of fusion
 Lack of penetration
 Porosity
 Undercut
 Slag inclusion
 Crack
 Distortion
 Faulty weld size and poor profile
 Concavity
 Underfill
 Excess penetration
 Blowhole
 Burnthrough
 Overlap
88. What is meaning of PWHT, why it Is required?
 Post weld heat treatment, this is required to remove residual stress left in the joint
which may cause of brittle fracture.
89. Why pre heating is required on some pipe before start welding?
 To slow down the cooling rate
 To remove moisture
90. Why post heating is done on some pipe after the welding?
 To maintain the homogeneous structure( Having uniform composition of structure )
91. What is the pre heat temperature for carbon steel above 25mm thk.
 79°C
92. What is the soaking temperature for CS during PWHT?
 593°C to 649°C
93. what is the soaking time for Alloy and CS during PWHT?
 Alloy minimum 2 hr/inch
 CS min. 1 hr/inch
94. What is the heating and cooling rate during PWHT?
 The PWHT heat and cooling rate above 316°C shall not exceed to 222°C/hr divided by
the wall thickness in inches, but in no case shall be more than 222°C/hr.
95. What is the pre heat temperature for alloy steel?
  P4 is 149°C
 P5A,B and C, is 177°C
96. What is the soaking temperature for Alloy steel during PWHT?
 P3 is 593°C- 718°C
 P4 is 704°C - 746°C
 P5 is 704°C - 760°C
97. What is the Post heat temperature for Alloy steel ?
 300°C
98. What is 4 or 5 digit coding for electrode as per AWS classification SFA 5.1?
 E – designates an Electrode
 70 –designates tensile strength min. in ksi or mpa.
 18– designates welding position and type of covering
 1 – designates electrode intended military req’t.( greater toughness and lower moisture
content )
99. Where the use of electrode E7018 is recommended?
 For strength steel
 For high thickness carbon steel
 Higher carbon equivalent material
100. Why the electrode E7018 is called low hydrogen electrode
 The low hydrogen electrodes have in their coating ingredient, which produces carbon
dioxide during melting. The Co2 gives gaseous shielding for the metal and prevents
atmospheric hydrogen from entering in arc atmosphere. By this way the weld metal has
low level of hydrogen.
101. What chlorine content in water while conducting hydrotest?
 For SS 30ppm
 For CS 250ppm