Satorp Interview Questionnare1

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 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.

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?

 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 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.



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.

 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 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 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.

 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.

 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 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 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 % II ASTM A106 Gr. C – 0.35 %. 34) What is WPS?

 A document providing the required welding variables for a specific

application 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 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?

 Galvanized steel materials 39) What are the types of bolts and spec?

 A193 B7, A320 B8, JERES-L-109 40) What is color coding?

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.

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?

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