SATORP INTERVIEW QUESTIONNARE (PIPING)

1) What are the JERES specs for hydro testing?

 JERES-A-004 – General Requirements of Pressure Testing
 JERES-A-007 - Hydrostatic testing fluids and Lay up procedure
 JERES-L-150 - Pressure testing of plant piping & pipelines.
2) What is a dead leg?
 Dead Legs: Piping sections that are potential for internal corrosion due to
flow stagnation (sthirta, na bahna).
 Dead legs are created mainly by flow stagnation enhanced with presence of
settled water and solid deposits.
 When the length of the section or branch , for 2 inch pipes and larger, is
longer than three times its pipe diameter, or 1.22 m (4 ft) in length, the
length of the dead leg is the distance measured from the outside diameter
of the header (or run) to the near end of the branch valve.
 For branch connections of 1-½ inch NPS and smaller, the length of the
dead leg is the distance measured from the end of the boss to the near
end of the valve.
 SATORP INTERVIEW QUESTIONNARE (PIPING)

3) What is the different ASME 31 code for pressure piping?

A. ASME B31.1 - Power piping.
B. ASME B31.2 - Fuel Gas Piping.
C. ASME B31.3 - Process piping.
. ASME B31.4 - Pipeline Transportation system for liquid
hydrocarbon & other liquid.
E. ASME B31.5 - Refrigeration Piping.
F. ASME B31.8 - Gas transmission & distribution piping system.
G. ASME B31.9 - Building services piping.
H. ASME B31.11 - Slurry transportation piping system.
4) What are the factors in a mill test certificate?
 Chemical composition
 Mechanical properties ( hardness, tensile strength, yield strength,
elongation, reduction of area)
 Heat number
5) Which is the rope used for lifting the external coated pipe?
 Nylon
6) What are the minimum clearance b/w a pipe and a structure?
 50mm
7) What is the hydro test holding time for A/G piping?
 30 min
8) What are the important activities to be checked during flange alignment fit
up?
 Misalignment
 Flange face
 Rotation of flanges (±2.4 mm)
 Tilt (dhalan, jhukao) of the flange ( shall not exceed 1.6 mm from the
square position)
 Flange face thickness, gasket thickness ± 1.6 mm
 Combination of vertical, horizontal and rotational offset ± 3.2 mm
9) What are the piping inspector responsibilities?
 Material receiving +inspection
 Ensure that approved procedure and ITP are used by construction.
 Pipe fit up activities
 SATORP INTERVIEW QUESTIONNARE (PIPING)

 Retention (maadahe hifz) of QC reports and records.

 Line checking
 Hydro test activities
 Reinstatement activities
10) How can you identify an ISO in a P&ID?
 Line number, service, instrument, equipment, and slope.
11) What is an insulation kit?
 To isolate between above ground and underground.
12) What is insulation gasket?
 Isolation of dissimilar metal flanged joints (electrical insulation)
 Insulating joints for cathodic protection.
 E.g. PIKOTEK GASKETS.
13) What are PIKOTEK Gaskets and what are their limitations?
 It is non metallic gaskets made of self energized Teflon seal supported by
glass reinforced epoxy laminated to 316 stainless steel core.
 The minimum required gap shall be 3.2 mm.
 It shall not be used services with temp. 154’C or higher
 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.
14) What are the general points to be checked prior to hydro test?( pre-
pressure checklist)
 Seal weld threaded nipples from headers to 1st block of valve
(hydrocarbon service) per JERES-L-110
 Guides are in direct contact with piping horizontal run at 3 locations
(6mm gap required). Relocate guides per drawing. These are welded to
the pressure boundary.

 Check valve is oriented in the wrong direction (flow arrow). Reverse

check valve to assure correct flow direction. Reposition valve & restore
internals immediately after test, COMPANY to witness.
 Piping clearance to structural bracing is (50 mm spacing required).
 Install permanent gaskets at flange sets 1, 4, 5, 6 on ISO dwgs. per
approved torque tables and install spectacle blinds oriented as per
approved P&ID.
 SATORP INTERVIEW QUESTIONNARE (PIPING)

 Completely remove all water and debris from low point/valve cavity for
the in-line Valves with SS 400 trim, do so immediately after test. Clean
with dry compressed air and re lubricate sealing surfaces with
approved lubricant in preparation for "ambient" lay-up specified in test
package.
 Indicate “No Punch items. “As applicable
QA is reviewed/initialed/dated prior to package certification to verify
completeness.
15) What are NCR, CAR, and DR?

 NCR: (Non Conformity report): A record reporting the variation from the
specified requirements.
 CAR: Corrective action report: A record reporting the action taken to
eliminate (door karma) the effect and causes of an existing non –conformity,
defect or other undesirable situation in order to prevent recurrence (taqleed).
 DR: Deviation report: A record of the concessions (reaayat) granted by client
or owner to certain deviation from project specification.
16) What are specifications?
 Specifications (Specs) are guideline details for construction requirements to
assure minimum quality standards are listed and met.
17) What is an SIS?
 Safety Instruction Sheet that gives full design details related to a piping
system or line.
18) What is Schedule ‘Q’?
 Schedule Q stands for Owner’s minimum quality requirements for
Contractor/Subcontractor quality system.
19) What are the points to be checked before pipe fit up?
 Oil, moisture, rust, scale, sand, paint, metallic coatings (e.g., zinc), or other
foreign matter shall be removed from the weld surface and at least 25 mm (1
in) of adjacent base metal prior to welding, including any such coatings on
temporary attachments or supports.
 Pipes and Fittings for fit-up will be placed on temporary pipe bed 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.
 SATORP INTERVIEW QUESTIONNARE (PIPING)

 Use markers with free lead, sulfur, and water soluble chloride not more than
50ppm for SS and other alloy materials.

20) There is damage in the received material, what will you do?

 All damage material shall be placed in quarantine (jabri herasat) area

with visible identification. Material Over, Short and Damage report
O.S&D shall be issued. A Non-Conformance Report shall be raised for
materials with severe damages.

 QC inspector shall monitor all the O.S & D and NCR issued and their
corrective and Preventive action taken.

 Non conforming materials shall be clearly marked, segregated and

controlled so that their unauthorized or inadvertent (beiradah) use is
prevented and their final disposition formally documented and recorded.
21) 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, and socket ends
shall be firmly (bah azm) attached.
 Pipe shall not be rolled or dropped off trucks.
 End bevel protectors shall remain on pipes and fittings while in storage,
protectors shall not damage internal or external 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
(banawat) 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
24) What are the ASME codes for Flanges?
 ASME B16.5 PIPE FLANGES AND FLANGED FITTINGS (UPTO 24”)
 SATORP INTERVIEW QUESTIONNARE (PIPING)

 ASME B16.47 LARGE DIAMETER FLANGES (ABOVE 24”)

25) What is the colour code for the material?( standard)
 PFI ES 22( PIPING FABRICATION INSTITUTE)
26) What is the code for PMI (JERES)?
 JERES-A-206- POSITIVE MATERIAL INSPECTION
27) How you inspect the flush grinding?
 Any distortion resulting from the butt weld shall be removed and ground
(pissahuaa) 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.
28) What things are found in a Piping Isometric drawing?
 Line conditions, references to drawings, materials of construction(Bill Of
Materials), continuations, orientation, piping and drawing details and
notes, revision control and approval status.
28) What kind of inspection required during gasket installation?

 QC Piping Inspector will ensure the cleanliness of the gasket surfaces of

the flanges and the condition of the gasket. Care shall be taken during this
operation to prevent entering of debris in the pipe or equipment.
 QC piping Inspector shall verify on site, prior to installation, each gasket
has the proper material size and rating according to drawings and line
class. Gaskets will have an individual painted mark, which will identify the
rating number.
 For gaskets 24” and less, colours code on the gaskets shall be applied on
the outside surface, Mark shall be an approximately 1 inch in length
circumferentially.
 For Gaskets 24” and above, will be market in two locations each.
 Spiral wound gaskets should have three colours, which identify the
particular material spec, rating and gasket with inner ring respectively.
 During reinstatement, QC Piping Inspector shall verify that bolting is
tightened according JERES-L-351.
 QC Inspectors shall inspect, before hydro test and during lines
reinstallation that all permanent gasket are installed accordingly.
29) What is the difference b/w torqueing of CS & SS bolting?
 Yield strength of CS is greater than SS.
30) Explain spectacle plate?
 SATORP INTERVIEW QUESTIONNARE (PIPING)

 Blind flange is used to isolate equipment or other piping during the leak
test, need not be leak tested.
31) How many threads can be visible after seal welding threaded joints?
 Zero
32) What is the basic difference between Pipe specification A106 Gr.A / Gr.B/ Gr.C.?
 Difference is due to the Carbon content.
% of carbon content in: -
I. ASTM A106 Gr. A – 0.25 %
II. ASTM A106 Gr. B – 0.30 %
III. ASTM A106 Gr. C – 0.35 %.
34) What is WPS (weld procedure, tariqa specification, tafseel)?
 A document providing the required welding variables atal for a specific
application to assure repeatability by properly trained welders and welding
operators.
35) What is PQR (procedure qualification record)?
 A record of welding variables (pather ki lakir) used to produce an
acceptable test weldment and the results of tests conducted on the
weldment to qualify a welding procedure specification.
36) What is PMI?
 Verification that the nominal chemical composition of an alloy material is
as specified and ordered.
37) What are the gauges used for fit up?
 Bridge cam, High Low gauge
38) What material used for drinking water service?
 SATORP INTERVIEW QUESTIONNARE (PIPING)

 Galvanized steel materials

39) What are the types of bolts and spec?
 A193 B7, A320 B8, JERES-L-109
40) What is colour coding?
 Marking of piping bulk materials to identify the Material.
41) What are the different types of JER documents?
 JEREP- Jubail Export Refinery Engineering Procedures
Uniform method of assembling directions to accomplish various engineering
activities.
 JERES-Jubail Export Refinery Engineering Standard
Minimum requirements for the selection, design, construction, test,
maintenance and repair of equipment & related facilities.
 JERMS-Jubail Export Refinery Material Specifications
To establish minimum engineering, design, fabrication and testing
requirements for the procurement of material and equipment.
 JERSD- Jubail Engineering Refinery Standard Drawing
Engineering drawing that is pre approved by JER Management for through out
the company.
 JERITP-Jubail Export Refinery Inspection And Test Plan
Minimum requirements set by the company to conduct inspection
 JEREF- Jubail Export Refinery Engineering Forms
JER developed forms that shall be used as a tool for Design, Construction and
Pre-commissioning.
42) What are the different sections of ASME code? Where these sections are
referred?
A. ASME section I : - Rules for construction of power boiler.
B. ASME Section II : - Materials.
Part A – Ferrous materials.
Part B – Non-Ferrous materials.
Part C – Specification for electrodes & filler wire.
Part D – Properties.
C. ASME Section IV : - Rules for construction of Heating Boiler.
D. ASME Section V : - Non- destructive Examination.
E. ASME Section VI : - Recommended rules for care & operation of
heating boiler.
 SATORP INTERVIEW QUESTIONNARE (PIPING)

F. ASME Section VII : - Recommended guidelines for care of power

boiler.
H. ASME Section VIII : - Rules for construction of pressure vessels.
(Division I & II)
I. ASME Section IX : - Welding & Brazing qualification.
43) What types of PMI machines are available?
 X-Ray Fluorescence
 Optical Emission Spectrography
44) For sour service and NACE which material is used?
 HIC Carbon Resistant Material
45) Color coding for CS, LTCS, and Alloy?
 As per PFI ES-22.
46) What type of cutting used is SS? Types of Grinding wheel and how to identify
them?
 Plasma arc cutting and grinding wheel
 Types for grinding wheel are: Iron oxide, zirconium, Aluminum oxide.
 Identification by color coding.( blue)
47) Name the different types of Service Conditions?
 Temperature, pressure and fluid type
 SATORP INTERVIEW QUESTIONNARE (PIPING)

48) What are the acceptable branch connections and fittings? Also mention the limitations?

 Branch connections on any fittings are not allowed

 Branch connection is not a dead leg with any internal corrosion
concerns.
 Branch connections 4 inch and smaller (drain and vent valves and drip
legs of all sizes excluding dummy legs) are spaced a minimum
horizontal distance of 24 inches from fixed supports/obstructions.