Piping QC Course of Aramco & SABIC Part-1

This article is about Piping QC Course of Aramco, SABIC and other International oil and gas companies. Course series is developed for Engineers, Supervisors and QC professionals based on international standards and codes.

Piping QC Course

1. Which American institute standards does piping engineer refer?

The American Society of Mechanical Engineers (ASME) is the primary standard organization that piping engineers often refer to for designing, fabricating, and inspecting piping systems. The ASME Boiler and Pressure Vessel Code (BPVC) Section VIII Division 1 and Section IX are commonly used for pressure vessel and piping design, while the ASME B31 series of codes cover various aspects of piping design, construction, and inspection, including B31.1 for power piping, B31.3 for process piping, B31.4 for pipeline transportation systems for liquid hydrocarbons and other liquids, and B31.8 for gas transmission and distribution piping systems.

Other standards organizations such as the American Petroleum Institute (API), American Society for Testing and Materials (ASTM), and American Welding Society (AWS) also provide relevant standards and specifications that may be referenced by piping engineers depending on the specific industry and project requirements.

2. Explain the post weld heat treatment?

Post weld heat treatment (PWHT) is a controlled heating and cooling process that is applied to welded joints or structures after they have been welded. It involves heating the welded area to a specific temperature and holding it at that temperature for a certain period of time, followed by controlled cooling. The purpose of PWHT is to modify the microstructure of the weld and surrounding base metal to achieve desired mechanical and metallurgical properties.

There are several reasons why PWHT may be performed:

1. Stress Relief: Welding can introduce residual stresses into the material, which can lead to distortion or cracking. PWHT helps to relieve these stresses by allowing the material to expand and contract uniformly, reducing the risk of deformation and cracking.
2. Increase the Strength: PWHT can improve the strength and toughness of the weld and base metal. By subjecting the material to specific temperatures, it can undergo phase transformations and grain growth, resulting in a stronger and more ductile structure.
3. Hardness Control: Some materials, such as certain high-alloy steels, can experience increased hardness in the heat-affected zone due to rapid cooling during welding. PWHT can help reduce this hardness and improve the material’s machinability and resistance to brittle fracture.
4. Hydrogen Diffusion: Welding processes can introduce hydrogen into the weld, which can cause hydrogen-induced cracking. PWHT can help in diffusing and removing the trapped hydrogen from the weld, reducing the risk of cracking and improving the integrity of the joint.
5. Reduce the risk of cracking.

3. What are the piping inspector responsibilities?

As a piping inspector, the responsibilities typically include:

1. Material Receiving Inspection (MRI): Inspecting incoming materials, such as pipes, fittings, valves, and flanges, to ensure they meet the specified requirements, including dimensions, material grade, and documentation.
2. Ensuring Compliance with Approved Procedures and ITP: Verifying that construction activities follow the approved welding procedures, inspection and test plans (ITP), and applicable codes and standards. This includes reviewing and validating the qualifications of welders, welding procedures, and inspection techniques.
3. Pipe Fit-up Activities: Monitoring and inspecting the fit-up of pipes, fittings, and other components to ensure proper alignment, joint preparation, and overall quality of the weld joints. This involves verifying the accuracy of dimensions, alignment, and joint clearances.
4. QC Records and Reports: Documenting and maintaining quality control (QC) records and reports related to inspections, non-conformities, and corrective actions. This includes recording inspection findings, test results, and maintaining a comprehensive record of the construction and inspection activities.
5. Line Checking: Conducting visual and dimensional inspections of completed piping installations to verify compliance with the approved drawings, specifications, and applicable codes. This involves checking for proper pipe supports, alignment, clearance, and overall quality of the installed piping system.
6. Hydro Testing Activities: Overseeing and inspecting hydrostatic testing activities, including reviewing the test procedures, verifying test pressures, monitoring the test duration, and inspecting for any leakage or failure during the test. This ensures the integrity and pressure tightness of the piping system.
7. Reinstatement Activities: Inspecting and verifying the proper reinstallation and reassembly of piping systems after hydro testing, including the reinstallation of valves, instruments, insulation, and other components. This ensures that the piping system is restored to its operational condition.

4. After what time Calibration of relief valves, temperature records and pressure gauges?

According to SAES-A-004, the calibration intervals for relief valves should not exceed one week. This means that relief valves need to be calibrated at least once every week to ensure their proper functioning and reliability.

For pressure gauges and pressure recorders, the calibration interval should not exceed one month. This means that these devices should undergo calibration at least once every month to maintain their accuracy and reliability in measuring pressure.

It is important to adhere to these specified calibration intervals as per SAES-A-004 to ensure the safety and effectiveness of the relief valves, pressure gauges, and pressure recorders used in industrial processes. Regular calibration helps identify any deviations or inaccuracies in these devices and allows for timely corrective measures to be taken.

5. What is quality?

Quality refers to the standard or level of excellence of something when compared to similar things. It is a measure of how well a product, service, or process meets or exceeds the expectations and requirements of customers or stakeholders.

6. What is quality Assurance?

Quality assurance (QA) is a systematic approach or set of activities implemented to ensure that a product, service, or process meets or exceeds predetermined quality standards. It involves monitoring and evaluating various aspects of quality throughout the entire lifecycle, from design and development to production, delivery, and customer satisfaction.

7. What is quality control Procedure?

A quality control procedure is a documented set of instructions or guidelines that outlines the specific steps and activities to be followed in order to ensure the quality of a product, service, or process. It provides a systematic approach for conducting quality control activities and serves as a reference for individuals involved in quality assurance and quality control.

The content and structure of a quality control procedure may vary depending on the industry, organization, and specific requirements. However, some common elements typically included in a quality control procedure are:

1. Objective and scope: Clearly defining the purpose and extent of the quality control procedure.
2. Responsibilities and roles: Identifying the individuals or departments responsible for performing quality control activities and their respective roles and responsibilities.
3. Documentation requirements: Specifying the types of documents, records, or forms to be used for documenting quality control activities, including inspection reports, test results, and non-conformance reports.
4. Inspection and testing procedures: Describing the methods, techniques, and equipment to be used for inspecting and testing the product or process to ensure compliance with quality standards.
5. Acceptance criteria: Defining the predetermined criteria or standards that must be met for a product or process to be considered acceptable or conforming to quality requirements.
6. Non-conformance management: Outlining the procedures for identifying, documenting, and addressing non-conformities or deviations from quality standards, including corrective and preventive actions.
7. Records and reporting: Describing the requirements for maintaining and organizing quality control records, as well as procedures for reporting quality control results to relevant stakeholders.

8. What is weld map?

A weld map is a document or drawing that provides detailed information about the weld joints in a particular project or structure. It is typically created during the planning and design phase of a welding project and is used as a reference throughout the fabrication and construction processes.

9. What is LBE?

LBE stands for “Logbook Entry.” LBE refers to the process of documenting violations, inspection observations, comments, job clarifications, recommendations, and other relevant information in the inspection logbook on construction sites. The inspection logbook serves as a means of communication with the SAPMT (Site Area Project Management Team) and helps maintain a record of non-compliance, inspection findings, and important details related to the project.

The purpose of the LBE is to document any violations observed against the requirements of project documents, company standards and procedures, or applicable codes. It also serves as a platform to record inspection observations, provide comments or recommendations, and clarify any job-related information. This includes specifying the location of the observed violations on the jobsite, facilitating clear communication and understanding between the inspection team and the SAPMT.

By maintaining an inspection logbook with LBEs, project stakeholders can track and address non-compliance issues, ensure adherence to project requirements, and promote accountability and transparency in the construction process. The logbook entries can also serve as a valuable reference for future inspections, audits, or reviews.

10. What are the general requirements for test manifold and fittings?

The general requirements for test manifold and fittings include:

1. Pressure Testing: The pressure testing manifold should undergo a separate pressure test to ensure its integrity. The pressure test should be conducted at a pressure that is at least 1.2 times the system test pressure.
2. Pressure Rating: The pressure rating or design of the components of the test manifold, including isolation valves, pipe nipples, and fittings, should exceed the system test pressure by a minimum of 20%. This ensures that the components can withstand the higher pressure during the testing process.
3. Blow Down Valve: A blow down valve of adequate pressure rating should be installed in the test manifold. This valve allows for the safe depressurization of the system after the testing is complete.
4. Pressure Rating of Test Components: All test piping, fittings, and hoses should be designed or have adequate pressure ratings that match or exceed the system class or test pressure. This ensures that the components can handle the pressure without any failure or leakage.
5. Isolation Devices: Paddles, spectacle blinds, or other fabricated test items used to isolate test sections should have a minimum code class rating that is equal to or higher than the systems under test. This ensures proper isolation and containment during the testing process.