satorp interview questionnare1

8/13/2019 Satorp Interview Questionnare1

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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.

Dead legs are created mainly by flow stagnation enhanced with presence ofsettled 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, thelength 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.




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.

D. 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 is the minimum clearance b/w a pipe and a structure?

50mm

7) What is the hydrotest 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 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

Retention 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 under ground. 12) What is insulation gasket?

Isolation of dissimilar metal flanged joints ( electrical insulation)

Insulating joints for cathodic protection.

Eg. 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.

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 relubricate 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 is NCR, CAR, 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 the effect and causes of an existing non –conformity, defect or other

undesirable situation in order to prevent recurrence.

DR: Deviation report: A record of the concessions granted by client or ownerto 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 forContractor/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.

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 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 withsevere 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 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 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 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”)

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

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 gaskethas 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 locat ions 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 toquing of CS & SS bolting?

Yield strength of CS is greater than SS.

30) Explain spectacle plate?

Blind flange is used to isolate equipment or other piping during the leaktest, 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 %

II ASTM A106 Gr. C – 0.35 %.

34) What is WPS?

A document providing the required welding variables for a specificapplication to assure repeatability by properly trained welders and welding

operators.

35) What is PQR?

A record of welding variables 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 isas 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?

Galvanized steel materials

39) What are the types of bolts and spec? A193 B7, A320 B8, JERES-L-109

40) What is color 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

activites.

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.

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

boiler.




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.

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