PIPING INTERVIEW QUESTIONNAIRE

1. What factors to consider for site selection?

Ans : District classification, Transportation facilities, Manpower
availability, industrial infrastructure, community infrastructure, availability
of raw water, effluent disposal, availability of power, availability of
industrial gas, site size and nature, ecology and pollution.

2. What are different standards?

Ans : Most commonly use standards are as follows:
Sr. Standard Description
1. ANSI B18.2 Square and hexagola 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 buttwelding fittings
5. ANSI B16.11 Forged steel socketwelding and threaded fittings
6. ANSI B16.25 Buttwelding ends
7. ANSI B16.28 Short elbow radius and returns
8. MSS-SP-43 Stainless steel buttweld 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 buttwelding ends.

3. What are various temporary closures for lines?

Ans : Line blind valve, line blind, spectacle plate, double block and bleed,
blind flanges replacing a removable spool.

4. Where jacked screwed flange is used ?

Ans : For spectacle discs, one flange is jacked screw flange. This flange
has two jacked screws 180 degree apart which are used to create
sufficient space between flange for easy removal and placement of line
blind or spectacle blind.

5. What is double block and bleed?

Ans : Two valves with bleed ring in between with a bleed valve connected
to the hole of bleed ring.

6. Where blind flange is used ?

Ans : It is used with view to future expansion of the piping system, or for
cleaning, inspection etc.

TOWERS

7. What are crude oil ranges?

Ans : Crude oil BP Range: 100F-1400F, lightest material: Butene below
100F, Heavier materials- upto 800F, Residue above 800F.

8. What is batch shell process?

Ans : feed, heat,condense,heat more,condense, low quality.

9. What are types of towers?

Ans : Stripper, Vacuum tower, trayed, packed towers.

10. What is chimney tray?

Ans : It’s a solid plate with central chimney section, used at drawoff
sections of the tower.

11. What factors to consider while setting tower elevation?

Ans : 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.

12. How to located tower maintenance access nozzles ?

Ans : At bottom, top and intermediate sections of tower, must not be at
the downcomer section of tower and in front of internal piping.

13. How to located feed nozzle ?

Ans : Must be oriented in specific area of tray by means of internal
piping.

14. How to located temperature and pressure instruments ?

Ans : Temperature in liquid space, at downcomer side and pressure in
vapor space, in area except downcomer sector.

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PIPING INTERVIEW QUESTIONNAIRE

COMPRESSORS

1. What are the types of compressors?

Ans : Positive Displacement, Centrifugal and Axial, rotary screw, rotary
vane, rotary lobe, dynamic, liquid ring compressors.

2. What are types of compressor drives?

Ans : Electric motor, gas turbine, steam turbine and gas engine.

3. How Centrifugal compressors work ?

Ans : Highspeed 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?
Ans : 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 ?

Ans : 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 auxillary equipments of compressor?

Ans : 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?

Ans : Gravity and pressurized.

8. What factors to be considered while designing compressor housing?

Ans : Operation, Maintenance, Climate conditions, Safety, Economics.

9. What are the compressor housing design points?

Ans : Floor elevation, building width, building elevation, hook centerline
elevation.

10. What are the types of compressor cases?

Ans : Horizontal split case, Vertical split case.

11. What are compressor suction line requirements ?

Ans : 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?
Ans : 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 interstage line and in
discharge line before block valve.

13. What points to be considered for reciprocating compressor piping

layout?
Ans : 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?

Ans : On ground with no shelter, Open sided structure with a roof,
Curtain wall structure (Temperate climates), Open elevated installation,
Elevated multicompressor structure.

DRUMS

15. What are drum internals?

Ans : Demister pads, Baffles, Vortex breakers, Distribution piping.

16. What are drum elevation requirements?

Ans : NPSH, minimum clearance, common platforming, maintenance,
operator access.

17. What are drum supports?

Ans : Skirt for large drums, legs, lugs, saddles for horizontal drums.

18. What are necessary nozzles for non-pressure vessel?

Ans : Inlet, outlet, vent, manhole, drain, overflow, agitator, temperature
element, level instrument, and steamout connection.

19. What are necessary nozzles for pressure vessel?

Ans : Inlet, outlet, manhole, drain, pressure relief, agitator, level guage,
pressure gauge, temperature element, vent and for steamout.

20. What is preferred location for level instrument nozzles?

Ans : 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 vapor outlet end.

21. What is preferred location for process nozzles on drum?

Ans : Minimum from the tangent line.
22. What is preferred location for steam out nozzle on drum?
Ans : At the end opposite to the maintenance access.

23. What is preferred location for vent ?

Ans : AT the top section of drum at the end opposite the steam out
connecton.

24. What is preferred location for pressure instrument nozzle on drum?

Ans : Must be anywhere in the vapor space, preferable at the top section
of drum

25. What is preferred location for temperature instrument?

Ans : Must be in liquid space, preferably on the bottom section of drum.

26. What is preferred location for drain?

Ans : Must be located at the bottom section of drum.

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PIPING INTERVIEW QUESTIONNAIRE

1. 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.
2. What are functions of valves?
Ans : Isolation, regulation, non-return and special purposes.
3. What are isolating valves?
Ans : Gate, ball, plug, piston, diaphragm, butterfly, pinch.
4. What are regulation valves?
Ans : Globe, needle, butterfly, diaphragm, piston, pinch.
5. What are non-return valves?
Ans : check valve,
6. What are special valves?
Ans : multi-port, flush bottom, float, foot, pressure relief, breather.
7. 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.
8. 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.
9. Which standard specifies trim numbers for valve ?
Ans : API 600.
10. What are wetted parts of valve?
Ans : All parts that come in contact with surface fluid are called wetted
parts.
11. What is wire drawing?
Ans : 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?
Ans : Valve in which the closing operation of valve is achieved by
90degrees turn of the closing element.
13. What pressure tests are carried out on valves?
Ans : Shell-hydrostatic, seat-hydrostatic, seat-pneumatic
14. What are available valve operators?
Ans : Handlever, handwheel, 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?
Ans : Full port design and regular port design, according to type of seat,
soft seat and metal seat.
16. What are ball valve body types?
Ans : Single piece, double piece, three piece, the short pattern, long
pattern, sandwitch and flush bottom design.
17. Why ball valves are normally flanged?
Ans : Because of soft seat PTFE which can damage during welding.
18. What are butterfly valve types?
Ans : Double flange type, wafer lug type and wafer type.
19. What are types of check valve?
Ans : Lift check valves and swing check valves.
20. What are non-slam check valves?
Ans : Swing check valve, conventional check valve, wafer check valve,
tilting disc check valve, piston check valve, stop check valve, ball check
valve.
21. Where stop check valve is used ?
Ans : In stem generation by multiple boilers, where a valve is inserted
between each boiler and the main steam header. It can be optionally
closed automatically or normally.
22. Where diaphragm valves are used ?
Ans : Used for low pressure corrosive services as shut off valves.
23. What is Barstock Valve?
Ans: Any valve having a body machined from solid metal (barstock).
Usually needle or globe type.
24. What is BIBB Valve?
Ans: A small valve with turned down end, like a faucet.
25. What is Bleed Valve?
Ans: Small valve provided for drawing off liquid.

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26. What is BlowDown Valve?
Ans Refers to a plug type disc globe valve used for removing sludge and
sedimentary matter from the bottom of boiler drums, vessels, driplegs
etc.
27. What is Breather Valve?
Ans: A special self acting valve installed on storage tanks etc. to release
vapor or gas on slight increase of internal pressure ( in the region of ½ to
3 ounces per square inch).
28. What is Drip Valve?
Ans: A drain valve fitted to the bottom of a driplet to permit blowdown.
29. What is Flap Valve?
Ans: A non return valve having a hinged disc or rubber or leather flap
used for low pressure lines.
30. What is Hose Valve?
Ans: 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.
31. What is Paper-Stock Valve?
Ans: 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.
32. What is Root Valve?
Ans: 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.
33. What is Slurry valve?
Ans: A knife edge valve used to control flow of non-abrasive slurries.
34. What is Spiral sock valve?
Ans: A valve used to control flow of powders by means of a twistable
fabric tube or sock.
35. What is Throttling valve?
Ans: Any valve used to closely regulate flow in the just-open position.
36. What is Vacuum breaker?
Ans: 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.
37. What is Quick acting valve ?
Ans: 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.
38. What is diverting valve ?
Ans : This valve switch flow from one main line to two different outlets.
WYE type and pneumatic control type with no moving part.
39. What is sampling valve?
Ans : Usually of needle or globe pattern, placed in branch line for the
purpose of drawing all samples of process material thru the branch.
40. What are blow off valve?
Ans : It is a variety of globe valve confirming with boiler code
requirements and specially designed for boiler blowoff service. WYE
pattern and angle type, used to remove air and other gases from boilers
etc.
41. What is relief valve?
Ans : 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.
42. What is safety valve?
Ans : Rapid opening(popping action) full flow valve for air and other
gases.
43. What is foot valve?
Ans : Valve used to maintain a head of water on the suction side of sump
pump, basically a lift check valve with integrated strainer.
44. What is float valve?
Ans : 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.
45. What are flush bottom valves?
Ans : Special type of valves used to drain out the piping, reactors and
vessels, attached on pad type nozzles.
46. What are types of flush bottom valves?
Ans : Valves with discs opening into the tank and valves with disks into
the valve.
47. What are the uses of three-way valve?
Ans : Alternate connection of the two supply lines to a common delivery
vise versa, isolating one safety valve, division of flow with isolation
facility.
48. What are uses of four way valve?
Ans : Reversal of pump suction and delivery, By pass of strainer or
meter, reversal of flow through filter, heat exchanger or dryer.
49. What is metal seated lubricated plug valve?
Ans : A plug valve with no plastic material, where grease is applied to
contacting surfaces for easy operation.
50. What are three patterns of plug valve design?
Ans : Regular pattern, short pattern and ventury pattern.

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51. What is regular pattern plug valve?
Ans : Rectangular port, area almost equal to pipe bore, smooth transition
from round body to rectangular port, for minimum pressure loss.
52. What are short pattern plug valve?
Ans : Valves with face to face dimension of gate valve, as a alternative to
gate valve.
53. What are ventury pattern plug valve?
Ans : Change of section through the body throat so graded to have
ventury effect, minimum pressure loss.
54. What are inverted plug design valve?
Ans : Plug valve with taper portion up of plug. For 8” and higher size.
55. What is pressure balanced plug valve?
Ans : With holes in port top and bottom connecting two chambers on top
and bottom of plug, to reduce turning effort.
56. What are Teflon sleeved plug valve?
Ans : PTFE sleeve between plug and body of valve, low turning effort,
minimum friction, temperature limitation, anti static design possible.
57. What are permasil plug valve?
Ans : Plug valves with Teflon seat instead of sleeves, for on off
applications, can handle clean viscous and corrosive liqiuids, Graphite seat
for high temperature applications. Drip tight shut off not possible.
58. What are eccentric plug valve?
Ans : Off center plug, corrosive and abrasive service, on off action,
moves into and away from seat eliminating abrasive wear.
59. What is dimensional standard for plug valve?
Ans : API 599.
60. What is pinch valve?
Ans : Similar to diaphragm valve, with sleeves of rubber or PTFE, which
get sqeezed to control or stop the flow, Cast iron body, for very low
service pressures like isolation of hose connections, manufacture
standard.
61. What is needle valve?
Ans :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.
62. How to install a globe valve ?
Ans : 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.
63. What are globe valve port types?
Ans : Full port: More than 85% of bore size, Reducer port: One size less
than the connected pipe.
64. What are globe valve disk types?
Ans :Flat faced type for positive shutoff, loose plug type for plug renewal
or needle type for finer control.
65. What are characteristics of globe valve stem?
Ans : Always rising design, with disk nut at the lower end and handwheel
at upper end.
66. What are types of globe valve?
Ans : Angle globe valve, plug type disc globe valve, wye-body globe
valve, composite disc globe valve, double disc globe valve.
67. What is angle globe valve?
Ans : Ends at 90 degree to save elbow, higher pressure drop.
68. Where plug type disc globe valve is used?
Ans : For severe regulating service with gritty liquids such as boiler
feedwater and for blow off service.
69. Where WYE body globe valve is used ?
Ans : In line ports with stem emerging at 45 degree, for erosive fluids
due to smoother flow pattern.
70. What is double disc globe valve ?
Ans : Has two discs bearing on separate seats spaced apart, on a single
shaft, for low torque, used for control valves.
71. What are port types for gate valves?
Ans : Full port and reduced port. Default is reduced bore. Full port has to
be specified in bom.
72. How to close a gate valve ?
Ans :Turn the handwheel in clockwise direction.
73. What is lantern ring?
Ans : It’s a collection point to drain off any hazardous seepages or as a
point where lubricant can be injected, it is in the middle of packing rings.
74. What are types of gate valves?
Ans : Solid plane wedge, solid flexible wedge, split wedge, double disc
paralles seats, double disc wedge, single disc single seat gate or slide,
single disc parallel seats, plug gate valve.
75. What are the types of bonnets?
Ans : Bolted bonnet, bellow sealed bonnet, screwed on bonnet, union
bonnets, A U-bolt and clamp type bonnet, breechlock bonnet, pressure
seal bonnet.

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Choke Valves are specially designed for Oil & Gas well head applications.

Choke Valves are used for surface & sub surface context. They are used for controlling the flow on
production, reinjection and subsurface well heads. The well flow is controlled with Choke Valve. The
purpose of the choke valves serve is to kill the pressure from reservoir and regulate the downstream
pressure in flow lines. In Choke Valve , they allow fluid flow through a small opening designed to kill the
reservoir pressure. The reservoir fluids can contain sand particles Choke valves are designed to handle
erosive service.

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NPSH (Net Positive Suction Head)

The difference between inlet pressure and the lowest pressure level inside the pump is called
NPSH: Net Positive Suction Head. NPSH is therefore an expression of the pressure loss that takes
place inside the first part of the pump housing.
The pressure inside a pump varies from the inlet on the suction side to the discharge port on the
discharge side. In the first part of the pump, the pressure decreases before it increases on the discharge
side to a level higher than the intake pressure.
The difference between inlet pressure and the lowest pressure level inside the pump is called NPSH: Net
Positive Suction Head. NPSH is therefore an expression of the pressure loss that takes place inside the
first part of the pump housing. The size of the NPSH is shown in the figure to the right.
NPSH will cause the lowest pressure inside the pump to decrease below the evaporation pressure of the
pumped liquid, if the inlet pressure is too low. Consequentially, cavitation occurs in the pump, causing
noise and leading to breakdowns.
NPSHR (Net Positive Suction Head Required) is provided in the data material for all pumps. NPSHR
indicates the lowest inlet pressure required by the specific pump at a given flow to avoid cavitation.
Piping QA FLUOR DANIEL
PIPING QUIZ & ANSWERS
Piping QA
1. What is the pipe size range, per Fluor Daniel standard, for pipe spools that are to be shop fabricated?
3” diameter and larger <2.1/2” and larger>
2. What is the pipe size range, per Fluor Daniel standard, for pipe spools that are to be field fabricated?
2” diameter and smaller
3. Define what piping is considered field assembly.
Off-the-shelf components that make-up a piping assembly and do not require cutting and / or
welding
<If no field fabrication is required>
4. Define what piping is considered rack loaded, per Fluor Daniel standard, and what pipe size ranges is
involved.
Piping in the PIPERACK that crosses two or more supports.
3” and larger.
5. All shop fabricated piping spools (mark pieces) are shipped from the fabrication shop in a geometry
that is defined by length, width, and height. Assuming it to be a box, there are two situations that you must
avoid in regard to the box and the mark pieces within. Describe these two situations and describe the
undesirable result if you do not avoid them.
Piece mark must fit within the shipping box otherwise it may not be transported.
Skewed placement of the piece mark within the shipping box could result in crowding out other
piece marks.
<Press fit should be avoided to ensure piece mark fits shipping box>
6. Define a field weld (FW) and when it is used.
Field Weld is made somewhere other than the fabrication shop. Used to connect two mark pieces
(or components) together.
Describe three things you must consider when locating a field weld and why they must be considered.
Accessibility:
The weld must be in a place that is accessible to the welder
Constructability:
The weld must be placed so the constructors can position the piece mark prior to welding.
Size of spool piece to ensure it fits shipping box and can be transported.
Economics:
Made in a location that would lessen or eliminate the need for additional scaffolding.
Piping QA
Self-supporting so temporary supports are not required during construction.
Made on the smaller side of a reducer.
Preferably made in the horizontal
8. Describe a field fit-up weld (FFW) and when it is used.
Field Fit Weld is a weld made somewhere other than the fabrication shop. The fabrication shop
adds additional length of material to the spool piece. This additional length gives the field
variance for adjustment when the location of the connecting point is not known.
<May require field alteration>
9. Per Fluor Daniel standard, what is the construction (fitting type) of:
Pipe size range 2 ½” and larger? Butt-weld
Pipe size range 2” and smaller? Socket Welded
Pipe size range 2” and smaller? Screwed or Threaded
10. What is the minimum (not absolute minimum) distance between welds that Fluor Daniel likes to use?
3 inches
11. What is the absolute minimum distance between welds (used only as a last choice)?
Pipe Size (NPS) Min. distance b/w welds
1/8” 3/16
1 /4” 1/4
3/8" 5/16
1/2" 7/16
3/4" 1/2
1" 11/16
1 1/4" 13/16
1 1/2" 15/16
2" 1 3/16
2 1/2" 1 9/16
3" 1 3/4
3 1/2" 2
4" 2 1/4
5" 2 3/4
Half the outside diameter of pipe (6” and larger)
12. What do the letters HAZ mean?
Heat Affected Zone
Kavimagi Page 3 of 13 13. What is the effect of the HAZ?
Weakens the material (pipe wall)
Piping QA
14. How far from the weld, is the HAZ?
¼” or 1”
15. Why do piping designers care about the HAZ?
If two HAZ’s overlap each other it may result in failure of the pipe
16. When is the HAZ considered in threaded construction?
When threaded connection is seal welded
17. What are the pressure ratings of forged steel Socket Weld Fittings?
3000#
6000#
18. What are the pressure ratings of forged steel threaded fittings?
2000#
3000#
6000#
19. What are the pressure ratings of malleable iron threaded Fittings?
150#
300#
20. What are the pressure ratings of cast iron threaded fittings?
125#
250#
List the wall thickness for pipe, starting with the thinnest wall to the heaviest wall:
Carbon Steel & Alloy steel (13 schedules)
Sch 10,
Sch 20,
Sch 30,
Sch 40,
Std Wt,
Sch 60,
Sch 80,
XS,
Sch 100,
Sch 120,
Sch 140,
Sch 160,
XXS
Stainless Steel (4 schedules)
Sch 5S,
Sch 10S,
Sch 40S,
Sch 80S
Piping QA
22. What is the technical term used for the sag in pipe caused by gravity and how does affect piping
design?
Deflection
It govern the amount of pipe span
<causes leakage at flanges>
<causes stress on pipe>
23. If one 4” carbon steel pipe is schedule 40 and another 4” carbon steel pipe is schedule 80….
Which has the greater sag and why?
4" sch 40 has the greater sag because its wall thickness is less than the wall thickness of the sch
80 - the thinner the wall, the shorter the length the line will span.
Which weighs more and why?
4" sch 80 because it's wall thickness is more than that of the sch 40, more material= more weight
Which requires fewer support point and why?
4" sch 80 because it's thicker wall allows it to span farther, reducing the number of times support
is needed.
<more rigid / stiffer>
24. Pipeway/Piperack loading/stuffing drawings.
Which lines qualify for loading/stuffing
Lines 3" and larger that cross two or more pipe supports.
Why is loading/stuffing done (the advantages)?
It provides an early start for construction.
It reduces the amount of ground area taken by storage of pipe
25. Line size changes
When is swage used for a line size change?
When reducing from or to socket welded or threaded construction on at least one end.
When is a butt-weld reducer used for a line size change?
When reducing from or to butt welded construction on both ends.
When/where do you use eccentric, bottom flat swages or reducers and why?
In any horizontal run of pipe, that has two or more supports within that run.
To maintain a common bottom of pipe elevation for the two line sizes.
When/where do you use eccentric, top flat swages or reducers and why?
Used at the final reduction on a pump end suction line.
Piping QA
To prevent cavitation of the pump.
When/where do you use eccentric, side flat swages or reducers and why?
Used when two equipment connections are so close that the two connecting, adjacent lines
interfere with each other after the line size change.
If they are side flat toward each other, the lines may clear.
<Used on vertical pipe to maintain common back of pipe>
When do you use butt-weld reducing 90 degree elbows and why?
Normally it is not FLUOR piping practice to use reducing butt-weld 90 degree reducing elbows.
If they are used, it will be where a size change is required and there is insufficient space available
for an elbow and a reducer or an elbow and a reducing flange - or if the client requires it.
Why would a short radius butt-weld 90-degree ell be used?
To adhere to FLUOR piping practice 000 250 2650 where it states 10" and larger elbows at a nozzle
of a vertical vessel are short radius (decreases the "l" dimension so a standard vessel pipe
support can be used).
<Space limitations>
Why would a short radius butt-weld 90-degree ell not be used?
It is easy to "lose" a short radius elbow if shipped to the jobsite or fabrication shop with long
radius elbows of the same size.
Additional tracking effort may result to keep the short radius elbow from being "lost" or used
inadvertently where it was not intended to be used.
Often the use of a short radius elbow requires client approval, or process review, or stress
approval - all taking time that would not be taken for a long radius elbow.
<when pressure drop is a concern – short radius elbow has more pressure drop.
26. What is a trimmed ell and when is it used?
A trimmed elbow is a butt weld 90 degree long radius elbow that is cut and beveled to match the
original bevel, the resulting change of direction is no longer 90 degrees but is a non-standard
angle suited for the piping geometry requiring it.
Trimmed elbows are used when a line routing must have a change of direction that is not satisfied
by a 90 or 45-degree elbow or by elbows being rolled or offset.
Describe a stub-on connection and when it is used?
A stub-on connection is a branch connection made to a header without the use of fittings - the
connection is made from pipe. the branch pipe is contoured (fish-mouthed) to match the curvature
of the header to which it will be connected (a fillet weld). A hole is made in the header that should
match the inside diameter of the branch pipe. The stub-on connection is not the same
construction as a
Piping QA
stub-in connection - but the resulting geometry is the same as a stub-on. Stub-on connections are
generally 90 degree, but can be other angles.
Branch table
28. Describe a stub-in connection and when it is used?
Fluor piping does not use the stub-in construction. A stub-in connection is the same as a stub-on
connection as far as the resulting geometry and material goes, but the construction is different.
The branch pipe may or may not be contoured to match the inside diameter of the header - if it is
not, then it is a straight cut. The header will have a hole cut in it that nearly matches the outside
diameter of the branch pipe. The branch pipe is inserted into the hole in the header and is
connected via a fillet weld. Like the stub-on, the stub-in is generally 90 degree and other angles
are possible.
Client request
29. Describe a reinforcing pad and when it is used?
Reinforcing pads are made from the same size, wall thickness and material as the pipe header to
which they are welded.
Reinforcing pads are used at stub-on and stub-in branch connections and occasionally at support
trunnions when specified by the stress sketch, if required per the line list or if required per the
branch chart in the piping material specification.
30. What document (name and 5-diget number) does a piping designer refer to determine what branch
connection to use?
Piping material specification
31. What are the two documents (not specifications) that will tell a piping designer when branch
reinforcement is required?
Stress sketch
Line list
<Branch chart>
32. What is the pipe size range in which all flanges are standard?
24 inch and smaller
33. What is the pipe size range in which all flanges are not?
26 inch and larger
List the information to be placed on the isometric that will fully describe a non-standard flange and what is
the reason we would include this information?
Reason for including the information.
To guarantee, without failure, the flanges are compatible.
Information to be placed on ISO.
Piping QA
ANSI number or other industry number (API, MSS)
Size
Rating
Facing
Outside diameter of flange
Bolt circle diameter
Bolt hole diameter
Number of bolt holes
Flange bore
Material
Bolt hole orientation
Flange thickness
35. What facing is required on a steel flange that will be bolted to a cast iron flange and why?
Flat Face
There is a risk of breaking the cast iron flange if it is bolted to a raised face steel flange.
36. What are two pressure ratings of cast iron flanges and what are the ratings of compatible steel
flanges?
125# Cast iron to 150# steel,
250# cast iron to 300# steel.
37. How is cast iron flange attached to steel pipe?
The flange is threaded on.
38. What are two reasons for using lap joint construction?
To reduce the cost of components - a less expensive carbon steel flange may be used in lieu of a
stainless steel flange.
Flange can be rotated to aid in bolthole alignment.
39. What fitting (not flange) must be used in lap joint construction and what are the names of two the
types of these fittings?
Stub end <Lap joint stub end>
ANSI & MSS
40. What is the difference between a van stone flange and a slip on flange?
The shape of the contact point where the face of flange contacts the lip of the stub end is rounded
on the van stone flange and is square on the slip on flange.
41. In lap joint construction, how many welds are on a slip flange?
Zero.
In lap joint construction, how many welds are on a van stone flange?
Zero.
Piping QA
43. List the types of steel flanges.
Weld neck
Slip on
Threaded
Socket welded
Van stone
Reducing
Expanding
Blind
<Lap joint>
<Orifice>
<Slip on reducing>
44. List the faces of steel flanges.
Raised face
Flat face
Ring joint
Tongue and groove
Male & Female
45. List the ratings of steel flanges.
150#
300#
400#
600#
900#
1500#
2500#
46. How are flange boltholes oriented on flanges on vertical line?
Boltholes straddle the north-south-east-west flange centerlines
47. How are flange boltholes oriented on flanges on horizontal line?
Boltholes straddle the vertical and horizontal flange centerlines
Valves are used for three basic flow functions (not control valves or pressure safety valves). List three
functions and the type of valve used for each function.
Function
BLOCK THROTTLE CHECK
<Start / stop> <prevent back flow>
Type
GATE/BALL/PLUG/BUTTERFLY <needle> – BLOCK
GLOBE <plug or butterfly or needle> – THROTTLE
CHECK – CHECK
Piping QA
49. What are the two styles of butterfly valves in flanged piping and their associated type of bolt?
A. WAFER - STUD BOLT/MACHINE BOLT
B. LUG TYPE - CAP SCREW
50. What are the two main styles of check valves in flanged piping and their associated type of bolt?
A. SWING - STUD BOLT/MACHINE BOLT
B. WAFER/SPLIT DISC - STUD BOLT/MACHINE BOLT
51. Not using a ladder or platform, how is a valve operated that is:
Too high - CHAIN OPERATOR
Too low - EXTENSION STEM
52. What is the minimum clearance between the outside diameter of a valve hand wheel and the next
obstruction?
Three inches
53. If a valve hand wheel projects into an aisle way, to what elevation must the bottom of the hand wheel
be raised above HPFS (High Point Finished Surface) or platform?
6'-6" plus or minus 3" (6'-3" to 6'-9")
54. What manually operated item is added to a valve that is either to large or is to high a pressure to
operate and how do you know it will be required (give the name of the specification)?
- A GEAR OPERATOR
- MATERIAL SPECIFICATION
55. If a pressure safety valve has a block vale upstream of it, what note must appear on the P&ID relating
to this block valve and why?
• CSO (car sealed open) or LO (locked open).
• To help ensure that the valve is open during normal plant operation so that if a condition
resulting in overpressurization occurs, the valve is open and the relief valve can function
properly.
56. If a pressure safety valve downstream of it, what note must appear on the P&ID relating to this block
valve and why?
• CSO (car sealed open) or LO (locked open)
• To help ensure that the valve is open during normal plant operation so that if a condition
resulting in overpressurization occurs, the valve is open and the relief valve can function
properly.
57. The piping downstream of a pressure safety valve that discharges to a closed system must be routed
in a specific direction, what is this direction and why?
• Routed in such a manner as to free drain into the collection header.
So no liquid can collect and possibly obstruct the free release of pressure.
Piping QA
58. If a pressure safety valve has a downstream block valve, excluding accessibility, how is the vale hand
wheel to be oriented and why?
• The handwheel is to be located within the lower 180 degrees - horizontal to horizontal.
<horizontal or downward>
• This is to prevent the disc falling into the port if the stem corrodes - thereby closing the valve
and preventing the free release of pressure.
59. If a pressure safety valve has a rupture disc upstream, what is the purpose of the rupture disc?
The rupture disc isolates the relief valve from the potentially corrosive atmosphere of the system
to be protected - protecting the stem from corrosion.
60. When a pressure safety valve discharges vertically to atmosphere, what must be added to the lowest
part of the tail pipe, what size is it and why is it added?
• A weep hole.
• 1/4" diameter
• To drain the collection of rain water in the open tailpipe that if allowed to collect could obstruct
the free release of pressure
61. What is the end preparation for the end tailpipe of a pressure safety valve discharging vertically to
atmosphere and why?
• Square cut/plain end
• There is no need to bevel or 45-degree chamfer because it is unnecessary cost.
62. What is the formula for calculating the free standing (unguided) length of a tailpipe of a pressure
safety valve discharging vertically to atmosphere?
1.67 x outside diameter (in inches) of the Tail Pipe = the height in feet.
63. If a pressure safety valve has a small, valved and plugged connection in the area between the block
valve and the pressure safety valve, describe the purpose and operation of this valve.
For bleeding pressure and venting any trapped commodity so, the relief valve can be safely
removed for maintenance.
64. Per Fluor Daniel Standard, what is the rule for establishing the height of a tailpipe of a pressure safety
valve that discharges to atmosphere?
The top of a tailpipe discharging to atmosphere must be a minimum of 8'-0" above any platform
within a 25'-0" radius of the tailpipe.
65. The spring on a pressure safety valve must be oriented in which direction and why?
• Vertically upward.
To keep the spring out of any liquid that could corrode the spring.
Piping QA
66. Cooling water piping at the channel side of a shell and tube heat exchanger that is located outside in
the sunlight will typically have a THERMAL RELIEF VALVE located between the exchanger nozzle and
the block valve. Why is this done?
To protect the tubes of the exchanger from splitting due to overpressurization of the system when
the valves upstream and downstream of the exchanger are closed. Sunlight can cause a
temperature rise of the trapped liquid, causing a rise in pressure.
67. What is the most common body style for control valves?
Globe
68. In a control valve manifold with block valves upstream and downstream of the control valve, what is
placed between the upstream block valve and the control valve and what is its purpose?
• 3/4" valved & plugged bleed valve.
• To drain and depressurize the volume of trapped liquid for the safe removal of the control valve
for maintenance.
69. If a control valve manifold has a bypass line what is the distance between the bypass valve and the
main line and why?
• Minimum distance.
• To prevent a dead leg in the bypass line.
70. What is the minimum clearance between the top of the diaphragm on a control valve and the nearest
obstruction above it?
1’-0” (12 inches)
71. In a control valve manifold with upstream and down stream block valves
A. What is the breakout spool piece for?
Easy removal of the control valve.
B. What is the preferred configuration of the breakout spool piece and why?
• Preferred configuration is with an elbow.
• It is easier to remove than a straight spool piece that requires a flange spreader. The "l" shape
allows gravity to aid in its removal.
72. Who determines the size of the control valve?
Process
73. Who determines the size of the bypass valve?
Process
Who determines the upstream and downstream block valves?
Process
Piping QA
75. If you are establishing the overall length of a control valve main fold for allocation of space and you do
not have a vendor drawing giving the face to face dimension of the control valve, what valve will you use
as a substitute face to face dimension (assume the control valve is 6”-3003RF)?
• A 6"-300# GLOBE VALVE OR PIPING PRACTICE 000 250 2701
• <17 ½ inches>
76. When a control valve and its downstream block valve are the same size and rating, they can be bolted
together. What possible problem can occur when these two valves are bolted together?
The handwheel of the block valve may interfere with the topworks of the control valve.
Also give me two solutions that could correct the problem.
• If the boltholes permit - rotate the block valve so the interference is gone.
• Add two flanges back to back, and, if necessary add a spool piece to give the necessary
clearances.
• <place valve in the vertical>
77. There are three things that establish the height of a valued drain (bottom of drain top of finished
surface). One thing that sets this height is Fluor Daniel standard (6”), what are two others?
• Clearance for rodding out the drain.
• Clearance required for the addition of a bucket to catch the liquid.
78. What are two industry terms when a threaded connection is also welded?
Seal welding
Back welding
79. What must be used on a threaded connection if it is to receive the weld referred to in question 69, and
why should it not be used?
• Thread compound or "pipe dope."
If thread compound/pipe dope is present and the connection is to be seal welded, the heat could
cause a small explosion, injuring the welder.

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Technorati Tags: piping questions,piping FAQ,piping questionarre

Steam Piping Questions and Answers for the Piping Designers/Engineers
1. When installing steam traps, what is the ideal distance between the heat exchanger and the trap
outlet?
12-36 inches (0.3-0.9 m).
2. After piping has been completed in a new steam system or branch, what should be done next?
Blow down the system.
3. Should a check valve be provided to allow automatic drainage of a portion of the steam system when
pressure has been turned off?
No.
4. When should an automatic drain valve be used in conjunction with steam traps?
When the traps may be subjected to freezing conditions.
5. Will reduced differential pressure reduce trap capacity?
Yes, it will.
6. How much will 1 PSI (0.68 bar) of positive differential pressure lift condensate?
2 feet (0.6 m).
7. What do I need to consider for an outdoor installation?
Keep three things in mind: Do not oversize a steam trap; keep discharge lines as short as possible; and
insulate all supply, discharge and return lines.
8. Two identical steam coils are in parallel in an air handler. Under those circumstances, can one trap
serve both coils?
No
9. Should trap by-passes be a part of every trap installation?
Not necessarily.
10. Is it always best to oversize steam traps, just to be sure?
No.
11. Unions usually make it easy to replace a trap quickly. But when does a union slow down the
replacement?
When it is installed in-line and the piping is well anchored.
12. What is "syphon drainage?"
Syphon drainage refers to installation of a trap above the device being drained.
13. Safety drain traps are often used when condensate must be lifted to an overhead return. Since they
are connected in parallel, it stands to reason that the same pressures reach the primary trap and the
safety drain trap. Why doesn't the safety drain discharge at the same time as the primary trap?
Because the safety drain discharge is installed above the primary trap.
14. A large heat exchanger is operated with a modulated steam pressure. Maximum steam pressure is 30
psig (2 bar). The condensate return line is located 12 feet (3.7 m) overhead. What trap is recommended?
A pumping trap plus F&T in series.
15. Is installing freeze-proof all-stainless traps a valid method to protect outdoor traps from freezing?
No.
16. When syphon drainage is necessary, should the syphon pipe be sized one size smaller than the
nominal size for the trap?
Yes, but never less than 1/2" (15 mm).
17. Whenever possible, should condensate be pumped versus gravity drainage?
No.
18. What might result when two steam-consuming units are drained by a single trap?
Short circuiting.
19. When condensate is returned overhead, can a check valve sometimes be used?
Yes.
20. Does every 2 feet (0.6 m) of lift in syphon drainage increase pressure differential by 1 PSI (0.68 bar)?
No.
21. Should a steam trap be located as close to the drip point as possible?
Yes.
22. If a safety drain trap is used, should it be located below the primary trap?
No.
23. What is recommended when installing steam systems in freezing environments?
Keep trap discharge lines as short as possible, insulate all supply, discharge and return lines; and be sure
there are no low points in the system that aren't drained.
24. Is it best to locate a steam trap below the drip point?
Yes.
25. If unions are used on both sides of the steam trap, should they be in-line?
No.
26. Does trapping by the letters apply only to IB traps?
No.
27. Can there be a problem draining two heat exchangers with a single trap?
Yes.
28. Should the diameter of the piping on the outlet of the heat exchanger always be reduced?
No.
29. What is a good way to provide an area where dirt and scale can fall out?
An extended drip leg below the takeoff to the trap.
30. Is syphon drainage when the trap must be installed above the drip point?
Yes.
31. What should I do when I have an elevated return line or modulating pressure service with insufficient
positive pressure to evacuate the condensate?
Install a safety drain upstream of the primary trap, install a pumping trap downstream of the primary trap,
and install a vented receiver and pump downstream of the primary trap.

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PROCESS PLANT TERMINOLOGY

Process Plant Terms

Refinery

A refinery is a plant that takes crude oil as its feed or charge stock and converts it into the many
petroleum products that people use; Some of these are gasoline, jet-fuel, kerosene, butane, propane, fuel
oil and asphalt.

Hydrocarbon

The hydrocarbon compound contains hydrogen and carbon. Hydrocarbon compounds are numerous and
form the basis for petroleum products. They exist mostly as vapors and liquids but may also be solid. In
general, piping systems refineries and gasoline plants transport hydrocarbons or utilities.
Gasoline Plant

The gasoline plant takes natural gas (a vapor) as its charge stock and separates the vapor’s heavier
products out and re-injects the lighter gas (methane) into a pipeline or perhaps into the gas field it came
from. Again gasoline, propane and butane are extracted as products. But, since a gasoline plant starts
with a vapor, the heavier hydrocarbons do not exist in its charge stock; so heavier products cannot be
made. Asphalt s one of the products that is classified as a heavy hydrocarbon and is not produced in a
gasoline plant.

Chemical Plant

The chemical plant takes semi-refined products from refineries and gasoline plants and reprocess them,
in this case it is also act as a Petrochemical plant. Sometimes blending in other products and converts
them into certain chemicals which may be sold as a finished consumer product. One such product widely
demanded today is plastic. Chemical plants make many ingredients in modern medicines.

Tank Farm

The tank farm is the area that contains the huge storage tanks of the refinery and gasoline or chemical
plants. The tanks are usually isolated from the main processing units in case of fire. They may be 200° or
more in diameter and will contain the plant’s charge stock for several days. The tanks also store the
plant’s products, until the shipment goes to the consumer.

Flare Systems

The flare system transports vapors (via a piping system) to a flare stack which is very tall and has a flame
burning at the top. This system burns waste gases and also collects and burns relief valve discharges. At
night the flare stack usually stands out -sending flames high into the air. This is waste gas burning. if it did
not burr, it would pollute the air.

Instruments

Instruments tell the operator what is happening inside a vessel or pipe. There are four basic groups of
instruments, namely temperature, pressure, flow and level.

Fluid

Most students may think of fluid as liquid, but it can also be a vapor. Fluid means something that will flow-
something not solid. Piping directs fluid flow.

Process Plant Utilities:

The utility is a refinery’s service portion. While a home has water, gas and electricity, a refinery or other
plant has many more, some of which are below.

Steam

Steam services many plant items. Heat generates steam in fired boilers or heater which will make many
different steam pressures and temperatures. They apply heat and convert condensate (pure water) to
steam (a vapor). The steam then goes to the different plant units in the piping systems which use the
steam.

Many students think they have seen steam, but they haven’t. They cannot actually see steam: it is
invisible. What they have seen is the condensate condensing out of the steam. That is where the term
condensate” comes from.

Condensate

As the energy in steam is used, the steam turns to condensate. Another piping system collects this
condensate, which is returned under a row pressure to a collection point and is pumped through the boiler
tubing and converted to steam again. So the condensate is in a constant cycle from steam to condensate
to steam.

Fuel Oil

Fuel oil is another utility that refineries make and partially consume. It is also sold as a product to heat
homes and fires furnaces in private business.

Instrument Air

A utility that operates the plant instruments is instrument air. A piping system distributes this air, which
has been compressed and dried to remove, all its moisture, as the moisture would harm the instruments.

Utility Air

Utility air drives air motors and blow air on objects to clean them, such as some barbers blow cut hair off
customers with air hoses.

Cooling Water

Cooling water cool various streams in a plant. The water starts at a cooling tower and is pumped through
a piping system to exchangers, which exchange heat. it comes out boner-much like water from a hot
water heater in a home. This water then returns to the cooling tower, which cools the water. and then is
ready for more circulation into the unit. Like the steam and condensate system above, this is a constantly
c system.

Drains
An underground utility collects drains from funnels or catch basins and, in a separate piping system,
transports them to a disposal point. Since no pressure is in this drain piping, the pipes must slope to
cause flow. This slope is usually 1 foot per 100 feet of tine or greater.
It can be very difficult to design drain systems. Since they run underground, they must miss all other
underground items. The drainage system must twist and turn to miss all the process equipment
foundations.
Most plants also have more than one drain system. They may have an oily water sewer a storm water
sewer and an acid sewer. The oily water sewer handles the oily drips and drains. The storm water sewer
collects surface runoffs from rains. The acid sewer collects acid drains and drips. There may be many
other types of separate drain systems.

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