1. What are the main Duties / Responsibility of the piping inspector?

Ans- QA/QC Inspector shall be ensure that all the works are carried out as per IFC (Issued For
Construction) Drawings, Project specification and standards and he has also co-ordinate with the
client QC Inspector for inspection.
Material receiving inspection → Storage & preservation → Cutting, assembly & fit-up →
Pre-welding inspection → Visual inspection of socket & threaded joints → Pneumatic test for
reinforcing pad → Pickling & passivation → Database reporting → Visual inspection of completed
spools → Piping pre-inspection & spool erection → orifice flange inspection → Pipe support
inspection → Verification of slope → Internal cleanliness → Valve installation → Piping flange joint
inspection → Pre-test punch listing → Hydro testing → pre-commissioning.
2. Describe the difference between QA & QC?
• Quality Control is the operational techniques (Inspection, Examination & Testing) that are used to
fulfil requirements for quality. Quality Assurance is the system of action and planning needed to
provide confidence that a Product or Service will satisfy quality requirements
3. What are the Piping and Welding Inspector requirements?
Piping One Inspector per twenty five (25) workers
Welding One Inspector per ten(10) workers
Welding One Inspector per eight(8) workers (alloy)

DRAWINGS

4. What is a P&ID??
Ans-P&ID means PIPING AND INSTRUMENTAION DIAGRAM.
It shows the piping layout & detailed notes related to piping and instrumentation.
5. What is isometric drawing? What type of information do you get from Isometric drawings?
Ans- isometric detailed piping system or line drawing with reference to construction and material
requirement. (IFC - Issued For Construction Drawings).
Line routing, Line orientation, Northing, easting & elevation, Bill of
material, Insulation type, NDT requirement, Revision status, Material class, Design, operating &
testing temp/pressure, paintsystem, slope, Service details, flow direction, support details, notes.
6. How can you identify an ISO in a P&ID?
ANS- Line no. , service, instrument, equipment and slope.
7. What is a PIP? What kinds of information & requirement are found in pip?
Ans- Process industry practices.Its details requirement for fabrication in industry practices. These
are often the basis for SA standards.Example- PIP P NO. 1CB2S01 (Piping material specification)
8. What is piping line designation?
A specification name in “Alphanumeric” designation describe the future of a piping system.
9. Line class 103CS3C is listed on the Isometric Drawing. Explain each________
1 03 CS 3 C

Raised face Flange rating 300 Carbon steel Crossonallowance Service details

STANDARDS &CODES
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
10. What is Specification/Code/Standards?
➢ Ans- A specification is a guide line to assure the minimum quality standard are met.
➢ Code is a rule or law in which an item or product to met. Exp- AWS(American welding
Society),API(American Petroleum Institute)
➢ Standard is a level of quality to be tested of an item or product.Exp- ASTM (American
Society forTesting&material ).
11. Which American institute standard does piping engineer refer?
A. The American Petroleum institute (API).
B. The American Iron & Steel institute (AISI).
C. The American Society for Testing and materials (ASTM).
D. The American National standard institute (ANSI).
E. The American welding society (AWS).
F. The American Water Works Association (AWWA).
G. The American Society for Mechanical Engineers (ASME).
12. What is the different ASME 31 code for pressure piping?
A. ASME B31.1 - Power piping(Power Piping: piping typically found in electric power
generating stations, in industrial and institutional plants, geothermal heating systems, and
central and district heating and cooling systems).
B. ASME B31.2 - Fuel Gas Piping.
C. ASME B31.3 - Process piping(This Code prescribes requirements for materialsand
components, design, fabrication, assembly, erection,examination, inspection, and testing of
piping & This Process Piping(B31.3)have been developed considering piping typically
found in petroleum refineries; chemical, pharmaceutical, textile,paper, semiconductor, and
cryogenic plants; and related processing plants and terminals.).
D. ASME B31.4 - Pipeline Transportation system for liquid hydrocarbon & other liquid(piping
transporting products which are predominately liquid between plants and terminals and
within terminals, pumping, regulating, and metering stations;).
E. ASME B31.5 - Refrigeration Piping.
F. ASME B31.8 - Gas transmission & distribution piping system(This Code covers the design,
fabrication,Installation, inspection, and testing of pipeline facilities used for the
transportation of gas. This Code also covers safety aspects of the operation and maintenance
of those facilities).
G. ASME B31.9 - Building services piping.
H. ASME B31.11 - Slurry transportation piping system.
10. Which American standardis reffered for selection of following piping lement?
A. Flange B. Butt-weld fittings C. Gasket D. Socket & Threaded Fittings
E. Valves F. Pipes
A- Flanges
I ASME B16.1 - Cast iron pipes flange & flangefittings.
II ASME B16.5 - Carbon Steel pipes flange & flange fittings. (up to24”)
III ASME B16.47- Large diameter steel flange. (above 24”)
B- Butt Weld fittings
I ASME B16.9 – Steel Butt welding fittings.
II ASME B 16.28- Butt- Welded short radius elbow & returns bend.
C- Gasket
I ASME B16.20 – Metallic gasket for pipes flange- spiral wound, Octagonal ring joint &
jacketed flanges.
II ASME B 16.21 –Non Metallic gasket
D- Socket & Threaded
I ASME B 16.11 – Forged Steel socket welding & Threaded fittings.
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
 E- Valves
I ASME B`16.10 – Face to Face & End to End Dimension of valves.
II ASME B 16.34 – Flanged & butt-weld ends steel valves ( pressure & Temp.ratting)
Except- Ball , plug & Butterfly valves.
F – Pipes
I ASME B36.10M - Welded & Seamless wrought steel pipes.
II ASME B36.19M – Stainless Steel pipes.
11 . 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.
I. ASME Section IX : - Welding and Brazing Qualification.
12.What is the ASTM code for the …………..
A. Pipes………….
I. Carbon Steel : - ASTM A53 Gr. A/B, ASTM A106 Gr. A/B/C, ASTM A333 Gr.1/Gr.6
II. Alloy Steel :-ASTM A335 Gr.P1/P2/P5/P7/P9/P11/P12/P22.
III. Stainless Steel :-ASTM A312TP304/TP304L/TP304H/TP308/TP310/TP316/TP316L/
TP316H/TP317/TP321/TP321H/TP347/TP347H/TP348/TP348H.
IV. Nickel Steel :-ASTM A333Gr.3/ Gr.8.
B. Wrought Iron fittings ……….
I. Carbon Steel :-ASTM A234Gr.WPA/B, ASTM A420 Gr.WPL6.
II. Alloy Steel :-ASTM A234 WP1/WP5/WP7/WP9/WP11/WP12/WP22.
III. Stainless Steel :-ASTM A403 WP304/WP304L/WP304H/WP309/WP310/WP316/
WP316L/WP316H/ WP317/WP321/WP321H/WP347/WP347H/WP348.
IV. Nickel Steel :-ASTM A420WPL6/WPL8.
C. Forged Fittings ……………
I. Carbon Steel :-ASTM A181. ASTM A105, ASTM A350 LF1/2.
II. Alloy Steel :-ASTM A182F1/F2/F5/F7/F9/F11/F12/F22.

III. Stainless Steel :-ASTM A182F6/F304/F304L/F304H/F310/F316/F316L/F316H/F321/

F321H/F347/F347H/F348.
IV. Nickel Steel :-ASTM A350 LF3, ASTM A522.
D. Cast Fittings………………….
I. Carbon Steel :-ASTM A216, ASTM A352 LCB/C.
II. Alloy Steel :-ASTM A217 WC1/WC6/WC9/C5/C12.
III. Stainless Steel :-ASTM A217 CA15, ASTM A296 CA15, ASTM A351 CF8/CF3/CH20/
CK20/CF 8M/CF 3M/CF 8C/HK40.
IV. Nickel Steel :-ASTM A352LC3.

E. Plates…………………………..
I. Carbon Steel :-ASTM A285, ASTM A515, ASTM A516.
II. Alloy Steel :-ASTM A387 Gr.2/Gr.5/Gr.7/Gr.9/Gr.11/Gr.12/Gr.22.
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
 III. Stainless Steel :-ASTM A240 TP410/TP405/TP430/TP304/TP304L/TP309/TP310S/
TP316/TP316L/TP317/TP321/TP347/TP348
IV. Nickel Steel :-ASTM A203 Gr.D/Gr.E, ASTM A353.
B. Tubes…………………….
I. Carbon Steel :-ASTM A178/179/192, ASTM A334 Gr.1/6.
II. Alloy Steel :-ASTM A161T1, ASTM A213T1/T2/T5/T7/T9/T11/T12/T22.
III. Stainless Steel :-ASTM A213
TP304/TP304L/TP304H/TP310/TP316/TP316L/TP316H/
TP317/TP321/TP321H/TP347/TP347H/TP348/TP348H
IV. Nickel Steel :-ASTM A334Gr.3/Gr.8
13. What is NCR, CAR, DR? ?
• NCR- CONTRACTOR shall issue Non-Conformance Reports (NCRs) for all violations by the
CONTRACTOR, subcontractors, manufacturers and/or suppliers to Contract requirements
and COMPANY approved CONTRACTOR quality plan(s), inspection & test plans, and
procedures. CONTRACTOR shall submit a copy of each NCR to the Company Representative
within 48 hours of issue.
• 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.
PIPES& SUPPORTS

14. What is piping & pipeline?

Ans- Piping is the system which is used to transport the medium or services one point to another
pointwithin the boundary or battery limit.Pipeline is the system which is used to transport the
medium or services one destination to anotherdestination beyond the boundary line, Generally
pipeline is underground.
UG- Underground (Cross country pipeline).
AG- Above ground (If pressure is less and no safety problems).
15. What type of codes and standards (PIPE) do you use as a piping inspector?
Ans- ASME B31.1, ASME B31.3, ASME B31.4, ASME B31.8
16. What is a Material List or Material Take-Off Sheet (MTO)?
• Details of materials used in construction of Isometric.
17. How the pipe fittings are classified based on end connections?
Ans- Pipe fittings are classified based on end connection as: -
» Socket weld fittings » Screwed end fittings. » Beveled end or Butt weld fittings.
» Spigot socket fittings » Buttress end fittings
18. What is material receiving inspection?
Ans- Match physical condition in field to service condition shown on Drawings/Hardware lists
• Specification and marking/color-coding & PMI
• Identification of grade by ASTM spec listed on dwg/bolting list will give clear reqmts.
• Identification of fittings and flanges by correct ratings, sizes, class, schedules as marked on
fittings & mill certificates.
• For the correct Scheduling of Pipe, by a Vernier Caliper and ensure piping is within tolerances.
19. How will you store the material in the storage area?
➢ All material shall be handled with care during fabrication and installation to prevent
damage.
➢ End protectors on pipes , Flange, weld bevel , threads and socket ends shall b firmly
attached.

MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»

 ➢ End bevel protectors shall remain on pipes and fittings while in storage protectors shall not
damage internal or external.
➢ Flange face and threads shall be protected from rust by applying suitable rust preventives.
➢ After completion of pre-fabrication, the spool be cleaned and free from weld spatters arc
strikes and foreign materials on outside and inside of pipes.
20. Name the different types of Service Conditions?
Ans- NFS: - Normal services-Not subjected to D,M or high pressure fluid services.
Category M-Toxic and Flammable
Category D- Non Flammable , Non Toxic and non damaging to human tissues (temp. -29c to 186 c)
High pressure fluid services Based on class 2500 rating for specified design temp.and material
group (ASME-B31.3)
21. Up to what temperature the carbon steel materials shall be used?
Ans- Carbon steel materials shall be used for temperature up to 425C.
22. Which material is used for temperature above 426C?
Ans- Alloy steel materials shall be used for temperature above 426C.
23. Where the ERW spiral & longitudinal pipes are used?
Ans- Use depends upon the availability of pipes. Nothing functional difference.
24. Where the ERW & Seamless pipes are used?
Ans- Above 18” ERW pipes are used. Below 18” seamless pipes are used. Seamless pipes can
sustain Higher temperature& pressure.
25. What is the main use of ASTM A53 & A106 Gr.B pipes?
Ans- ASTM A53 pipes are mainly used for utility services whereas A106 Gr. B pipes are used for
higher Pressure &temperature services.
26. Which type of material is used for corrosive fluid?
Ans- Stainless steel materials shall be used for corrosive fluid.
27. What is tack weld?
Ans- Tack weld is temporary weld to maintain joint alignment . All tack weld shall be made by
qualified welders. Tack thickness is 3.2 – 4.8 mm and lenth is 12.5- 25.4mm.
28. How do you check piping for the correct schedule?
Ans- Verify pipe material thickness by Vernier at end or UT on surface or stenciling done by
manufacturer (visual) or heat number, traceability by MTC of product.
29. From which side of pipe will you take a branch connection?
Ans- When fluid is Gas, Air or Steam and Cryogenic Service – Topside And When Fluid is Liquid –
Bottom Side.
30. For the verification/traceability of materials what are the different procedures to be used?
 PMI –Positive Material Inspection
 Marking & Color Coding
 Spools are stamped, stenciled, or clearly marked with a permanent marking method, properly
color-coded and uniquely identified, labeled& traceable to Isometric Drawings.
31. What is the standard mill tolerance for piping 2’’ & less?
Ans- 12% of nominal wall thickness.
32. What is the tolerance for ovality of piping?
Ans- 5% of nominal diameter at any cross section other than weld end & 3% at weld.
33. What type of connection is acceptable for a 24” header, 12” branch?
Ans- Weldolet or welded branch with reinforcement pad .
34. What is the basic difference between pipe specification A106 Gr.A/Gr.B/Gr.C?
Ans- Difference is due to the carbon contains…
1- ASTM A 106 Gr.A - 0.25%
2- ASTM A 106 Gr.B - 0.30% 3- ASTM A 106 Gr.C - 0.35%
35. Difference between carbon steel and stainless steel?

MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»

 ➢ CS: - Low cost, no chromium content, suitable for non-corrosive service upto 350 degree C,
max carbon 0.3%.
➢ SS: - Contains more than 12% Cr, 0.08% C, Suitable for corrosive, cryogenic, High temp
services, costly.
36. What is the minimum sized piping that can be installed on pipe racks?
Ø1”
37. Write types of piping supports?
➢ Guide support- A support restricting the movement perpendicular to pipe axis,But axial
movement is allowed.
➢ Anchor Support- A support fixing the pipe completely.
➢ Hanger Support- A support hanging the piping.
➢ Spring support – A resilient support which allows vertical movement.
➢ Resting support- A simple support bearing the pipe weight only.
➢ Shoe support- Shoe support is used to support the system at certain elevation from
ground level for lesser dia (<12’’).
38. Give an example of unique support details that allow piping freedom of movement for thermal
expansion.
Ans- Guide support, Moving saddle support, Expansion Ballons, Shoe Support, Spring Loaded.
39. How to cut a SS pipe and what are the things to be ensured before cutting?
Ans- SS pipes cutting by grinding or plasma cutting providing internal protection from spatter, slag.
40. What are the tolerance to be followed in piping?
Ans- The tolerance for axial dimension, face to face, centre to face and location of attachment shall
be + - 3mm maximum.
41. Weep hole size shall be drilled for dummy pipe support will be ________mm
Ans- Weep hole shall be located near base plate for all vertical dummy pipe support & near run
pipe at 6’O clock position for horizontal dummy.
42. What is color coding?
➢ Marking of piping bulk materials to identify the Material.
43. How do you control material in fabrication shop?
1) All materials shall have material specification and grade stamped or stenciled & clearly
marked with permanent marker.
2) All materials heat no. will be made traceable to MTC from approved vendor & no material
substitution will be done withut proper approval from company.
3) All materials shall be stored & stacked separately as per material grade.
4) Heat no. shall be transferred before cutting onto pipes that have to be cut.
5) All materials shall be color coded as per traceability procedure
44. How do you verify (name several items to check) that the correct piping material is used?
Ans- Material specification, Pipe size, schedule, length, flange face rating, olet size rating,
threaded/socket weld type, MTC, PMI report.
45. How many threads can be visible after seal welding threaded joints?
Ans- No, should cover all exposed threads.
46. What is the gap requirement for socket welds for new construction?
Ans- 1.5mm-3mm (ASME B31.3 fig 328.5.2C)
47. What is dead leg and explain?
➢ 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.
48. Draw the fit-up joint of system…………….

MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»

 FLANGES & FITTINGS
49. Kinds of flange...............
Ans-a) Based on pipe attachment………..
Slip-on, Socket weld, Screwed, Lap Joint, Weld Neck, Blind Reducing Integral
b) Based on pressure temperature rating…….
150#, 300#, 400#, 600#, 900#, 1500#,2500# (# - Class)
c) Based on facings………
Flat face, Raised face, RTJ (Ring type Joint), Tonge& groove, Male &
female
50. How do you identify fittings and flanges?
Ans- By material classification, size, rating, joint type (lap, socket, threaded, butt), face..
51. What are the important activites to be checked during flange alighnmentfitup.
➢ Missalignment
➢ Flange face
➢ Rotation of flange(+2.4mm)
➢ Tilt of the flange(shall not exceed 1.6 mm fromsquare position.)
➢ Flange face thickness, gasket thickness( +- 1.6mm)
➢ Combnation of vertical , horizontal and rotational offset +- 3.2 mm
52. Why weep hole is provided in pad?
Ans- Reinforcing pad of welded branch connection shall bepneumatically leak tasted with air
at 1.75 bar through a min. of one 6mm tapped went hole / weep hole for venting and
examined for leaks using a soap solution at a reduced pressure of 0.2 to 0.35 bar. The
6mmtapped vent shall not be locatedin the crotch of the branch.
53. What are the different b/w A punch & B punch?
➢ List of unfinished work or unmatched item according to drawing and specification before
hydrotest.
➢ A- To be done before hydrotest.
➢ B- tob done before mechanical completion.
54. What are Weldolet and Sockolet? And where they are used?
Ans- Weldolet is used for Butt weld branch connection where standard tee is not available due to
sizeRestrictions and the piping is of critical / high-pressure service. Sockolet is used for socket
weldingBranch connection, which require reinforcing pad.
55. Where blind flange is used?
Ans : It is used with view to future expansion of the piping system, or for cleaning, inspection etc.
56. What is the difference between torqueing CS and SS bolting?
➢ CS: - Yield strength High; Torque value High
➢ SS: - Yield strength low; Torque value low
57. What are jackscrews and when are they required?
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
 Ans- They are located at flange connection to facilitate maintenance and removal of spectacle and
orifice plates to facilitate maintenance.
58. What is often overlooked during orifice flange fabrication?
➢ Grinding butt welds orifice, machined smooth face,Orientation of taps and flush.
59. What NDT methods are required during orifice flange installations?
Ans- Visual and PT/MT
60. What are the main things you will check before Bolt torquing?
Ans- Size of bolt, Calibration of torque wrench, Manual /hydraulic require, Lubricant, Friction
factor for threaded lubricant, torque value,
61. What is preferred location for vent &Drain?
Ans : AT the top section of drum at the end opposite the steam outConnection and Drain Must be
located at the bottom section of drum.
VALVES & GASKETS

62. What are the types of Valves?

Gate valve, Globe valve, Butterfly valve, Needle valve, Check valve, Control valve, Knife gate
valve, Based on function……………
➢ non-return valve- Gate valve, Ball valve, Plug valve, Butterfly valve
➢ isolation valve- Globe valve, Needle valve, Butterfly valve
➢ regulation valve- Check valve
➢ special purpose valve- Knife gate valve, Foot Valve.
63. How the valves are classified based on end connection?
➢ Valves are classified based on end connection as: -
➢ Screwed ends.
➢ Socket ends.
➢ Flanged ends.
➢ Butt weld ends.
➢ Wafer type ends.
➢ Buttress ends.
(End connection means arrangement of attachment of the valve with the equipment or the
piping.)
64. How the valves are classified based on its method of operation?
Ans- Valves are classified based on its method of operation as: -
A. Self- operated valves--
B. Operated valves. →Mainly the check valves are self-operated and all other valve types comes
under operated valves.
65. What are butterfly valve types?
Ans : Double flange type, wafer lug type and wafer type.
66. What are types of check valve?
Ans : Lift check valves and swing check valves.
67. Write inspection items during valves installation?
1. Valve type correct at location
2. Valve test certificate
3. Valve tag as per P&ID
4. Valve direction of flow as per P&ID
5. Gasket bolts as per isometric & type
6. Handle direction
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
 7. Chain wheel installed
8. Valve flange face condition
68. What are the steps in selection of valve?
Ans : 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.
69. What pressure tests are carried out on valves?
Ans : Shell-hydrostatic, seat-hydrostatic, seat-pneumatic

70. What materials are used for construction of valves?

Ans : Cast iron, bronze, gun metal, carbon steel, stainless steel, alloy carbon steel, polypropylene
and other plastics, special alloys.
71. What is trim?
Ans : Trim is composed of stem, seat surfaces, back seat bushing and other small internal parts that
normally contact the surface fluid.
72. How many types of gaskets do you know?
➢ Full face (Asbestos) - Most commonly use.
➢ Spiral wound metallic(This gasket recommended for high temperature/pressure
application
➢ Ring type
➢ Metal jacketed
➢ Inside bolt circle
73. What kinds of the inspection required during Gasket Installation?
Ans- First Visual inspection of gasket free from any physical damage, Check gasket material as per
drawing & specification, Size, Rating,

TESTING

74. Define Hydrostatic Test, Pneumatic Test, Pressure Test, Service Test
 Hydrostatic test-A pressure test use for the leak test of a loop or system by the medium of
water with pressurization.
 Pneumatic Test- A pressure test use for the leak test of a loop or system by the medium of air
or other non-flamable gas.
 Pressure Test- A test conducted to piping or equipment by subjecting it to an internal
pressure using liquid or gas to ensure strength or tightness of the system at the test pressure.

75. What we check in water analysis and its value for CS & SS.
Ans – In water analysis we check PH value and chloride contents of water .
➢ For CS the PH value is 7.5 + - 5 &chloride <250ppm.
➢ For SS the PH value is 10.5 + - 0.5 & chloride <50ppm.
76. What we check in water analysis and its value for CS & SS.
Ans – In water analysis we check PH value and chloride contents of water .
➢ For CS the PH value is 7.5 + - 5 &chloride <250ppm.
➢ For SS the PH value is 10.5 + - 0.5 & chloride <50ppm
77. Where we attain test pressure and why?
Ans- We attain test pressure at highest pressure Gage because due to gravity, effect every 10m
height 1 bar pressure reduce.
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
 HYDROTEST MANIFOLD AND TEST LINE ARRANGEMENT

➢ Test Duration- The test pressure shall be maintained for a minimum of 30 minutes.
➢ Testing equipment-Manifolds, pressure gauges, relief valves, test blinds, pressure hoses, air
compressor, hand pump, torque wrench and hand tools etc. shall comply with safety
requirements.
➢ All gauges shall have a range such that the test pressure is within 30 to 70% of the full range.
➢ Manifold used in the test shall be separately pressure tested to at least 1.2 times the system
test pressure but not less than the discharge pressure of the pump used for the pressure
testing.
➢ Minimum Two Pressure gauges and relief valve to be installed during hydro test.
➢ Relief valve calibration period would beOne week
78. What is test limit?
Ans- Test limit is the boundary up to which the pressure testing is conducted.
79. What is punch list?
• List of unfinished work or unmatched item according to DRWG and specifications before
Hydrotest. A - To be done before Hydrotest B - To be done before MC C - To be done after MC
but before commissioning D - To be done before Plant Acceptance
80. What are the formats/ reports in a hydro test package?
 Table of contents
 Safety Instruction sheet for critical services
 Flow Chart of Test Packages
 Pre-Test Punch List
✓ Test Procedure & Pressure Test Diagram
✓ Related P&ID and Isometric Drawings
✓ Line List
✓ Pre-test Punch List Checklist I Form
 QA/QC Documentation of the system to be tested.
✓ Weld Inspection Summary Sheet
✓ NDE Record
✓ Isolation valve Test Certificates

MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»

 ✓ Flange Joint Inspection Report
✓ Internal Cleanliness
 Pressure Testing
✓ Verification of Temporary gaskets
✓ Verification of Test blind rating
✓ Checklist for Verification of system readiness for Testing
✓ Calibration certificates for Pressure gauge
✓ Calibration certificates for Pressure & Temperature recorders
✓ Test manifold Certificate
✓ Water Analysis (test medium)
✓ Pressure Test Report Form
✓ Re-Instatement or Final Assembly Inspection (Final Punch List)
81. What are the points to be checked for the Reinstatement?
➢ Flushing & hydro test complete and documented as accepted.
➢ lAll test vents & drains plugged and seal welded
➢ ines drained and lay-up per customer approved specification
➢ Valves (400 SS Trim) tested in-line removed, cleaned, & lubricated for Ambient lay-
up
➢ Jacking screws, process blinds (spectacles, spades, etc) correctly installed
➢ Spring Hangers & components (bellows, etc) adjusted per mfg instructions.
➢ Weep holes plugged with heavy grease (reinforcement pad air test complete)
➢ Chain wheel operators installed
➢ All instruments, control valves & check valves reinstalled in correct flow position
➢ Restriction orifice/flow elements installed
➢ Relief Valves are Pop tested/calibrated, tagged and SAP approved/installed
➢ All Temporary Test Components (spools, test blinds, gaskets etc) are removed
➢ Correct bolts/gaskets are installed and torqued.
➢ Check Valves and internals reinstalled (Internal Cleanliness & gasket check)
➢ All Start-up items installed (strainers, filters, other items restricted from test.
➢ Chemical Cleaning completed and documented
➢ Final Line Check complete & meets all special process specs. See Spec Check.

82. What are the general criteria checked for line-checking?

➢ All joints (flange, threaded, welded or mechanical seals) are left exposed for visual leak
detection during the strength test.
➢ All permanent flange joints were inspected, gasket mat'l verified & properly torqued.
➢ Drains shall be provided at all low points of the piping system.
➢ Vents and drain valves, both temporary and permanent, conforms with the piping class or
rating.
➢ Supports are installed. Additional temporary support may be installed as required.
➢ Expansion joints and spring hangers or spring supports are provided with temporary
restraints.
➢ Drains are provided immediately above check valves (vertical lines)
➢ All threaded joints up to the first block valve of hydrocarbon pipeline are seal welded.
Thread engagement has been verified & accepted.
MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»
 ➢ The pressure testing manifold is separately pressure tested to at least 1.2 times the system
test pressure but not less than the discharge pressure of the pump used for the pressure
testing.
➢ Pressure gages and pressure recorders are calibrated within one (1) month before the test.
Check stickers at the time of the test.
➢ Line compliance with Isometrics:
A) Correct Materials utilized grade/schedule (Bill of Mat'ls)
B) Correct flange and fittings rating
C) Construction tolerances.
83. Some applicable LINE CHECK PUNCH…….
Ans- Check following points…..
1) Completion of welding inspection reports, NDT , PWHT, WPS
2) Inspection of all Supports and weep holes, orifice Flanges & Pads
3) Gasket types, Material, Size,
4) Valve type, Material, Size and Flow directions
5) Bolts and nuts, Types, material, Size and tightness
6) Vent & Drain, Location, Size, Orientation
84. When you will apply 24 hours recorded hydro test?
Ans- If for justifiable safety reasons the UG line must be backfilled, then the joints shall remain
exposed during testing, otherwise the test shall be a 24 hour recorded test.
85. What are the different types of hardness tests carried out?
Ans- Brinell hardness Test, Rockwell Hardness Test,Vickers Hardness Test.

86. What are Three Types of Destructive Examination?

Ans- Impact Test, Bend Test, Tensile Test
87. Relief valve calibration would be..........
Ans- one week.
88. Difference between RT & UT?
➢ RT: - Uses X-ray or Gamma ray to detect discontinuities reveals mostly volumetric. Planar
defects & subsurface defects not detectable easily
➢ UT:-Uses ultrasonic beam to detect discontinuities reveals both planar & volumetric
defects, but size & exact location of defects are not easily identifiable. Possible only on
materials that do not detract UT waves.
89. Difference between PT & MT?
➢ MT:- Only Applicable for ferromagnetic materials & able to detect both surface & sub
surface discontinuities, compare to PT examination it takes less time for testing &
inspection; Applicable for large temp range.
➢ PT:- Applicable for both ferromagnetic & non ferromagnetic materials & able to detect only
surface discontinuities, It requires more time; Applicable for small temp range.
➢ DOCUMENTS
90. What is inspection test plan (ITP) ?
Ans- It is mandatory item in quality plan it’s to guide and assure the quality in a specific types of
works in a specific sequence of QC activity steps.
91. What 4 types of inspection point found in ITP?
Ans- i) Hold ii) Witness iii) review iv) surveillance
92. What reference will be found in ITP (inspection test plan) ?
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Ans- Standard & Codes, Quality Control Procedure (QCP), Quality Control Form (QCF)
93. Explain the defences between the 4 types of inspection point?
a) Hold - QA/QC organization shall be notified of the timing of inspection or test in advance.
Inspection or test shall not be carried out without the QA/QC organization representative in
attendance.
b) Witness - Witness- QA/QC organization shall be notified of the timing of Inspection or test in
advance. However, the inspection or test shall be performed as scheduled if the QA/QC
organization representative is not present.
C) surveillance- QA/QC organization to monitor work in progress without notice from Construction
Organization.
d) Review - Review and approval of documents
94. What is the quality control procedure (QCP)?
Ans- It is documentation details the specification, steps needed to full-fill the QC activity in the ITP.
95. What is quality control form (QCF)?
Ans- It is a written documentation detailing a specific activity in the ITP & QCP.
96. What is material list or material takes off sheet?
Ans- It details of material used in construction of piping, using with isometric.
97. What is Schedule ‘Q’?
• Schedule Q stands for Owner’s minimum quality requirements for Contractor/Subcontractor
quality system.

MD. HABIB NAUKHEZ «GULF ASIA SAUDI ARAB»