Piping QC Questions CBT Related & General Information

This article is about Piping QC Questions Cbt related to topic of Mechanical Inspection as per Saudi Aramco or International Standards. This questions can be useful for who are attending CBT Aramco Test or other international test for Mechanical QC Inspector or Engineer.

Piping QC Questions CBT Related & General Information

1. What is an Inspection & Test Plan (SATIP)?

Answer: It is a mandatory item in the Quality Plan to guide and assure quality in a specific type of work in and a sequence of QC activity. A SATIP is a Saudi Aramco Test & Inspection Plan
indexed of inspection activity using SAIC.

2. What is meant by QA/QC?

QA – system of action and planning needed to provide confidence that a product or services will satisfy quality requirements.
QC – is the operational techniques (Inspection, Examination & Testing) that are used to fulfill quality requirements.

3. What are the three types of Bolt Joints?

Answer: 1. Snug Tight 2. Pre-Tensioned 3. Slip Critical

4. State the procedure in bolt pre-tensioning?

1. In erection of steel structure, fastening materials such as bolts, nuts and washers shall be in accordance with ASTM A325, ASTM F436 and other applicable Code and Standard for primary connections.

2. Fastening materials for secondary connections shall be ASTM A307.
3. Fastening materials shall not be reused without prior approval.
4. Mill Certificates shall be verified as per ASTM Specifications.
5. Identify the conditions of connected plies, faying surfaces, bolt holes, burrs, and washer as per 12-SAMSS-008.
6. Check the fastening materials as per approved contract drawings and specifications.
7. All joint surfaces, including those adjacent to the bolt heads, nuts and washers shall be free of burrs, dirt and other foreign materials that would prevent solid seating of parts. (PIPSTS05130 & 12-SAMSS-008).
8. Fasteners shall be inserted and aligned in the bolt hole and care to prevent undue damage of the thread joints.
9. Bolt assembly shall be brought to snug tight condition to ensure that it has a firm contact with the faying surfaces.
10. Bolt shall be tightened in sequence and systematic starting from the most rigid part of the joint to the free edges to minimized relaxation of the previously pre-tensioned bolts.
11. If impact wrenches to be used, it shall be of adequate capacity, sufficient supply of air to perform the required tightening.
12. All nuts shall be wax-dipped so as to reduce the friction during the installations and torquing.
13. Fasteners that are pre-tensioned and ready for inspection shall be color coded.
14. Bolts shall have full thread engagement or penetration with the nut. The bolt length used shall be such that the end of the bolt extends beyond or at least flush with outer face of the
nut.
15. If Calibrated wrench to be used, it shall be calibrated in a daily basis.

5. What is PIP?

Answer: PIP means Process Industry Practice that deals with a common Industry Practices regarding manufacturing, installations, constructions, erections, and etc.

6. What is the maximum segment of the piperack to allow for structural steel thermal expansion?

Answer: 42.5 meters (140 ft.)

7. What is the Saudi Aramco Engineering Standard used in grouting of Steel Structure and Equipment?

Answer: SAES-Q-010

8. What is the Saudi Aramco Engineering Standard used in the Structural Design Criteria for Non Building Structures?

Answer: SAES-M-001

9. Discuss how Tension Calibrator Works?

Answer: Is a hydraulic device that indicates the pretension that is develop in a bolt that is installed in it. By tightening the fastener, the calibrator induces a pressure that is transmitted to
the hydraulic fluid which is also connected to the pressure gauge. The gauge gives a reading equivalent to the fastener tension in kilograms or in pounds. Also it will check if your torque
wrench has been calibrated properly.

10. What is Snug Tight?

Answer: Is a condition where a faying surface has a firm contact with the application of few impacts of the impact wrench or with the full effort of an iron worker using an ordinary spud
wrench.

What Saudi Aramco “Letter codes” are applicable for different types of equipment installations & where are the code references found?

1. Vessels (C&D) ASME VIII.
2. Exchangers (E-004) API 660.
3. Air Coolers (E-007) API 661 (Coolers).
4. Pumps (Centrifugal-G-005) API (610, 682).
5. Pumps (Positive Displacement-Injection-G-006) (Antifoam Injection Pump).
6. Compressors (Centrifugal-K-402) API (617).
7. Compressors (Reciprocating-K-403) API (618, 680).
8. Boilers – ASME I & ASME B31.1 for piping portions.
9. Turbines (K501, 502) – None on our project.
10. Mixers (G-005, K503) Antifoam Tank Mixer.
11. Fired Heaters (F-001) Furnaces and Burners, Comb Chambers, Thermal Oxidizer API 560.
12. Air Blowers-Procedures needed for installation.
13. Flares & Stacks (F-007) Procedures needed from vendor for installation – API 521, API 526, AWS D1.1, ASME IX.
14. Cooling Towers.

ITPQCP/FIPReferenced Std/Specs Code references, Candidate must know how to follow the path to the correct code for each item.

What documents will control the erection sequence and control work activities in accordance with Schedule Q and the approved Quality Procedure?

PIPING MATERIAL INSPECTION

Internals and Hardware

Match physical condition in field to service condition shown on Drawings/Hardware lists

 How do you verify (name several items to check) that correct material is used? Specification and marking/color-coding and Positive Material Identification.
 How do you identify grade of material and hardware by markings? ASTM spec listed on dwg/bolting list will give clear requirements.
 How do you identify fittings and flanges? Correct ratings, sizes, class, schedules as marked on fittings & mill certs
 How do you check piping for the correct schedule? Use a Vernier Caliper and ensure piping is within tolerances.
 What are the tolerances for physical straightness and defects?
 What is the standard mill tolerance for piping? 87-1/2% (all) to 115% (greater than 2”), 120% (2’’ & less) of nominal pipe thickness.

OVALITY OF SECTIONS CONSTRUCTED

1. What is the tolerance for ovality of piping?

1%.

Example: 24” piping is 610mm. One joint can be 610 x 610 (oval), another can be 604 x 616 (1% out & within tolerance).

When matched for fitting, how will internal alignment of piping meet 1.5 mm tolerance in SAES-W-011?

Crescent technique for repairing ovality is required (method statement). Crescent is (2) 12 mm crescent shaped plates separated by steel bar center that distributes load and bearing force and increases efficiency, doubles production by and reduces potential damage to piping. Jacking limits (30 ton maximum for CS, 20 ton for SS) to 25 mm max. Cold bending and forming repairs including rolling thick repads require a method statement and must conform to ASME B31.3. Hammering on steel is not allowed and evidence of hammer marks is cause for rejection and removal of affected item.

Flanged Joints (SAES-L-050, PIPs PNSC series, Checklists, PFI-ES-3)

1. What are the different types of mating flanges? There are 4 most common RF, RFSO, RTJ, and FF.
2. Describe good inspection practice during gasket installation? List common problems associated with poor practice.

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