Piping QC Course of Aramco & SABIC Part-3

This article is about Piping QC Course Part-3 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. Do u know about Ethane and Methane Gases?

Ethane: Ethane is a hydrocarbon with the chemical formula C2H6. It is a gaseous component of natural gas and is often extracted along with methane. Ethane is used as a fuel, both for heating and as a petrochemical feedstock. It is commonly used in ethylene production, which is a key building block for various plastics and chemicals.
Methane: Methane is the simplest hydrocarbon with the chemical formula CH4. It is the primary component of natural gas and is formed through natural processes, such as the decomposition of organic matter. Methane is a potent greenhouse gas and plays a significant role in climate change. It is also a valuable source of energy and is used as a fuel for heating, electricity generation, and various industrial processes.

2. What is the relation between Brinell Hardness No. and Rockwell Hardness No.?

The relationship between Brinell Hardness Number (BHN) and Rockwell Hardness Number (HRC) is not a direct conversion but can be approximated for some materials. The specific relationship between the two hardness scales can vary depending on the material being tested. However, a general approximation can be made that 22 HRC is roughly equivalent to 238 BHN.

It’s important to note that the Brinell and Rockwell hardness tests measure hardness using different methods. The Brinell test involves applying a known load to the surface of a material using a hardened steel ball and measuring the diameter of the resulting indentation. The Rockwell test, on the other hand, measures the depth of penetration of an indenter under load and does not rely on the measurement of an indentation diameter.

3. What is the difference between torquing CS & SS bolting?

The difference between torqueing carbon steel (CS) and stainless steel (SS) bolting is primarily influenced by the material properties and the corresponding torque requirements.

Carbon Steel (CS):
- Yield Strength High: Carbon steel generally has higher yield strength compared to stainless steel. It means that carbon steel can withstand higher levels of stress before permanent deformation occurs.
- Torque Value High: Due to the higher yield strength, carbon steel bolts typically require higher torque values during installation to achieve the desired clamping force. The higher torque helps to ensure proper tightening and prevent loosening under operational loads.
Stainless Steel (SS):
- Yield Strength Low: Stainless steel has lower yield strength compared to carbon steel. Stainless steel is typically chosen for its corrosion resistance rather than its strength.
- Torque Value Low: Due to the lower yield strength, stainless steel bolts generally require lower torque values during installation. Excessive torque can cause deformation or damage to the stainless steel material, so it is important to use the recommended torque values to avoid overtightening.

4. Name the different types of Service Conditions?

There are various types of service conditions that can be categorized based on their specific requirements. Some commonly recognized service conditions include:

Normal Service (Category M): This refers to standard operating conditions where the equipment or system is not exposed to extreme temperatures, pressures, or corrosive substances. It represents typical service conditions without any specific additional requirements.
High Pressure Fluid Service (Category D): This service condition involves handling fluids under high pressures, which may require additional considerations in terms of material selection, design, and construction. It is necessary to ensure the equipment and components can withstand the elevated pressure and provide reliable performance.
Corrosive Service: This service condition involves the presence of corrosive substances that can degrade or damage the equipment or system. It may require the use of corrosion-resistant materials, protective coatings, or other measures to prevent corrosion and ensure the longevity of the equipment.
High Temperature Service: This service condition involves operating at elevated temperatures, which can affect the material properties and performance of the equipment. Components and materials used in high-temperature service must be able to withstand the thermal stresses and maintain their mechanical integrity.
Low Temperature Service: This service condition involves operating at extremely low temperatures, which can cause brittleness and affect the toughness of materials. Specialized materials and designs are required to ensure the equipment can withstand the low temperatures without failure.
Sour Service: Sour service conditions involve the presence of hydrogen sulfide (H2S) gas or other sulfur compounds, which can be highly corrosive and pose a risk to the equipment’s integrity. It requires the use of suitable materials, coatings, and corrosion-resistant measures to prevent sulfide stress corrosion cracking and maintain safety.

5. Differentiate B 31 codes for pressure Piping?

The B31 codes published by the American Society of Mechanical Engineers (ASME) provide guidelines for different types of pressure piping systems. Here’s a differentiation of the B31 codes for pressure piping:

A. ASME B31.1 – Power Piping: This code covers piping systems used in power plants, including boilers, heating systems, and other power generation facilities.

B. ASME B31.2 – Fuel Gas Piping: This code applies to piping systems that transport fuel gases, such as natural gas, propane, and butane, for use in industrial, commercial, and residential applications.

C. ASME B31.3 – Process Piping: This code covers piping systems used in chemical plants, refineries, and other processing facilities. It includes both pressurized and non-pressurized systems for the transportation of various fluids.

D. ASME B31.4 – Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids: This code is specific to pipelines used for the transportation of liquid hydrocarbons, such as crude oil and petroleum products, as well as other liquids.

E. ASME B31.5 – Refrigeration Piping: This code addresses the requirements for piping systems used in refrigeration and cooling applications, including both mechanical and absorption refrigeration systems.

F. ASME B31.8 – Gas Transmission and Distribution Piping Systems: This code pertains to the design, construction, and operation of piping systems for the transmission and distribution of natural gas and other fuel gases.

G. ASME B31.9 – Building Services Piping: This code covers piping systems within buildings, including heating, cooling, and sanitary systems, as well as compressed air, vacuum, and other utility piping.

H. ASME B31.11 – Slurry Transportation Piping Systems: This code is specific to piping systems used for the transportation of solid-liquid mixtures, often referred to as slurry, in industries such as mining, dredging, and mineral processing.

6. What is Accepted Miss Alignment for fit-up inspection?

The accepted misalignment for fit-up inspection can vary depending on the applicable code or standard being followed. However, as per the information provided:

i. 1.5 mm: This is the accepted misalignment for fit-up inspection according to ASME B31.3, which is the code for process piping. It means that the maximum allowable misalignment between two pipe ends during fit-up is 1.5 mm.

ii. 1.6 mm: This value is not specific to fit-up inspection but rather refers to the maximum permissible mismatch or misalignment between two components in a weld joint as per ASME Section IX. ASME Section IX provides guidelines for welding and brazing qualifications. The 1.6 mm value likely corresponds to the maximum allowable mismatch or misalignment during the preparation and alignment of the components before welding.

7. What are maximum diameter allowed in threaded joint in hazardous service?

In hazardous services, as per SAES-L-110, the maximum size allowed for threaded connections is 1½ inches for standard fittings and valves. However, if a larger size is required for maintenance purposes, a maximum size of 2 inches may be allowed. It’s important to note that these specifications may vary based on the specific project requirements and applicable codes and standards. It’s always advisable to refer to the project specifications and relevant guidelines for accurate and up-to-date information regarding the maximum diameter allowed in threaded joints in hazardous service.

8. How you will manage Preservation?

To manage preservation effectively, the following steps can be taken:

Pipe storage: Ensure that pipes are not stored directly on the ground. Instead, they should be placed on mounds or sleepers to prevent damage. This helps protect the pipes and their coatings.
Stack pipes carefully: When stacking pipes, ensure that they are stacked in a manner that avoids damage to the pipes or their coatings. Proper alignment and support should be provided to maintain the integrity of the pipes.
Fittings and valves: Store fittings and valves in shipping crates or on racks to protect them from damage. This helps maintain their condition and prevents any potential issues during storage.
End protection: Attach firm end protectors to pipes, flanges, weld bevels, threads, and socket ends. This provides an additional layer of protection against potential damage or contamination during storage.
Stainless steel protection: If dealing with stainless steel materials, take extra precautions to protect them from exposure to seawater splash during shipment and storage. This helps prevent corrosion and maintain the quality of the stainless steel.

It’s important to refer to relevant standards and guidelines such as SAES-H-200 and SAES-L-350 for specific requirements and best practices regarding preservation. Additionally, consider implementing proper inventory management, inspection, and maintenance procedures to ensure the preservation of materials throughout their storage period.

9. How will you manage the material traceability?

To effectively manage material traceability, the following steps can be taken:

Material identification: Before cutting the pipe material, ensure that all relevant information is transferred onto the cut piece. This includes essential details such as Heat Number (Heat No), ID Number, Manufacturer Code, Grade, and Thickness. This information helps establish the traceability of the material.
Permanent marking system: Utilize a permanent marking system to transfer the material information onto the cut piece. This can be achieved through methods such as stamping, laser engraving, or etching. Ensure that the marking is clear, legible, and resistant to fading or removal during subsequent handling or processing.
Documentation and record-keeping: Maintain accurate documentation and records of the material traceability information. This includes recording the unique identifiers, such as Heat Number, associated with each piece of material. This documentation serves as a reference for tracking and verifying the origin and characteristics of the material throughout the fabrication process.
Material control procedures: Implement stringent material control procedures to ensure that the marked pieces are properly identified, stored, and tracked. This may involve maintaining a centralized material storage area, establishing clear labeling systems, and implementing inventory management practices to prevent mix-ups or misplacements.
Quality assurance checks: Conduct regular quality assurance checks to verify the accuracy and completeness of the material traceability information. This may involve periodic inspections of the marked pieces, verification against accompanying documentation, and cross-referencing with supplier records to ensure consistency and reliability.

10. If you are going to weld pipe with header how to identify piping specification?

To identify the piping specification when welding a pipe with a header, it is important to have permanent markings on both the branch pipe and header indicating their respective material specifications. Additionally, if a reinforcement pad is required, the header pipe should be used. These measures ensure clear identification and adherence to the specified material requirements during the welding process.

11. What is INCR when will you raise INCR?

INCR stands for Internal Non-Conformance Report. It is a document raised when an internal non-conformance or deviation is identified within a project. The purpose of an INCR is to document and address any violation of project specifications, standards, or codes.

An INCR is typically raised when there is a deviation from the specified requirements or when an error or non-conformance is identified during inspections, audits, or quality control processes. It serves as a formal record of the non-conformance and is used to initiate corrective actions and ensure that the issue is addressed and resolved appropriately.

Raising an INCR helps in maintaining the quality and compliance of the project by identifying and rectifying any deviations from the required standards. It enables proper documentation, investigation, and resolution of non-conformances, ensuring that the project meets the necessary specifications, standards, and codes.

12. What is Material Receiving Inspection?

Material Receiving Inspection is the process of inspecting and verifying the received materials or equipment against the specified requirements and documentation. It is an essential step in quality control to ensure that the materials or equipment received meet the necessary standards and specifications.

During the Material Receiving Inspection, the following activities typically take place:

Verification of documentation: The relevant documents such as drawings, material take-off, material requisition, purchase requisition, purchase order, packing list, material test certificate, vendor inspection report, inspection release note, and delivery note are checked for accuracy and completeness.
Physical inspection: The received materials or equipment are visually inspected to ensure they are free from any damage, defects, or discrepancies. This may involve checking the quantity, dimensions, markings, labels, and overall condition of the items.
Verification of material test certificates: The material test certificates provided by the vendor or supplier are reviewed to confirm that the materials meet the required specifications and standards. This includes checking the material grade, mechanical properties, chemical composition, and any other relevant test results.
Compliance with purchase order: The received materials or equipment are compared against the details specified in the purchase order to ensure that the correct items have been delivered.
Documentation and record keeping: The results of the Material Receiving Inspection are documented, including any findings, observations, deviations, or discrepancies. This documentation serves as a record for future reference and may be used for traceability and quality control purposes.

13. What is method of Statement?

A Method Statement is a document that outlines the step-by-step procedure for carrying out a specific task or activity in a safe and efficient manner. It is commonly used in industries such as construction, engineering, and manufacturing where there are higher risk activities involved.

The purpose of a Method Statement is to provide clear instructions and guidelines to workers, contractors, and other stakeholders involved in the project. It serves as a documented plan that ensures the work is performed safely, follows established procedures, and complies with relevant regulations, standards, and best practices.

A typical Method Statement includes the following information:

Title and Scope: Clearly defines the task or activity that will be performed.
Objectives: Outlines the specific goals and objectives of the task or activity.
Responsible Parties: Identifies the individuals or teams responsible for executing the work.
Equipment and Materials: Lists the necessary equipment, tools, and materials required for the task.
Sequence of Work: Provides a step-by-step procedure for carrying out the work, including any specific instructions, precautions, or safety measures that need to be followed.
Risk Assessment: Identifies potential hazards, assesses risks, and outlines control measures to mitigate those risks.
Safety Precautions: Describes the safety procedures, personal protective equipment (PPE) requirements, and emergency protocols to be followed during the task.
Quality Control: Specifies any quality control measures or inspections that need to be conducted during the work.
Environmental Considerations: Addresses any environmental concerns or measures to minimize environmental impact during the task.
References and Attachments: Includes any relevant documents, drawings, or references that support the Method Statement.

14. What is API and ANSI, ASTM, ASME, ISO, PQP, & ITP?

ITP: Inspection & test plan
PQP: Project Quality Planning
ISO: International standard organization
ASME: American society for mechanical engineers
ANSI: American national standard institute
ASTM: American Society for testing materials

15. Explain Dry layup inspection?

Dry layup inspection refers to a method of preserving and protecting equipment or pipelines during periods of non-operation or maintenance by using various drying techniques. The goal is to remove moisture and prevent corrosion, ensuring the equipment remains in good condition and ready for use when needed.

During dry layup, different drying media can be employed, such as hot dry air, controlled dew point inert gas, drying chemicals like glycol or methanol, or a combination of these techniques. These media are introduced into the equipment or pipelines to absorb any moisture present and create a dry environment.

The process typically involves placing drying media between two pipeline scrapers or using gelled scrapers that contain drying chemicals. These scrapers are then inserted into the pipeline, effectively spreading the drying media throughout the system.

The choice of drying media and technique depends on the specific requirements of the equipment or pipeline being preserved. The objective is to ensure that all moisture is removed to prevent corrosion and damage to the internal surfaces.

Dry layup inspection helps maintain the integrity and longevity of the equipment during periods of non-operation or maintenance. It is an essential part of preservation strategies to protect against the harmful effects of moisture and corrosion, ensuring that the equipment is ready for use when it is put back into service.

Dry layup is based on international standard SAES-A-007.