1. Differences between code ANSI B31.1 and code ANSI B31.3?

Answer: There is only one major difference between the two, B31.1 is for Power Piping and B31.3 is for
Refinery/Chemical Plant Piping.
2. There is a power plant inside a Process refinery. Where exactly the ANSI B31.1 & ANSI B31.3 scope
break occurs? +++\\

Answer: Based on my experience there were two cases. Case #1, B31.1 stopped at the Power Plant Unit
block valves. Thus all piping inside the Power Plant was B31.1. Case #2, B31.1 stopped at the equipment
(Boiler) isolation block valves and then all other piping was B31.3. This is normally the choice of the
owner/operator/client.
3. Which of the following piping system is more health hazardous. A) Fuel oil piping b) Process piping with
Caustic c) process piping with HF acid d) Sulphuric acid piping.
Answer: c) process piping with HF acid
4. There is a steam piping with low pocket but without steam trap. What will be worst consequence of this
layout?
Answer: There will be a build up of condensate to the point that a slug will be pushed by the steam flow.
This slug of condensate will cause “water hammer” and could rip the piping apart.
5. In what circumstance, the reducer of a pump suction piping will be in bottom flat position. Explain why
the reducer should be so.
Answer: When reducers are placed in pipe Rack they are generally bottom side flat to maintain BOP to
facilitate supporting.
6. A P&ID shows a spec break (at Flange) between carbon steel & stainless steel specification. What
additional arrangements you have to make for that dissimilar material flange joint?
Answer: Use the Gasket and bolts from the SS spec.
7. A stainless steel piping specification mentions Galvanized carbons steel bolts. What is your first reaction
for this and how do you rectify it?
Answer: If that is what the Spec call for then that is what I am supposed to use. But, I would ask the Piping
Material Engineer (PME) why he/she specified galvanized bolts.
8. “Stress intensification factor (SIF)” Where do we use this? Explain this term. How many types of these
SIF’s exist?
Answer: Stress Intensification Factor (SIF) is a multiplier on nominal stress for typically bend and
intersection components so that the effect of geometry and welding can be considered in a beam analysis.
Stress Intensification Factors form the basis of most stress analysis of piping systems. As for the quantity,
ask a Stress Engineer.
9. When all design parameters are same, whose thermal expansion is higher among the following? A)
Carbon steel b) Stainless steel c) Duplex steel d) Cast Iron e) Galvanized Carbon steel.
Answer: b) Stainless steel
10. In a hose station the hose couplings used for water, air & steam should be different type. Do you agree?
Explain your view.
Answer: I agree. If they are all the same then the hoses can be connected to the wrong services and could
result in the injury of an operator (i.e.: thinking the hose is connected to water when it is connected to
steam).
11. What is your view on the usage of Metallic expansion joints? When they become necessary and when
they could be avoided?
Answer: I do everything I can as a piping designer to avoid the use of all types of expansion joints.
Expansion joints are always the weakest point in any system where they are used.
12. In what order do you arrange the pipes in the Pipe rack and why? How much % of area should be
reserved for Future expansion? Specify a range.
Answer: The largest hottest lines on the outside edge of the pipe rack working in with cooler lines in towards
the middle of the rack. This allows the longer loop legs as you lay the loops back over the other lines to the
other side of the rack and back. The lower temperature loops would be “nested” inside the larger, hotter
loops.
“Future rack space” is normally at the direction of the Client. It may be anything from 0% to as much as
25%.
13. What are different standards?
Answer: Most commonly use standards are as follows:
Sr. Standard Description
1. ANSI B18.2 Square and hexagonal head bolts and nuts
2. ANSI B16.3 Malleable iron threaded fittings
3. ANSI B16.4 Cast iron threaded fittings.
4. ANSI B16.9 Steel butt welding fittings
5. ANSI B16.11 Forged steel socket welding and threaded fittings
6. ANSI B16.25 Butt welding ends
7. ANSI B16.28 Short elbow radius and returns
8. MSS-SP-43 Stainless steel butt weld fittings
9. MSS-SP-83 Pipe Unions
10. API 605 Large diameter carbon steel flanges
11. ANSI B16.1 Cast iron pipe flanges and flanged fittings
12. ANSI B16.5 Steel pipe flanges and flanged fittings
13. ANSI B16.47 Large diameter steel pipe flanges and flanged fitts.
14. ANSI B16.20 Ring joint gaskets and grooves for pipe flanges
15. ANSI B16.21 Non metallic gaskets for pipe flanges
16. API 601 Metallic gasket for refinery piping.
17. API 5L Specification for line pipe.
18. ANSI B16.10 Welded and seamless wrought steel pipes
19. ANSI B36.19 Welded and seamless austenitic stainless steel pipe
20. ANSI B16.10 Face to face and end to end dimensions of valves
21. ANSI B16.34 Steel valves, flanged and butt welding ends.
14. What are various temporary closures for lines?
Answer: Line blind valve, line blind, spectacle plate, double block and bleed, blind flanges replacing a
removable spool.
15. What is double block and bleed?
Answer: Two valves with bleed ring in between with a bleed valve connected to the hole of bleed ring.
16. Where blind flange is used?
Answer: It is used with view to future expansion of the piping system, or for cleaning, inspection etc.
17. What is batch shell process?
Answer: Feed, heat, condense, heat more, condense, low quality.
18. What are types of towers?
Answer: Stripper, Vacuum tower, trayed, packed towers.
19. What is chimney tray?
Answer: It’s a solid plate with central chimney section, used at draw off sections of the tower.
20. What factors to consider while setting tower elevation?
Answer: NPSH, Operator access, Maintenance access, Minimum clearance, reboiler type, common area,
type of support, Tower dimensions, type of head, bottom outlet size, foundation details, minimum
clearances.
21. How to located tower maintenance access nozzles?
Answer: At bottom, top and intermediate sections of tower, must not be at the down comer section of tower
and in front of internal piping.
22. How to located feed nozzle?
Answer: Must be oriented in specific area of tray by means of internal piping.
23. How to located temperature and pressure instruments?
Answer: Temperature in liquid space, at down comer side and pressure in vapour space, in area except down
comer sector.

VALVES
1. What are the steps in selection of valve?
Answer: What to handle, liquid, gas or powder, fluid nature, function, construction material, disc type,
stem type, how to operate, bonnet type, body ends, delivery time, cost, warranty.
2. What are functions of valves?
Answer: Isolation, regulation, non-return and special purposes.
3. What are isolating valves?
Answer: Gate, ball, plug, piston, diaphragm, butterfly.
4. What are regulation valves?
Answer: Globe, needle, butterfly, diaphragm, piston.
5. What are non-return valves?
Answer: check valve.
6. What are special valves?
Answer: multi-port, flush bottom, float, foot etc.
7. What materials are used for construction of valves?
Answer: Cast iron, bronze, gun metal, carbon steel, stainless steel, alloy carbon steel, polypropylene and
other plastics, special alloys.
8. What is trim?
Answer: Trim is composed of stem, seat surfaces, back seat bushing and other small internal parts that
normally contact the surface fluid.
9. Which standard specifies trim numbers for valve?
Answer: API 600.
10. What are wetted parts of valve?
Answer: All parts that come in contact with surface fluid are called wetted parts.
11. What is wire drawing?
Answer: This term is used to indicate the premature erosion of the valve seat caused by excessive velocity
between seat and seat disc, when valve is not closed tightly.
12. What is straight through valve?
Answer: Valve in which the closing operation of valve is achieved by 90 degrees turn of the closing element.
13. What pressure tests are carried out on valves?
Answer: Shell-hydrostatic, seat-hydrostatic, seat-pneumatic.
14. What are available valve operators?
Answer: Hand lever, hand wheel, chain operator, gear operator, powered operator likes electric motor,
solenoid, pneumatic and hydraulic operators, Quick acting operators for non-rotary valves (handle lift).
15. What are two types of ball valve?
Answer: Full port design and regular port design, according to type of seat: - soft seat and metal seat.
16. What are ball valve body types?
Answer: Single piece, double piece, three pieces, the short pattern, long pattern, sand witch and flush bottom
design.
17. Why ball valves are normally flanged?
Answer: Because of soft seat PTFE which can damage during welding.
18. What are types of check valve?
Answer: Lift check valves and swing check valves.
19. Where diaphragm valves are used?
Answer: Used for low pressure corrosive services as shut off valves.
20. What is Bar stock Valve?
Answer: Any valve having a body machined from solid metal (bar stock). Usually needle or globe type.
21. What is Bleed Valve?
Answer: Small valve provided for drawing off liquid.
22. What is Blow Down Valve?
Answer: Refers to a plug type disc globe valve used for removing sludge and sedimentary matter from the
bottom of boiler drums, vessels, drip legs etc.
23. What is Breather Valve?
Answer: A special self acting valve installed on storage tanks etc. to release vapour or gas on slight increase
of internal pressure ( in the region of ½ to 3 ounces per square inch).
24. What is Drip Valve?
Answer: A drain valve fitted to the bottom of a drip let to permit blow down.
25. What is Flap Valve?
Answer: A non return valve having a hinged disc or rubber or leather flap used for low pressure lines.
26. What is Hose Valve?
Answer: A gate or globe valve having one of its ends externally threaded to one of the hose thread standards
in use in the USA. These valves are used for vehicular and firewater connections.
27. What is Paper-Stock Valve?
Answer: A single disc single seat gate valve (Slide gate) with knife edged or notched disc used to regulate
flow of paper slurry or other fibrous slurry.
28. What is Root Valve?
Answer: A valve used to isolate a pressure element or instrument from a line or vessel, or a valve placed at
the beginning of a branch form the header.
29. What is Slurry valve?
Answer: A knife edge valve used to control flow of non-abrasive slurries.
30. What is Spiral sock valve?
Answer: A valve used to control flow of powders by means of a twistable fabric tube or sock.
31. What is Throttling valve?
Answer: Any valve used to closely regulate flow in the just-open position.
32. What is Vacuum breaker?
Answer: A special self-acting valve or nay valve suitable for vacuum service, operated manually or
automatically, installed to admit gas (usually atmospheric air) into a vacuum or low-pressure space. Such
valves are installed on high points of piping or vessels to permit draining and sometimes to prevent
siphoning.
33. What is Quick acting valve?
Answer: Any on/off valve rapidly operable, either by manual lever, spring or by piston, solenoid or lever
with heat-fusible link releasing a weight which in falling operates the valve. Quick acting valves are
desirable in lines conveying flammable liquids. Unsuitable for water or for liquid service in general without
a cushioning device to protect piping from shock.
34. What is diverting valve?
Answer: This valve switch flow from one main line to two different outlets. WYE type and pneumatic
control type with no moving part.
35. What is sampling valve?
Answer: Usually of needle or globe pattern, placed in branch line for the purpose of drawing all samples of
process material thru the branch.
36. What are blow off valve?
Answer: It is a variety of globe valve confirming with boiler code requirements and specially designed for
boiler blow off service. WYE pattern and angle type, used to remove air and other gases from boilers etc.
37. What is relief valve?
Answer: Valve to relieve excess pressure in liquids in situations where full flow discharge is not required,
when release of small volume of liquid would rapidly lower pressure.
38. What is safety valve?
Answer: Rapid opening (popping action) full flow valve for air and other gases.
39. What is foot valve?
Answer: Valve used to maintain a head of water on the suction side of sump pump, basically a lift check
valve with integrated strainer.
40. What is float valve?
Answer: Used to control liquid level in tanks, operated by float, which rises with liquid level and opens the
valve to control water level. It can also remove air from system, in which case, air flows out of system in
valve open condition, but when water reaches valve, float inside valve raises to close the valve and stop flow
of water. Used in drip legs.
41. What are flush bottom valves?
Answer: Special type of valves used to drain out the piping, reactors and vessels, attached on pad type
nozzles.
42. What are types of flush bottom valves?
Answer: Valves with discs opening into the tank and valves with disks into the valve.
43. What are the uses of three-way valve?
Answer: Alternate connection of the two supply lines to a common delivery vise versa, isolating one safety
valve, division of flow with isolation facility.
44. What are uses of four way valve?
Answer: Reversal of pump suction and delivery, By pass of strainer or meter, reversal of flow through filter,
heat exchanger or dryer.
45. What are three patterns of plug valve design?
Answer: Regular pattern, short pattern and ventury pattern.
46. What is regular pattern plug valve?
Answer: Rectangular port, area almost equal to pipe bore, smooth transition from round body to rectangular
port, for minimum pressure loss.
47. What are short pattern plug valve?
Answer: Valves with face to face dimension of gate valve, as a alternative to gate valve.
48. What are ventury pattern plug valve?
Answer: Change of section through the body throat so graded to have ventury effect, minimum pressure
loss.
49. What are inverted plug design valve?
Answer: Plug valve with taper portion up of plug, for 8” and higher size.
50. What is pressure balanced plug valve?
Answer: With holes in port top and bottom connecting two chambers on top and bottom of plug, to reduce
turning effort.
51. What are Teflon sleeved plug valve?
Answer: PTFE sleeve between plug and body of valve, low turning effort, minimum friction, temperature
limitation, anti static design possible.
52. What are eccentric plug valve?
Answer: Off centre plug, corrosive and abrasive service, on off action, moves into and away from seat
eliminating abrasive wear.
53. What is dimensional standard for plug valve?
Answer: API 599.
54. What is pinch valve?
Answer: Similar to diaphragm valve, with sleeves of rubber or PTFE, which get squeezed to control or stop
the flow, Cast iron body, for very low service pressures like isolation of hose connections, manufacture
standard.
55. What is needle valve?
Answer: Full pyramid disc, same design as globe valve, smaller sizes, sw or threaded, flow control, disc can
be integral with stem, inside screw, borged or barstock body and bonnet, manufacturers standard.
56. How to install a globe valve?
Answer: Globe valve should be installed such that the flow is from the underside of the disk, usually flow
direction is marked on the globe valve.
57. What are globe valve port types?
Answer: Full port: More than 85% of bore size, Reducer port: One size less than the connected pipe.
58. What are globe valve disk types?
Answer: Flat faced type for positive shutoff, loose plug type for plug renewal or needle type for finer
control.
59. What are characteristics of globe valve stem?
Answer: Always rising design, with disk nut at the lower end and hand wheel at upper end.
60. What are types of globe valve?
Answer: Angle globe valve, plug type disc globe valve, wye-body globe valve, composite disc globe valve,
double disc globe valve.
61. What is angle globe valve?
Answer: Ends at 90 degree to save elbow, higher pressure drop.
62. Where plug type disc globe valve is used?
Answer: For severe regulating service with gritty liquids such as boiler feed water and for blow off service.
63. Where WYE body globe valve is used?
Answer: In line ports with stem emerging at 45 degree, for erosive fluids due to smoother flow pattern.
64. What is double disc globe valve?
Answer: Has two discs bearing on separate seats spaced apart, on a single shaft, for low torque, used for
control valves.
65. What are port types for gate valves?
Answer: Full port and reduced port. Default is reduced bore. Full port has to be specified in BOM.
66. How to close a gate valve?
Answer: Turn the hand wheel in clockwise direction.
67. What is lantern ring?
Answer: It’s a collection point to drain off any hazardous seepage or as a point where lubricant can be
injected; it is in the middle of packing rings.
68. What are types of gate valves?
Answer: Solid plane wedge, solid flexible wedge, split wedge, double disc parallels seats, double disc
wedge, single disc single seat gate or slide, single disc parallel seats, plug gate valve.
69. What are the types of bonnets?
Answer: Bolted bonnet, bellow sealed bonnet, screwed on bonnet, union bonnets, A U-bolt and clamp type
bonnet, pressure seal bonnet.

MECHANICAL EQUIPMENTS

1. What are the types of compressors?

Answer: Positive Displacement, Centrifugal and Axial, rotary screw, rotary vane, rotary lobe, dynamic,
liquid ring compressors.
2. What are types of compressor drives?
Answer: Electric motor, gas turbine, steam turbine and gas engine.
3. How Centrifugal compressors work?
Answer: High speed impellers increase the kinetic energy of the gas, converting this energy into higher
pressures in a divergent outlet passage called a diffuser. Large volume of gas at moderate pressure.
4. What are types of steam turbine and why are they popular?
Answer: Condensing and non-condensing, Popular because can convert large amounts of heat energy into
mechanical work very efficiently.
5. Where gas turbine drive is used?
Answer: Desserts and offshore platforms where gas is available, for gas transmission, gas lift, liquid
pumping, gas re-injection and process compressors.
6. What are the auxiliary equipments of compressor?
Answer: Lube oil consoles, Seal oil consoles, Surface condensers, Condensate pump, Air blowers, Inlet air
filters, Wast heat system, compressor suction drum, knock out pot, Pulsation dampner, volume
bottles, Inter and after coolers.
7. What are the types of seal oil system?
Answer: Gravity and pressurized.
8. What factors to be considered while designing compressor housing?
Answer: Operation, Maintenance, Climate conditions, Safety, Economics.
9. What are the compressor housing design points?
Answer: Floor elevation, building width, building elevation, hook centreline elevation.
10. What are the types of compressor cases?
Answer: Horizontal split case, Vertical split case.
11. What are compressor suction line requirements?
Answer: Minimum 3D straight pipe between elbow and inlet nozzle, increases based on inlet piping layout.
4D.
12. What are necessary parts of inlet line of compressor?
Answer: Block Valve, Strainer, Break out flanges in both inlet and outlet to remove casing covers,
Straightening vane in inlet line if not enough straight piece in inlet line available, PSV in inter stage line and
in discharge line before block valve.
13. What points to be considered for reciprocating compressor piping layout?
Answer: High pulsation, simple line as low to grade as possible for supporting, analog study, all branches
close to line support and on top, Isolate line support from adjacent compressor or building foundations.
14. What are the types of compressor shelters?
Answer: On ground with no shelter, Open sided structure with a roof, Curtain wall structure (Temperate
climates), Open elevated installation, Elevated multi compressor structure.
15. What are drum internals?
Answer: Demister pads, Baffles, Vortex breakers, Distribution piping.
16. What are drum elevation requirements?
Answer: NPSH, minimum clearance, common platforming, maintenance, operator access.
17. What are drum supports?
Answer: Skirt for large drums, legs, lugs, saddles for horizontal drums.
18. What are necessary nozzles for non-pressure vessel?
Answer: Inlet, outlet, vent, manhole, drain, overflow, agitator, temperature element, level instrument, and
steam out connection.
19. What are necessary nozzles for pressure vessel?
Answer: Inlet, outlet, manhole, drain, pressure relief, agitator, level gauge, pressure gauge, temperature
element, vent and for steam out.
20. What is preferred location for level instrument nozzles?
Answer: Away from the turbulence at the liquid outlet nozzle, although the vessel is provided with a vortex
breaker, instrument should be set in the quiet zone of the vessel for example on the opposite side of the weir
or baffle or near the vapour outlet end.
21. What is preferred location for process nozzles on drum?
Answer: Minimum from the tangent line.
22. What is preferred location for steam out nozzle on drum?
Answer: At the end opposite to the maintenance access.
23. What is preferred location for vent?
Answer: At the top section of drum at the end opposite the steam out connection.
24. What is preferred location for pressure instrument nozzle on drum?
Answer: Must be anywhere in the vapour space, preferable at the top section of drum.
25. What is preferred location for temperature instrument?
Answer: Must be in liquid space, preferably on the bottom section of drum.
26. What is preferred location for drain?
Answer: Must be located at the bottom section of drum.

MULTIPLE CHOICE QUESTIONS

1. Which of the following is fully killed steel?

a) ASTM A 53 b) ASTM A 106 c) ASTM A 333 d) All of the above
Answer: B
2. What is the mill’s tolerance to be considered for the thickness calculation of seamless pipe as per
ASME B31.3?
a) 12 b) 12.25 c) 12.5 d) None of the above
Answer: C
3. Butt welded fittings (up to 600#) are generally used in which Size range?
a) 1/2” & above b) 2” & above c) Both a & b d) None of the above
Answer: B
4. ASME B16.10 describes about
a) Face to face & end to end dimensions of non-ferrous valves
b) Face to face & end to end dimensions of ferrous valves
c) Both a & b
d)None of the above
Answer: B
5. ASTM Std. for 6” C.S welded pipe is
a) A106 Gr.B b) A53 Gr.B c) API 5L Gr.B d) All of the above
Answer: B
6. ASTM Std. for 8” C.S 150# flange
a) A234 Gr.WPB b) A216 Gr.WCB c) A105 d) None of the above
Answer: C
7. Usually the ASTM Std. for 30” Low temp. C.S. EFW pipe is
a) A333 Gr.6 b) A106 Gr.B c) A671 Gr.CC60 Cl.32 d) All of the above
Answer: C
8.Which of the fluid Service is non-toxic in nature?
a) Category D b) Category M c) High Pressure fluid service d) Normal fluid service
Answer: A
9. All Pipe bends in CS are ____________
a) Hot formed b) Cold formed c) Both a & b d) None of the above
Answer: B
10. What is the Size range in NPS for ASTM A106 Seamless Pipe?
a) 1/8 to 46 b) 1/8 to 44 c) 1/8 to 48 d) None of the above
Answer: C
11. What is the dimensional standard for Small Bore Gate valve?
a) API-602 b) API-600 c) API-609 d) None of the above
Answer: A
12. What is the dimensional standard for Large Bore Gate valve?
a) API-602 b) API-600 c) API-609 d) None of the above
Answer: B
13. What is the dimensional standard for Small Bore Globe valve?
a) BS-5351 b) BS-5352 c) BS-1873 d) API-602
Answer: B
14. What is the dimensional standard for Large Bore Globe valve?
a) BS-5351 b) BS-5352 c) BS-1873 d) API-602
Answer: C
15. What is the dimensional standard for Check valve?
a) BS-5352 b) BS-1868 c) BS-1873 d) Both a & b
Answer: D
16. What is the dimensional standard for Ball valve?
a) BS-5351 b) BS-5352 c) BS-1873 d) None of the above
Answer: A
17. Steam pipe lines are usually _________________
a) ERW b) EFW c) Seamless d) None of the above
Answer: C
18. Low temperature Carbon steel shall be used below which temperature?
a) -20 °C b) -30 °C c) -29 °C d) -40 °C
Answer: C
19. What is the standard used for Welded and Seamless wrought steel pipe?
a) ASME B36.10 b) ASME B36.19 c) ASME B16.11 d) ASME B16.9
Answer: A
20. Small bore fitting are covered under which American Standard?
a) ASME B36.10 b) ASME B36.19 c) ASME B16.11 d) ASME B16.9
Answer: C
21. Large bore fittings are covered under which American Standard?
a) ASME B36.10 b) ASME B36.19 c) ASME B16.11 d) ASME B16.9 Answer:
D
22. Which Standard is used for large dia. flanges?
a) ASME B16.5 b) ASME B16.47 c) ASME B16.48 d) None of the above
Answer: B
23. _________is used as the fitting material in Low Temperature C.S. for sizes usually 2” & above
a) ASTM A420 Gr.WPL6 b) ASTM A350 Gr.LF2 c) Both a & b d) None of the above
Answer: A
24. _________is used as the fitting material in LTCS for sizes usually 11/2” & below
a) ASTM A420 Gr.WPL6 b) ASTM A350 Gr.LF2 c) Both a & b d) None of the above
Answer: B
25. _____________ is a Non-Return Valve.
a) Gate Valve b) Globe valve c) Ball Valve d) Check Valve
Answer: D
26. _________ is the maximum temperature till which Carbon Steel can be used as per ASME B 31.3
a) 420°C b) 429°C c) 425°C d) 427°C
Answer: C
27. _________ is the minimum temperature till which Carbon Steel can be used as per ASME B 31.3
a) -30°C b) -28°C c) -45°C d) -29°C
Answer: D
28. Generally _____________ is used as a by-pass Valve
a) Gate Valve b) Butterfly Valve c) Ball Valve d) Globe Valve
Answer: D
29. Types of Ball Valve:
a) Full Port b) Regular Port c) Soft Seat & Metal Seat d) All of the above
Answer: D
30. Types of Check Valve:
a) Lift type b) Swing type c) Wafer type d) All of the above
Answer: D
31. Gate & Ball Valve are ________________ valves
a) Isolating b) Regulating c) Non-return d) None of the above
Answer: A
32. Globe Valve is a ________________ valve
a) Isolating b) Regulating c) Non-return d) None of the above
Answer: B
33. What is the minimum thickness required for CS pipe which needs PWHT (Post Weld Heat Treatment)
requirement?
a) 18 mm b) 20 mm c) 19 mm d) 21 mm
Answer: C
34. What is the ASME code followed for design of piping systems in Process piping (Refineries &
Chemical Industries)?
A) ASME B31.1 B) ASME B31.3 C) ASME B31.5 D) ASME B31.9
Answer: B
1. What is the difference between stub in and stub on branches? Which one is preferred?
Answer: For branching of one size lesser of run pipe, Stub On is preferred. For other branching less than one
size of run pipe stub in is preferred. The Design is based on ANSI B 31.3.

2. What is the difference between Pipe and Tube?

Answer: Pipe is identified by NB and thickness is defined by Schedule whereas Tube is identified by OD.

3. From which size onwards NB of pipe is equal to OD of Pipe?

Answer: From the size 14” and onwards NB = OD of pipe.

4. Write down the outside diameter of following pipe?

A) 3 inch B) 6 inch C) 10 inch D) 14 inch
Answer: A) 3 inch = 88.9mm B) 6 inch = 168.28mm
C) 10 inch = 273.06mm D) 14 inch = 355 mm

5. What is the difference between machine bolt and stud bolt?

Answer: Machine bolt has a head on one side and nut on other side but stud bolt have nuts on both sides.

6. What is soluble dam?

Answer: Soluble dam is a water-soluble material used for restricting the purging gas within the pipe.

7. While welding of pipe trunion to pipe/reinforcement pad you have to put a hole or leave some portion of
welding why?
Answer: For venting of hot gas which may get generated due to welding.

8. What do you mean by following type of welding?

1. SMAW 2. TIG
Answer: SMAW = SHIELDED METAL ARC WELDING, TIG = TUNGSTEN INERT GAS WELDING.

9. What should be the radius of long radius elbow?

Answer: 1.5D (Where “D” is the diameter of the pipe)

10. Normally where do we use the following?

A) Eccentric reducers (ER) Concentric reducers (CR)
Answer: A )ER = Pump suction to avoid Cavitations, to maintain elevation (BOP) in rack.
B ) CR = Pump discharge, vertical pipeline etc.

11. Concentric reducer is used in pump suction. (Yes / No). Explain.

Answer: No. Air pockets may form if concentric reducer is used at pump suction, which results in
Cavitations, and cause damage to Pump. To avoid this problem, Eccentric Reducer with Flat Side Up (FSU)
is used in Pump Suction.

12. What do you mean by Cavitation in Pump?

Answer: A pump is designed to handle liquid, not vapour. Vapour forms if the pressure in the pump falls
below the liquid’s vapour pressure. The vapour pressure occurs right at the impeller inlet where a sharp
pressure drop occurs. The impeller rapidly builds up the pressure which collapses vapour bubbles causing
cavitation and damage. This is avoided by maintaining sufficient NPSH.
(Cavitation implies cavities or holes in the fluid we are pumping. These holes can also be described as
bubbles, so cavitation is really about the formation of bubbles and their collapse. Bubbles form whenever
liquid boils. It can be avoided by providing sufficient NPSH.)

13. What do you mean by NPSH? How do you calculate it?

Answer: NPSH = Net Positive Suction Head. NPSH is the pressure available at the pump suction after
vapour pressure is subtracted. It is calculated as: Static head + surface pressure head - the vapor pressure of
your product - the friction losses in the piping, valves and fittings. It thus reflects the amount of head loss
that the pump can sustain internally before vapour pressure is reached.

14. What is the ASTM code for the following?

A) CS pipe CS fittings C) CS flanges D) AS pipe P5/P11 E) Cast CS Valves
Answer: A CS pipe = A106 Gr.B B CS fittings = A234 Gr. WPB/WPBW
C CS flanges = A105 D AS pipe = A335 Gr P5/P11
E Cast CS Valves = A216 Gr. WCB

15. What is the thumb rule to calculate spanner size for given bolt?
Answer: 1.5 x diameter of Bolt

16. What is the thumb rule to calculate Current required for Welding?
Answer: Current (Amp) = [Diameter of Electrode (mm) X 40] + 20

17. What is steam tracing? How do we decide the location of SSM & CRM?
Answer: Steam Tracing is a process which is used to prevent the fluid passing through a process line from
freezing by keeping the temperature high enough for free flow of fluid and thus maintaining palpability.
SSM and CRM are generally located 38M max for open system and 24 M max for closed system when we
use LP Steam up to 3.5-kg/sq cm. as a heating media.

18. Which piping items will you drop down before conducting Flushing and Hydro test?
Answer: Items like Control Valve, Orifice plates, Rotameters, safety valves; Thermo wells are dropped or
replaced with temporary spools before hydro test.

19. Why do we provide a Dampener in the Piping of Reciprocating Pump?

Answer: To take care of Pulsation.

20. Why do we provide Full Bore Valve in connecting pipeline of Launcher/Receiver?

Answer: For Pigging.

21. Which parameters will u check during checking Piping Isometrics?

Answer: Bill of Material, Pipe Routing w.r.t. GAD, Supporting arrangement, details of insulation, hydro test
pressure, painting specs and provision of Vent and Drains at appropriate locations.

22. What is the ANSI/ASME dimensional standard for steel flanges & fittings?
A) B16.3 B)16.5 C) B16.9 D) B16.10
Answer: (B)

Stress Analysis :
1. What is the objective of stress analysis?
Answer: - A. To ensure that the stresses in piping components in the system are within allowable
limits.
B. To solve dynamic problems developed due to mechanical vibration, fluid hammer, pulsation, relief
valves, etc.
C. To solve problems associated due to higher or lower operating temperature as: -
I. Displacement stress range. II. Nozzle loading on connected equipment.
III. Pipe displacements. IV. Loads & moments on supporting structure.

2. What are the steps involved in stress analysis (or any stress package carries out)?
Answer: -
A. Identify the potential loads that the piping system would encounter during the life of the plant.
B. Relate each of these loads to the stresses and strains developed.
C. Get the cumulative effect of the potential loads in the system.
D. Decide the allowable limits the system can withstand without failure as per code.
E. After the system is designed to ensure that the stresses are within safe limits.

3. How the loads are classified in stress analysis package?

Answer: -
A. Sustained Loads : Those due to forces present during normal operation.
B. Occasional Loads : Those present during rare intervals of operation.
C. Displacement Loads : Those due to displacement of pipe.
(Self-limiting stresses due to thermal effects).

4. What are the sources of sustained load generated in piping system?

Answer: - A. Internal fluid pressure.
B. Dead weight of Pipe with fluid and its attachments.
Sustained load is calculated as: -
Weight of Pipe with Fluid + Internal fluid pressure load + Load due to springs (W+P1).

5. What are the Inputs required for stress analysis of a piping system?
Answer: - A. Pipe Size. B. Fluid Temperature. C. Pipe Material.
D. Model. E. Design pressure. F. Insulation Thickness. G. Specific gravity.
H. Friction coefficient.

6. How do you calculate the operating load?

Answer:-W +P1+T1
T1 – Load due to thermal expansion.

7. Give some Examples for occasional Loads.

Answer: -
A. Wind load. B. Seismic load. C. Forces due to relief or blow down.
D. Pressure wave generated due to water hammer effects
.
8. What is the failure theory subscribed under ASME B31.3?
A. Maximum principal stress theory (Rankines Theory).
B. Maximum Shear Theory. C. Octahedral Shear Theory.
Answer: - A. Maximum principal stress theory or Rankines theory.
9. Select the failure stress range for fatigue failure due to thermal expansion as per B31.3?
A. SA = (Sc+ Sh) 1.6f
B. SA = 1.25 (SC + Sh)
C. SA = (1.25 Sc+0.25Sh)f
Where, SA = Allowable Expansion stress Range.
Sc and Sh = Basic Allowable material stress in cold & hot conditions respectively.
f = Stress range reduction factor (1 for 7000 cycles.)
Answer: - C

10. What is the desired life cycle for Piping in operation?

Answer: - Desired life cycle for Piping in operation is 20 Years (7000 Cycles).
The normal no. of cycles for which the displacement or thermal stresses are designed is 7000 cycles.

11. How do you calculate the stress developed due to thermal expansion?
Answer: -
Stress developed, e= E x a, (a= DL/L)
……. Where, E = Young’s Modulus.
DL = Increase in length due to thermal expansion.
L = Original Length of the pipe.

12. How do you calculate the thermal expansion in a pipe?

Answer: - DL = ax DT x L
In the codes and many reported calculations, ais used as inclusive of DT. Thus the above formula is
written as:-
DL = ax L
Where, a= Coefficient of thermal expansion from ambient to operating temperature.
L = Length of the pipe.

13. What do you mean by Stress Intensity Factor (SIF)? Give some examples.
Answer: -
Stress Intensity Factor (SIF) is the ratio of maximum stress intensity to normal stress. It is used as
safe factor to account for the effect of localised stress on piping under respective loading. In piping it
is applied to welds, fittings, branch connections etc where stress concentration and possible fatigue
failuremay occur.
Example: - SIF for Reducer and Weldneck Flange is 1.0
SIF for socket weld flange is 1.3

14. How much should be the pressure for Hydro-Test?

Answer: -
Hydrotest pressure should be calculated as follow except as provided against point No D.
A. 1.5 Times of Design Pressure.
B. For a design temperature above the test temperature, minimum test pressure can be calculated as:
Pt = (1.5 X P X St) / S
………..Where, Pt : Minimum Test Pressure.
P : Internal design pressure.
St: Allowable stress at test temperature.
S : Allowable stress as design temperature.
.
C. If a test pressure as per above would produce a stress in excess of the yield strength at test
temp.the test pressure may be reduced to maximum pressure that will not exceed the yield
strength at test temp.
D. If the test pressure of piping exceeds the vessel pressure and it is not considered practicable to
isolate piping from vessel, the piping and vessel may be tested together at test pressure of the
vessel when approved by owner and provided the test pressure for vessel is not less than 115% of
piping design pressure adjusted for temperature as per point No.B.

15. How do you calculate the pipe spacing?

Answer: -
Pipe Spacing (mm) = (Do + Dt) / 2 + 25mm + Thickness of Insulation (mm).
Where: D0 : OD of Small size Pipe (mm).
Dt : OD of Flange of Large size Pipe (mm).

16. Which fluid is used in Heat Exchanger in shell side and tube side?
Answer: -
Generally corrosive fluid is used from the tube side (as tube can be easily replaced) and cleaner fluid
is used from shell side. Sometimes Hot fluid is also used from the shell side.

17. What is Reynolds number and what is the value of Reynolds number upto which the flow is
laminar?
Answer: -
It’s a dimensionless number to classify the nature of flow.
Re = a v d / f
………Where, Re : Raynold’s no.
a : Density of fluid.
d : Diameter of Pipe.
v : Average velocity of fluid.
f : Viscosity of fluid.
Flow is laminar upto Re=2100

18. Why do we provide Drip Leg in Steam Line?

Answer: -
To remove condensate when there is a rise of same in the pipe along the flow direction. If drip leg is
not provided in steam line, the condensate which forms inside the pipe will result in Water Hammer
effect causing damage to piping system.

19. What is the design standard followed for the calculation of allowable forces / Moments in
nozzles of centrifugal compressor & Steam turbines nozzle?
Answer: -
The strain sensitive equipment piping to be routed and supported to limit nozzle loading and moment
in equipment within allowable limits furnished by respective vendors or in absence of vendor data
API 560/610/615/621/661 & NEMA SM23. (Referred by API 617) is used for compressor & steam
turbine nozzle.

20. What is the mill tolerance to be considered for the thickness of pipe during stress analysis as
per ASME B31?
(i) 1% ii) 2.5% (iii) 7.5%
iv) 12.5% Answer : iv

21. Differentiate between static load and dynamic load?

Answer: -
Static loads are those which are applied slowly enough so that the system has time to react and
internally distribute the loads, thus remaining in equilibrium. In equilibrium, all forces and moments
are resolved (i.e., the sum of the forces and moments are zero), and the pipe does not move.
Dynamic loads are those which changes quickly with time. The piping system may not have time to
internally distribute the loads, so forces and moments are not always resolved & resulting in
unbalanced loads, and therefore pipe movement. Since the sum of forces and moments are not
necessarily equal to zero, the internally induced loads can be different either higher or lower than the
applied loads.

22. Give different types of dynamic loads with example?

Answer: - A. Random – Wind, Earthquake.
B. Harmonic – Equipment Vibration, Pulsation, Acoustic Vibration.
C. Impulse – Fluid Hammer, relief valve opening, slug flow.

23. What is Dynamic Analysis and why it is used?

Answer: - Dynamic analysis is performed for all two phase lines in order to ensure that the line
supported is safe from vibrations loads which may occur during normal operation as well as in start
up or any upset condition. (Diesel mixed with hydrogen in DHDT process).

24. What areWRC 107 / WRC 297?

Answer: - Localised stresses at Nozzle to Shell is calculated by WRC 107 / 297 and these
computed stress values shall be limited in accordance with ASME Sec VIII for Pressure Vessels.

25. Why loop is provided in piping system?

Answer: - To adjust thermal expansion.

26. What is the maximum expansion absorbed in loops in normal design?

Answer: - 10 Inches.

27. What is the allowable stress range for CS pipes?

Answer: - 2070 kg/cm2.

pipes supports: -
1. What are the Criteria for Pipe Supporting?
Answer: -
Following are the points, which should be taken into account for proper supporting: -
A. Load of bare pipe + fluid + insulation (if any).
B. Load of bare pipe + water fill.
C. Load of valves and online equipment and instrument.
D. Thermal loads during operation.
E. Steam out condition, if applicable.
F. Wind loads for piping at higher elevation, if required.
G. Forced vibration due to pulsating flow.
H. Bare pipe with size above 12” shall be supported with Pad or Shoe.

2. What is the basic span of supports for 2”/6”/10”/24” pipe?

Answer: - Basic Span is 5.5m / 9m / 11.5m / 15m respectively.

3. What is the function of providing the anchor, cross guide and guide for piping?
Answer: -
Anchor is provided to restrict all the axial and rotational movements of pipe, whereas cross guide is
provided to restrict displacements of pipe along with the axis perpendicular to its centerline and
Guide is provided to restrict the longitudinal movements of pipes along with its axis.

4. How is piping to Tank inlet nozzle is supported and why?

Answer: - Piping to Tank Nozzle is supported with spring type support (first support from Nozzle) in
order to make the nozzle safe from the loads which occurs due to the displacement of pipe
( Displacement may be due to thermal expansion of pipe, tank material, tank settlement etc).

5. What are the types of flexible spring hangers?

Answer: - 1. Constant Spring Hanger 2. Variable Spring Hanger.

6. What is the purpose of providing Graphite Pads in supports below shoes?

Answer: - To reduce the friction factor. The co-efficient of friction for Graphite Pads is 0.1

7. Where do you provide Anchor and Slotted Support of Heat Exchanger?

Answer: - Anchor support of Heat exchanger is provided on the side from which Tube bundle will
be pulled out for the purpose of maintenance work also it is based on the growth of the connecting
piping as exchanger should grow with the piping.

8. What should be the material of shoes for supporting AS pipes & why?
Answer: - If CS shoes are used then pad in contact with the pipe shall be of Alloy steel to avoid
dissimilar welding at pipe. To avoid alloy steel welding and dissimilar welding, fabricated clamps
either of CS or SS can be used.

9. What are sway braces?

Answer: -
Sway braces are essentially a double acting spring housed in a canister. Their purpose is to limit the
undesirable movement. Undesirable movement means movement caused by wind loading, rapid
valve closure, relief valve opening, two phase flow or earthquake.

10. What is the difference between variable spring hanger and constant spring hanger?
Answer: - Variable spring Hanger: - As the name itself indicates the resistance of the coil to a load
changes during compression.
Constant spring Hanger: - Constant spring hanger provides constant support force for pipes and
equipment subjected to vertical movement due to thermal expansion.

Pipe Fittings: -

1. How can flanges be classified based on Pipe Attachment?

Answer: - Flanges can be classified based on pipe attachment as: -
Slip – on. : - The Slip-on type flanges are attached by welding inside as well as
outside. These flanges are of forged construction.
Socket Weld. : - The Socket Weld flanges are welded on one side only. These are used for
small bore lines only.
Screwed. : - The Screwed-on flanges are used on pipe lines where welding cannot be carried out.
Lap Joint. : - The Lap Joint flanges are used with stub ends. The stub ends are welded with pipes &
flanges are kept loose over the same.
Welding Neck. : - The Welding neck flanges are attached by butt welding to the pipe. These are used
mainly for critical services where the weld joints need radiographic inspection.
Blind. : - The Blind flanges are used to close the ends which need to be reopened.
Reducing. : - The reducing flanges are used to connect between larger and smaller sizes without
using a reducer. In case of reducing flanges, the thickness of flange should be that of the higher
diameter.
Integral. : - Integral flanges are those, which are cast along with the piping component or
equipment.

2. How can flanges be classified based on Pressure- temperature ratings?

Answer: - Flanges are classified based on pressure temperature ratings as: -
A. 150 # B. 300 # C. 400 # D. 600 # E. 900 # F. 1500 #
G. 2500#
Pressure temperature rating carts in the standard ASME16.5 specify the non-shock working
gauge pressure to which the flange can be subjected to at a particular temperature.

3. How can flanges be classified based on facing?

Answer: - Flanges are classified based on facing as: -
A. Flat face. (FF) B. Raised face. (R/F) C. Tongue and groove. (T/G)
D. Male and female. (M/F) E. Ring type joint. (RTJ)

4. How can flanges be classified based on face finish?

Answer: - Flanges are classified based on face finish as: -
A. Smooth finish. B. Serrated finish.

5. Where the smooth finish flange & serrated finish flange finds its use?
Answer: - The smooth finish flange is provided when metallic gasket is provided and serrated
finish flange is provided when non-metallic gasket is provided.

6. What are the types of serrated finish provided on flange face?

Answer: - A. Concentric or B. Spiral (Phonographic)

7. How the serration on flanges is specified?

Answer: The serration on flanges is specified by the number, which is the Arithmetic Average
Rough Height (AARH).

8. Where the concentric serration is insisted for face finish?

Answer: - Concentric serration are insisted for face finish where the fluid being carried has very
low density and can find leakage path through cavity.

9. How the Gaskets are classified based on the type of construction?

Answer: - Based on the type of construction, gaskets are classified as: -
A. Full face. B. Spiral wound metallic. C. Ring type.
D. Metal jacketed. E. Inside bolt circle.

10. What is the most commonly used material for Gasket?

Answer: - Compressed Asbestos Fibre.

11. Which type of gasket is recommended for high temperature & high-pressure application?
Answer: - Spiral Wound Metallic Gasket.
11. What are the criteria for selection of MOC of Spiral Wound metallic Gasket winding
material?
Answer: - The selection of material of construction for Gasket winding depends upon: -
A. The corrosive nature and concentration of fluid being carried.
B. The operating temperature of the fluid.
C. The relative cost of alternate winding material.

12. What are the most common materials used for spiral wound metallic gasket winding?
Answer: - The most commonly used material for spiral wound metallic gasket winding is: -
A. Austenitic stainless steel 304 with asbestos filler.
B. Austenitic stainless steel 316 with asbestos filler.
C. Austenitic stainless steel 321 with asbestos filler.

13. Which material is used as filler material for spiral wound gasket in case of high temperature
services?
Answer: - For very high temperature services, graphite filler is used.

14. What is centering ring in connection to spiral wound gasket?

Answer: - Spiral wound gaskets are provided with carbon steel external ring called centering
ring.

15. What will be the AARH finish on flange face for using spiral wound gasket?
Answer: - 125-250 AARH finish.

16. On which type of flanges the use of spiral wound gasket are restricted?
Answer: - ASME B16.5 does not recommend the use of 150 #rating spiral wound gasket on
flanges other than welding neck and lapped joint type.

17. Up to what temperature limits the low strength carbon steel bolts should not be used for
flanged joints?
Answer: - Flanged joints using low strength carbon steel shall not be used above 200°C or below -
28°C.

17. How the pipe fittings are classified based on end connections?
Answer: - Pipe fittings are classified based on end connection as: -
A. Socket weld fittings. B. Screwed end fittings. C. Beveled end or Butt weld fittings.
D. Spigot socket fittings. E. Buttress end fittings.

18. Up to what temperature the carbon steel materials shall be used?

Answer: - Carbon steel materials shall be used for temperature up to 425°C.

19. Which material is used for temperature above 426°C?

Answer: - Alloy steel materials shall be used for temperature above 426°C.

20. Which type of material is used for corrosive fluid?

Answer: - Stainless steel materials shall be used for corrosive fluid.

21. Which type of piping materials are used for drinking water, instrument air etc?
Answer: - Galvanized steel materials shall be used for drinking water, instrument air and NI
lines (LP).

22. What is the difference between Pipe and Tube?

Answer: - Pipe is identified by NB and thickness is defined by Schedule whereas Tube is
identified by OD & its thickness as BWG (Brimingham wire gauge or 1/100 inch).

23. From which size onwards NB of pipe is equal to OD of Pipe?

Answer: - From the size 14” and onwards NB = OD of pipe.

24. What should be the radius of long radius elbow?

Answer: 1.5D (Where “D” is the diameter of the pipe.)

25. What should be the radius of short radius elbow?

Answer:- 1D(Where “D” is the diameter of the pipe.)

26. What is the basis of using of short radius & long radius elbow?
Answer:- Long radius elbow are used for small pressure drop whereas short radius elbow are used
for high pressure drops. For catalyst flows vary long radius elbows are used.

27. Normally where do we use the following?

A. Eccentric reducers. B. Concentric reducers.
Answer:
A. Eccentric reducers = Pump suction to avoid Cavitation, To maintain elevation (BOP) in rack.
B. Concentric reducers = Pump discharge, vertical pipeline etc.

28. Concentric reducer is used in pump suction. (Yes / No). Explain.

Answer: No. Air pockets may form if concentric reducer is used at pump suction, which results in
cavitation and cause damage to Pump. To avoid this problem, Eccentric Reducer with flat side up
(FSU) is used in Pump Suction.

29. Where the ERW spiral & longitudinal pipes are used?
Answer: - Use depends upon the availability of pipes. Nothing functional difference.

30. Where the ERW & Seamless pipes are used?

Answer: - Above 18” ERW pipes are used. Below 18” seamless pipes are used. Seamless pipes
can sustain higher temperature & pressure.

31. What is the main use of ASTM A53 & A106 Gr.B pipes?
Answer: - ASTM A53 pipes are mainly used for utility services whereas A106 Gr. B pipes are
used for high Pressure & high temperature services.

32. From which side of pipe will you take a branch connection?
Answer:- W hen fluid is Gas, Air or Steam and Cryogenic Service – Topside.
When Fluid is Liquid – Bottom Side.

33. Why don’t we take a branch for Cryogenic Service from bottom side though the fluid is in
liquid state?
Answer: - There is the chance of ice formation during normal operation and since ice flows from
the bottom of the pipe it will block the branch pipe connection.

33. Why do we provide High Point Vent (HPV) and Low Point Drain (LPD) in piping?
Answer: HPV – For removing Air during Hydro-test.
LPD – For draining water after conducting Hydro-test.

34. What do you mean by Jacketed Piping?

Answer: - 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.

35. What is the minimum distance to be maintained between two welds in a pipe?
Answer: - The thumb rule is that the minimum distance between adjacent butt welds is 1D. If
not, it is never closer than 1-1/2". This is supposedly to prevent the overlap of HAZs. Minimum
spacing of circumferential welds between centerlines shall not be less than 4 times the pipe wall
thickness or 25 mm whichever is greater.

36. What do you mean by IBR and which lines comes under IBR purview?
Answer: - IBR: Indian Boiler Regulation Act.
Steam lines with conditions listed bellow comes under IBR purview : –
• Lines for which design pressure is 3.5 kg/sq. cm and above.
• Line size above 10” having design pressure 1.0 kg/sq. cm and above.
• Boiler feed water lines to steam generator, condensate lines to steam generator and flash drum.

37. What are Weldolet and Sockolet? And where they are used?
Answer:-W eldolet and Sockolet are basically self-reinforced fittings. Weldolet is used for Butt weld
branch connection where standard tee is not available due to size restrictions and the piping is of
critical / high-pressure service. Sockolet is used for socket welding branch connection, which require
reinforcing pad.

38. What is the MOC for Superheated high pressure Steam Lines?
Answer:-A 335 Gr. P I / P 11, Composition: Cr. – ½ Mo (P1) / 1¼ Cr. – ½ Mo (P11)

39. What is the normal upstream and downstream straight length of orifice flow meter?
Answer: - Upstream - 15D Downstream - 5D
51. During fabrication you observed that one small crack has appeared on a fresh plate, what type of
measure you will take to obtain desired quality with minimum wastage?
Ans: First identify the exact length of crack by DP test. Drill on the end point to resist further crack.
Remove the crack portion by cutting the strip.

52. What is the minimum thickness of pipe that requires stress relieving to be done as per B31.3?
Ans: 19 mm thickness.

53. What is the diff. between Thermostatic and Thermodynamic Steam Trap?
Ans: Thermostatic Trap is actuated by Temp differential and is economic at steam pressure less than
6 PSI. It is operated by the movement of liquid filled bellows or by bimetal element, which may get
damaged by Water Hammer. Thermodynamic traps are most suited to applications where the pressure
downstream of trap is always less than about ½ the upstream pressure. These are suitable for pressure
higher than 8 PSI. Water hammer doesn’t affect it.

54. What is the Code for Sour Service?

Ans: Code for Sour Service is NACE MR–0175), NACE: National Association of Corrosion
Engineers.

55. What are Glandless Piston Valves? Where these are used?
Ans: Glandless piston valves are maintenance free valves used in the steam service.

56. What is the objective of stress analysis?

Ans: 1. To ensure that the stresses in piping components in the system are within allowable limits
2. To solve dynamic problems developed due to mechanical vibration, fluid hammer, pulsation, relief
valves, etc
3. To solve problems associated due to higher or lower operating temperature such as a)
Displacement stress range b) Nozzle loading on connected equipments c) Pipe displacements d)
Loads & moments on supporting structure

57. How much should be the pressure for Hydro-Test?

Ans: Hydro test pressure should be calculated as follow except as provided against point no-4.
1. 1.5 Times of Design Pressure.
2. For a design temperature above the test temperature, minimum test pressure can be calculated as:
Pt = (1.5 X P X St) / S
Where: -
Pt = Minimum Test Pressure. P = Internal design pressure.
St = Allowable stress at test temperature.
S = Allowable stress as design temperature. (See SE in table A-1 or S in table B-1/2/3).
3. If a test pressure as per above would produce a stress in excess of the yield strength at test temp.
the test pressure may be reduced to maximum pressure that will not exceed the yield strength at test
temp.
4. If the test pressure of piping exceeds the vessel pressure and it is not considered practicable to
isolate piping from vessel, the piping and vessel may be tested together at test pressure of the vessel
when approved by owner and provided the test pressure for vessel is not less than 115% of piping
design pressure adjusted for temperature as per point no 2.

58. How do you calculate the pipe spacing?

Ans: Pipe Spacing (mm) = (Do + Dt) / 2 + 25mm + Thickness of Insulation (mm).
Where: D0 = OD of Small size Pipe (mm), Dt = OD of Flange of Large size Pipe (mm).

59. How do you calculate the width of Pipe rack?

Ans: W = (f X n X s) + A + B. Where,
f: Safety Factor
= 1.5 if pipes are counted from PFD.
= 1.2 if pipes are counted from P&Id.
n : number of lines in the densest area up to size 450 NB
= 300 mm (estimated average spacing)
= 225 mm (if lines are smaller than 250 NB)
A: Additional Width for –
• Lines larger than 450 NB.
• For instrument cable tray / duct.
• For Electrical cable tray.
s: 300 mm (estimated average spacing)
: 225 mm (if lines are smaller than 250 NB)
B: future provision = 20% of (f X n X s) + A

60. Which fluid is used in Heat Exchanger in shell side and tube side?
Ans: Generally corrosive fluid is used from the tube side (as tube can be easily replaced) and cleaner
fluid is used from shell side. Sometimes Hot fluid is also used from the shell side.

61. What is Reynold’s number and what is the value of this up to which the flow is laminar?
Ans: It’s a dimensionless number to classify the nature of flow - Re= avd / f
Where: Re = Raynold’s no. a = Density of fluid. D = diameter of Pipe.
V = average velocity of fluid. F = Viscosity of fluid.
Flow is laminar up to Re = 2100

62. Give some Examples for occasional Loads.

Ans: Wind, wave & earthquake

63. What are the steps involved in stress analysis (or any stress package carries out)?
Ans:1. Identify the potential loads that the piping system would encounter during the life of the plant
2. Relate each of these loads to the stresses and strains developed
3. Get the cumulative effect of the potential loads in the system
4. Decide the allowable limits the system can withstand without failure as per code
5. After the system is designed to ensure that the stresses are within safe limits

64. How do you carry out Estimation?

Ans: 1. Input from Bid:
• P&Id, Line list, Temperature, Pressure.
• Overall Plant Layout and Piping corridor plan.
• Scope of work and the Specifications for the Job.
• Specifications for materials like PMS and VMS.
2. Value Addition:
• Items like Valves, Flanges, Specialty items, Reducers can be estimated from P&Id.
• Length of Pipes, Elbows, Width of Pipe Rack can be estimated by referring P&Id and Overall Plot
Plan.
• No of Tires (on rack) can be estimated by referring the spacing required for pipes and also the space
available.
• MTO for Steam Traps, Valves (for Vent and drain) can be calculated by using Thumb Rules.
3. Loads:
• Hydro Test Loads: Can be estimated by assuming all the Pipes (on a grid) empty except some
bigger size lines filled with Water.
• Actual Operating Loads: Gas lines to be considered as empty and rest of the lines to be considered
as filled with the Fluid (which they are suppose to carry in operating condition).
The load which ever is higher from above two cases should be referred for structural loading.

65. What are the different types of stresses that may get generated within pipe during normal
operation?
Ans: Axial Stresses (Tensile / Compressive), Shear Stresses, Radial Stresses, Hoopes Stresses.

66. How are the loads classified in stress analysis package?

Ans: 1. Sustained Loads 2. Occasional Loads 3. Displacement Loads (Self limiting stresses due to
thermal effects)

67. What are the Inputs for stress analysis of a piping system?
Ans: A) Pipe Size Fluid Temperature C) Pipe Material D) Model
E) Design pressure F) Insulation Thickness G) Specific gravity H) Friction coefficient.

68. What are the sources of sustained loads generated in piping system?
Ans: a. Pressure b. Dead weight of Pipe and attachments
Sustained load is calculated as
Weight of Pipe with Fluid + Pressure load + Load due to springs W+P1

69. How do you calculate the operating load?

Ans: W+P1+T1, T1 – Load due to thermal expansion

70. Mention some of Primary Loads (Have their origin in force)

Ans: Dead Weight, Pressure, forces due to relief or blow down, force due to water hammer effects.

71. Mention some of secondary Loads (Have origin in displacement)

Ans: • Force on piping due to tank settlement
• Vessel nozzle moving up due to expansion of vessel
• Pipe expansion or contraction
• Vibration due to rotational equipments

72. What is desired life cycle for Piping in operation?

Ans: Desired life cycle for Piping in operation is 20 Years (7000 Cycles). The normal no. of cycles
for which the displacement or thermal stresses are designed is 7000 cycles.

73. What is the failure theory subscribed under ASME B31.3?

(A) Maximum principal stress theory (Rankines Theory)
(B) Maximum Shear Theory
(C) Tresca Theory Ans: (A)
74. What are the types of failures encountered in Piping?
Ans: A. Catastrophic Failure B. Fatigue Failure

75. Select the failure stress range for fatigue failure due to thermal expansion as per B31.3.
(A) (1.6Sc+1.6Sh) f (B) 0.78 Sh (C) (1.25 Sc+0.25Sh) f (D) Sc+Sh
Ans: (C)
Sc and Sh = Basic Allowable material stress in cold & hot conditions respectively.
f = is the stress range reduction factor(1 for 7000 cycles)