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Have copies of other applicable piping/hydro standards at Test site, have open book discussion forum with candidate. Allow
candidate time and stress the importance of using Scope & Index when referring to Standards or searching for
references. USE PLANT PIPING CHECKLIST AS REFERENCE FOR TEST & ISO drawing Test
Identify the lowest point elevation on all drawings
Identify any Mark Numbers on drawings (samples given)
Identify any unusual features or items to be removed for hydrotest (orifice flanges, equipment, filters, traps,
Identify any valves requiring field hydrotesting
On each Drawing, list the following at the bottom of the drawing:
Line number
Piping Class
Flange ratings
Gasket types
Any Special Process Requirements (PWHT, NDT, Seal welding, etc) & SAES-W-011 100% requirements such as
SAES-W-011 (Welding)
Pre-Punch Checklist
1. Lay-up procedure and estimated service date has been determined (60-day rule).
2. Line completed and in compliance with SA standards & Isometrics (as built or redlined dwgs available during punching).
3. System boundaries have been clearly identified and temporary blinds have been installed per hydro test diagram.
4. Correct Construction Materials utilized (grade/schedule). PMI reports reviewed/OK. HIC Testing Certs available.
5. Correct rating of materials (flanges, forged fittings). Determine test limitations (psi).
6. Branch reinforcement meets SA standards and piping specifications.
7. Orifice flanges flush, seal welded internally and in correct orientation. NDT (PT) & visual inspection of internals documented and
accepted prior to flange tensioning.
8. Piping installed plumb and level, slope angle correct where required. 50MM minimum clearance can be obtained, especially after
insulation. Dead legs are not within 625mm of structural supports.
9. Weep holes and vent holes in reinforcement and wear pads. Air testing completed, OK.
10. Seal welding of threaded connections completed to the first block valve.
11. Valve types, location and orientation correct. Field hydrotesting report acceptable.
12. Correct bolts installed and identified. Stamping of hardware meets specifications.
13. Temporary gasket locations have been identified for gasket reinstatement on dwgs.
14. Correct gasket type, size and rating. Reports/dwgs for Gasket installation accepted.
Color-coded marking on hardware by QC has identified final torque acceptable.
15. Permanent supports and guides are installed. Temp. supports (if needed) installed.
16. All welding completed and documented, QC reports available.
17. NDT completed and all outstanding repairs completed, accepted and documented.
18. PWHT and hardness testing completed accepted and documented.
19. Water quality analysis requirements for flushing (12 inch and below) and filling are determined and Reports/certs are available.
Chemical additives to flushing and test water for heater coils and headers and other specialty items have been determined.
20. Flushing of lines to 12 diameter with appropriate quality water/chemicals has been performed. Cleaning with air and rags on lines
14 and above has been completed. Flushing Certificate accepted.
21. Check valves and/or flappers removed.
22. Instruments (level gauges, relief valves, control valves, orifices, etc) isolated, gagged and removed as required by SA standards.
23. Strainers, filters and in-line components removed as required by SA standards.
24. High point vents fully opened prior to and during filling to remove air from the system. Low point drain available and identified as
required.
25. Pressure gauges installed (2 minimum), with relief valve calibrated as required for 5% over pressurization.
General Information
What is an Inspection & Test Plan? A mandatory item in the Quality Plan that guides and assures quality in a specific type of work in a
specific sequence of QC activity steps.
What is a Quality Control procedure? A document that details the specific steps needed to fulfill the QC activity in the ITP
What is a Quality Control Form? A written documentation detailing a specific activity in the ITP & QC Procedure
What references will be found in ITPs? SA STDs, Procedures and code references, specifications
What is a specification? A specification is a guideline to assure that minimum quality standards are met
What 4 types of Inspection Action points are found in the ITP? Hold, Witness, Surveillance, Review
Explain the differences between the 4 types of Inspection points? Detail answer and ensure a clear understanding by candidate
What is a P&ID? Piping and instrument Diagram will show the piping layout and detailed notes relating to piping and instrumtation.
What is an SIS? Safety Instruction Sheet that gives full design details related to a piping system or line.
What is a piping system? Describes the specific service or fluid.
What is the piping line class designation? A specific name in alphanumeric designation describes features of a piping system.
Give an example of a line designation from Isometric Drawing? 1CS1P3 = 150# class, Carbon Steel, 1/16 CA, General Hydrocarbon
What is an isometric drawing? A detailed piping system/line drawing with reference to construction and material requirements
What things are found in a Piping Isometric drawing? Line conditions, references to drawings, materials of construction,
continuations, orientation, piping and drawing details and notes, revision control and approval status.
What is a Material List or Material Take-Off Sheet (MTO)? Details of materials used in construction of Isometric.
What is a PIP? Process Industry Practice details requirements for fabrication as Industry Practice. These are often the basis for SA stds
Give an example of a PIP? PNSC 0001, PNSC 0011, PNSC 0021
What kinds of information and requirements are found in PIPs? Common industry practices for manufacture & construction
Name the different types of Service Conditions? Temperature, pressure and fluid type
Material Inspection
Match physical condition in field to service condition shown on ISO/P&ID/SIS
How do you verify (name several items to check) that the correct piping material is used? Mill Cert, heat number, colorcoding & PMI, schedule, rating, Carbon Equivalent value for PREHEAT, diameter, class, grade.
How do you identify fittings and flanges? Correct ratings, sizes, class, schedules as marked on fittings & mill certs
How do you check piping for the correct schedule? Use a Vernier Caliper and ensure piping is within tolerances.
What are the tolerances for physical piping straightness and defects? Check the ASTM or API piping specification.
What is the standard mill tolerance for piping? 87-1/2% (all) to 115% (greater than 2), 120% (2 & less) of nominal
Valves of the correct rating and material. Check materials, CMTRs & trim during Valve Testing (Visual inspection)
Ovality
What is the tolerance for ovality of piping? 1%.
Example: 24 piping is 610mm. One joint can be 610 x 610 (oval), another can be 604 x 616 (1% out & within tolerance). When
matched for fitting, how will internal alignment of piping meet 1.5mm tolerance in SAES-W-011.
Crescent technique for repairing ovality is required (method statement). Crescent is (2) 12mm crescent shaped plates separated by
steel bar center that distributes load and bearing force and increases efficiency, doubles production by and reduces potential damage to
piping. Jacking limits (30 ton maximum for CS, much less for SS) to 25mm max. Cold bending and forming repairs including rolling
thick repads require a method statement and must conform to ASME B31.3. Hammering on steel is not allowed and evidence of
hammer marks is cause for rejection and removal of affected item.
Preheat
Determine Process
1.
SMAW ONLYFollow CE determination values in Drawings and Tables 3, 3A notes of SAES-W-011 for pipe, fitting, and flg.
2.
GTAW or GTAW/SMAWFor field fabrication or repair of carbon steel materials (all ASME P-No. 1 materials, including API
grades up to and including X60), use preheats listed in Standard Drawing W-AE-036451, sheet 1-8
Mill Certs
CE Values
GTAW Process
Heat Input
Combined
Determine Preheat Requirements
Thickness
from Table for GTAW
How can an inspector determine if cold spring exists visually on a flanged section of piping? Visual determination is easy. Close
inspection of flanged connection and any visible deformation, especially in small diameter sections.
When a flange connects to a pump or other equipment, is there any special tolerance involved? Yes, Mfg tolerance.
Piping spacing per AC 036207 and 50 mm rule between all piping and supports (Lessons Learned)
24 clearance from supports dead legs and drains, vents------------ Small diameter , 300MM from grade @ all piping.
Fittings, butt welds, etc, adjacent to hangers, clamps, supports, etc must be spaced to allow freedom of piping movement.
Alternatively, flush gind and NDT can be allowed as long as weld location will not restrict piping movement.
Know clearances listed in Section 5 & AC drawing 036207.
Valves (SAES-L-008)