Piping QT

PIPING QUESTIONAIRE
Questions related to Codes & standard: -

1. What is the ASME code followed for design of piping systes in !rocess piping
"#efineries & Cheical $ndustries%&
B 31.3
'. What are the "(% coon ASME ) *1 codes for pressure piping at Saudi Araco&
Answer: -
A. ASME B31.1 - Power piping.
). ASME B31.3 - Process piping.
C. ASME B31.4 - Pipeline Transportation system for liqui !yrocar"on # ot!er liqui.
+. ASME B31.$ - %as transmission # istri"ution piping system.
,. Which standards are referred for selection of following piping eleent&
A. -langes
). )utt Welded fittings
C. .as/et
+. Soc/et & 0hreaded fittings
E. 1al2es -. !ipes.
Answer: - A. -langes:-
$. ASME B1&.1' - (ast iron pipes flanges # flange fittings.
$$. ASME B1&.)' - (ar"on steel pipes flanges # flange fittings. *+p to ,4-.
$$$. ASME B1&.4/' - 0arge 1iameter steel flanges. *A"o2e ,4-.
). )utt welded fittings:-
$. ASME B1&.3' - Steel "utt weling fittings.
$$. ASME B1&.,$' - Butt-wele s!ort raius el"ows # returns "ens.
C. .as/et:-
$. ASME B1&.,4 5 AP6 -&41' - Metallic gas7ets for pipe flanges- Spiral woun8
9ctagonal ring :oint # :ac7ete flanges.
$$. ASME B1&.,1' - ;on metallic gas7et.
+. Soc/et & 0hreaded fittings:
$. ASME B1&.11' - <orge steel soc7et weling # t!reae fittings.
E. 1al2es:-
$. ASME B1&.14' - <ace to face # en to en imension of 2al2es.
$$. ASME B1&.34' - <lange # "utt-wele ens steel 2al2es *Press #Temp ratings. e=cept Ball8
Plug # Butterfly >al2es.
-. !ipes:-
$. ASME B3&.14' - ?ele # Seamless wroug!t iron pipes.
$$. ASME B3&.13' - Stainless steel pipes.
Questions related to Materials: -
1. What are the AS0M codes used on this pro3ect for aterials&
.o o2er the !ro3ect !iping Specification & identify all aterials
A. !ipes:-
$. Car4on Steel $$. Alloy Steel $$$. Stainless Steel $1. 5ic/el Steel.
). 0u4es: -
C. Wrought $ron -ittings: -
+. -orged -ittings: -
E. Cast -ittings: -
-. !lates: -
Answer: -
A. !ipes:-
$. Car4on Steel: - ASTM A)3 %r. A5B8 ASTM A14& %r. A5B5(8 ASTM A333 %r.15%r.&
$$. Alloy Steel: - ASTM A33) %r.P15P,5P)5P/5P35P115P1,5P,,.
$$$. Stainless Steel: - ASTM A31,TP3445TP34405TP344@5TP34$5TP3145TP31&5TP31&05
TP31&@5TP31/5TP3,15TP3,1@5TP34/5TP34/@5TP34$5TP34$@.
$1. 5ic/el Steel: - ASTM A333%r.35 %r.$.
). 0u4es:-
$. Car4on Steel: - ASTM A1/$51/3513,8 ASTM A334 %r.15&.
$$. Alloy Steel: - ASTM A1&1T18 ASTM A,13T15T,5T)5T/5T35T115T1,5T,,.
$$$. Stainless Steel: - ASTM A,13 TP3445TP34405TP344@5TP3145TP31&5TP31&05TP31&@5
TP31/5TP3,15TP3,1@5TP34/5TP34/@5TP34$5TP34$@8 ASTM A&4$ @A44.
$1. 5ic/el Steel: - ASTM A334%r.35%r.$
C. Wrought $ron fittings:-
$. Car4on Steel: - ASTM A,34%r.?PA5B8 ASTM A4,4 %r.?P0&.
$$. Alloy Steel: - ASTM A,34 ?P15?P)5?P/5?P35?P115?P1,5?P,,.
$$$. Stainless Steel: - ASTM A443 ?P3445?P34405?P344@5?P3435?P3145?P31&5
?P31&05?P31&@5 ?P31/5?P3,15?P3,1@5?P34/5?P34/@5?P34$.
$1. 5ic/el Steel: - ASTM A4,4?P0&5?P0$.
+. -orged -ittings: -
$. Car4on Steel: - ASTM A1$1. ASTM A14)8 ASTM A3)4 0<15,.
$$. Alloy Steel: - ASTM A1$,<15<,5<)5</5<35<115<1,5<,,.
$$$. Stainless Steel: - ASTM A1$,<&5<3445<34405<344@5<3145<31&5<31&05<31&@5<3,15
<3,1@5<34/5<34/@5<34$.
$1. 5ic/el Steel: - ASTM A3)4 0<38 ASTM A),,.
E. Cast -ittings: -
$. Car4on Steel: - ASTM A,1&8 ASTM A3), 0(B5(.
$$. Alloy Steel: - ASTM A,1/ ?(15?(&5?(35()5(1,.
$$$. Stainless Steel: - ASTM A,1/ (A1)8 ASTM A,3& (A1)8 ASTM A3)1 (<$5(<35(@,45
(A,45(< $M5(< 3M5(< $(5@A44.
$1. 5ic/el Steel: - ASTM A3),0(3.
E. !lates: -
$. Car4on Steel: - ASTM A,$)8 ASTM A)1)8 ASTM A)1&.
$$. Alloy Steel: - ASTM A3$/ %r.,5%r.)5%r./5%r.35%r.115%r.1,5%r.,,.
$$$. Stainless Steel: - ASTM A,44 TP4145TP44)5TP4345TP3445TP34405TP3435TP314S5
TP31&5TP31&05TP31/5TP3,15TP34/5TP34$
$1. 5ic/el Steel: - ASTM A,43 %r.15%r.E8 ASTM A3)3.
'. What is the 4asic difference 4etween !ipe specification A167 .r.A 8 .r.)8 .r.C.&
Answer: -
1ifference is ue to t!e (ar"on content.
B of car"on content in ' -
6. ASTM A14& %r. A C 4.,) B
66. ASTM A14& %r. B C 4.34 B
66 ASTM A14& %r. ( C 4.3) B.
*. What is the difference 4etween pipe specification AS0M A*1' 0! *6( & AS0M A*1'
0!*6(9: AS0M A*1' 0! *17 & AS0M A*1' 0! *179&
Answer: -
1ifference is ue to t!e (ar"on content. T!e 0etter D0- enotes lower percentage of car"on.
B of car"on content in' -
6. ASTM A31, TP 344 - 4.4$ B
66. ASTM A31, TP 3440- 4.43)B
666. ASTM A31, TP 31& - 4.4$ B
6>. ASTM A31, TP 31&0- 4.43)B
Questions related to !ipe -ittings: -
1. ;ow can flanges 4e classified 4ased on !ipe Attachent&
Answer: -
<langes can "e classifie "ase on pipe attac!ment as' -
Slip C on. ' - T!e Slip-on type flanges are attac!e "y weling insie as well as outsie. T!ese
flanges are of forge construction.
Soc7et ?el. ' - T!e Soc7et ?el flanges are wele on one sie only. T!ese are use for small
"ore lines only.
Screwe. ' - T!e Screwe-on flanges are use on pipe lines w!ere weling cannot "e carrie out.
0ap :oint. ' - T!e 0ap :oint flanges are use wit! stu" ens. T!e stu" ens are wele wit! pipes
# flanges are 7ept loose o2er t!e same.
?eling ;ec7. ' - T!e ?eling nec7 flanges are attac!e "y "utt weling to t!e pipe. T!ese
are use mainly for critical ser2ices w!ere t!e wel Eoints nee raiograp!ic inspection.
Blin. ' - T!e Blin flanges are use to close t!e ens w!ic! nee to "e reopene.
Feucing. ' - T!e reucing flanges are use to connect "etween larger an smaller siGes wit!out
using a reucer. 6n case of reucing flanges8 t!e t!ic7ness of flange s!oul "e t!at of t!e !ig!er
iameter.
6ntegral. ' - 6ntegral flanges are t!ose8 w!ic! are cast along wit! t!e piping component or
equipment.
'. ;ow can flanges 4e classified 4ased on !ressure- teperature ratings&
Answer: -
<langes are classifie "ase on pressure temperature ratings as' -
A. 1)4 H
B. 344 H
(. 444 H
1. &44 H
E. 344 H
<. 1)44 H
%. ,)44H
Pressure temperature rating carts in t!e stanar ASME1&.) specify t!e non-s!oc7 wor7ing
gauge pressure to w!ic! t!e flange can "e su"Eecte to at a particular temperature.
*. ;ow can flanges 4e classified 4ased on facing&
Answer: -
<langes are classifie "ase on facing as' -
A. <lat face. *<<.
B. Faise face. *F5<.
(. Tongue an groo2e. *T5%.
1. Male an female. *M5<.
E. Fing type Eoint. *FT:.
(. ;ow can flanges 4e classified 4ased on face finish&
Answer: -
<langes are classifie "ase on face finis! as' -
A. Smoot! finis!.
B. Serrate finis!.
,. Where the sooth finish flange & serrated finish flange finds its use&
Answer: -
T!e smoot! finis! flange is pro2ie w!en metallic gas7et is pro2ie an serrate finis! flange is
pro2ie w!en non-metallic gas7et is pro2ie.
7. What are the types of serrated finish pro2ided on flange faces&
Answer: -
A. (oncentric or
). Spiral *P!onograp!ic.
<. ;ow the serration on flanges is specified&
Answer:
T!e serration on flanges is specifie "y t!e num"er8 w!ic! is t!e Arithetic A2erage #ough
;eight "AA#;%.
=. Where the concentric serration is insisted for face finish&
Answer: -
(oncentric serration are insiste for face finis! w!ere t!e flui "eing carrie !as 2ery low
ensity an can fin lea7age pat! t!roug! ca2ity.
>. ;ow the .as/ets are classified 4ased on the type of construction&
Answer: -
Base on t!e type of construction8 gas7ets are classifie as' -
A. <ull face.
). Spiral woun metallic.
C. Fing type.
+. Metal Eac7ete.
E. 6nsie "olt circle.
16. What is the ost coonly used aterial for .as/et&
Answer: -
(ompresse As"estos <i"re.
11. Which type of gas/ets are recoended for high teperature & high-pressure
application&
Answer: -
Spiral ?oun Metallic %as7et # Fing :oint Type %as7et.
11. What are the criteria for selection of M?C of Spiral Wound etallic .as/et winding
aterial&
Answer: -
T!e selection of material of construction for %as7et wining epens upon' -
A. T!e corrosi2e nature an concentration of flui "eing carrie.
). T!e operating temperature of t!e flui.
C. T!e relati2e cost of alternate wining material.
1'. What are the ost coon aterials used for spiral wound etallic gas/et winding&
Answer: -
T!e most commonly use material for spiral woun metallic gas7et wining is' -
A. Austenitic stainless steel 344 wit! as"estos filler.
). Austenitic stainless steel 31& wit! as"estos filler.
C. Austenitic stainless steel 3,1 wit! as"estos filler.
1*. Which aterial is used as filler aterial for spiral wound gas/et in case of high
teperature ser2ices&
Answer: -
<or 2ery !ig! temperature ser2ices8 grap!ite filler is use.
1(. What is centering ring in connection to spiral wound gas/et&
Answer: -
Spiral woun gas7ets are pro2ie wit! car"on steel e=ternal ring calle centering ring.
1,. What will 4e the AA#; finish on flange face for using spiral wound gas/et&
Answer: -
1,)-,)4 AAF@ finis!.
17. ?n which type of flanges the use of spiral wound gas/et are restricted&
Answer: -
ASME B1&.) oes not recommen t!e use of 1)4 Hrating spiral woun gas7et on flanges ot!er
t!an weling nec7 an lappe Eoint type.
'1. Which type of piping aterials are used for drin/ing water: instruent air etc&
Answer: -
%al2aniGe steel materials are generally use for rin7ing water8 instrument air an ;6 lines *0P..
'*. -ro which si@e onwards 5) of pipe is eAual to ?+ of !ipe&
Answer: -
<rom t!e siGe 14- an onwars ;B I 91 of pipe.
!age < of 7*
Created 4yM$;$# 0;ABC#8 Chec/ed 4ySA5DAE S$5.;8 Appro2ed 4y BE5.AM 19 #e2.6
'(. What should 4e the radius of long radius el4ow&
Answer:
1.)1 *?!ere D1- is t!e iameter of t!e pipe..
',. What should 4e the radius of short radius el4ow&
Answer: -
11*?!ere D1- is t!e iameter of t!e pipe..
'7. What is the 4asis of using of short radius & long radius el4ow&
Answer: -
0ong raius el"ow are use for small pressure rop w!ereas s!ort raius el"ow are use for !ig!
pressure rops. <or catalyst flows 2ary long raius el"ows are use.
'<. 5orally where do we use the following&
A. Eccentric reducers.
). Concentric reducers.
Answer:
A. Eccentric reucers I Pump suction to a2oi (a2itation8 To maintain ele2ation *B9P. in rac7.
). (oncentric reucers I Pump isc!arge8 2ertical pipeline etc.
'=. Concentric reducer is used in pup suction. "Ees 8 5o%. EFplain.
Answer:
;o. Air poc7ets may form if concentric reucer is use at pump suction8 w!ic! results in ca2itation
an cause amage to Pump. To a2oi t!is pro"lem8 Eccentric Feucer wit! flat sie up *<S+. is
use in Pump Suction.
'>. Where the E#W spiral & longitudinal pipes are used&
Answer: -
+se epens upon t!e a2aila"ility of pipes. ;ot!ing functional ifference.
*6. Where the E#W & Sealess pipes are used&
Answer: -
A"o2e 1$- EF? pipes are use. Below 1$- seamless pipes are use. Seamless pipes can
sustain
!ig!er temperature # pressure.
*1. What is the ain use of AS0M A,* & A167 .r.) pipes&
Answer: -
ASTM A)3 pipes are mainly use for utility ser2ices w!ereas A14& %r. B pipes are use for !ig!
Pressure # !ig! temperature ser2ices.
*'. -ro which side of pipe will you ta/e a 4ranch connection&
Answer: -
? !en flui is %as8 Air or Steam an (ryogenic Ser2ice C Topsie.
?!en <lui is 0iqui C Bottom Sie.
**. Why donGt we ta/e a 4ranch for Cryogenic Ser2ice fro 4otto side though the fluid is
in
liAuid state&
Answer: -
T!ere is t!e c!ance of ice formation uring normal operation an since ice flows from t!e "ottom
of
t!e pipe it will "loc7 t!e "ranc! pipe connection.
!age = of 7*
**. Why do we pro2ide ;igh !oint 1ent ";!1% and 9ow !oint +rain "9!+% in piping&
Answer:
@P> C <or remo2ing Air uring @yro-test.
0P1 C <or raining water after conucting @yro-test.
*(. What do you ean 4y Dac/eted !iping&
Answer: -
Piping w!ic! is recogniGe as pro2iing t!e most uniform application of !eat to t!e process8 as
well
as maintaining t!e most uniform processing temperatures w!ere steam tracing is not capa"le of
maintaining t!e temperature of flui constant. +sually use for molten sulp!ur8 Polymers ser2ice.
*,. What is the iniu distance to 4e aintained 4etween two welds in a pipe&
Answer: -
T!e t!um" rule is t!at t!e minimum istance "etween aEacent "utt wels is 11. 6f not8 it is ne2er
closer t!an 1-15,J. T!is is supposely to pre2ent t!e o2erlap of @AKs. Minimum spacing of
circumferential wels "etween centerlines s!all not "e less t!an 4 times t!e pipe wall t!ic7ness or
,) mm w!ic!e2er is greater.
*7. What do you ean 4y $)# and which lines coes under $)# pur2iew&
Answer: -
6BF' 6nian Boiler Fegulation Act.
Steam lines wit! conitions liste "ellow comes uner 6BF pur2iew ' C
L 0ines for w!ic! esign pressure is 3.) 7g5sq. cm an a"o2e.
L 0ine siGe a"o2e 14- !a2ing esign pressure 1.4 7g5sq. cm an a"o2e.
L Boiler fee water lines to steam generator8 conensate lines to steam generator an flas! rum.
*<. What are Weldolet and Soc/olet& And where they are used&
Answer: -
? elolet an Soc7olet are "asically self-reinforce fittings.
?elolet is use for Butt wel "ranc! connection w!ere stanar tee is not a2aila"le ue to siGe
restrictions an t!e piping is of critical 5 !ig!-pressure ser2ice. Soc7olet is use for soc7et weling
"ranc! connection8 w!ic! require reinforcing pa.
*=. What is the M?C for Superheated high pressure Stea 9ines&
Answer: -
A 33) %r. P 6 5 P 118 (omposition' (r. C M Mo *P1. 5 1N (r. C M Mo *P11.
*>. What is the noral upstrea and downstrea straight length of orifice flow eter&
Answer: -
+pstream - 1)1 1ownstream - )1
Questions related to 2al2es: -
1. What is the function of 2al2es&
Answer: -
A. 6solation.
). Fegulation.
C. ;on-Feturn.
+. Special purpose.
!age > of 7*
'. ;ow the 2al2es are classified 4ased on their function&
Answer: -
A. $solation.
1. %ate 2al2e.
'. Ball 2al2e
*. Plug 2al2e.
(. Piston 2al2e.
,. 1iap!ragm >al2e.
7. Butterfly 2al2e.
<. Pinc! 2al2e.
). #egulation
1. %lo"e 2al2e.
'. ;eele 2al2e.
*. Butterfly 2al2e.
(. 1iap!ragm 2al2e.
,. Piston 2al2e.
7. Pinc! 2al2e.
C. 5on- #eturn
1. (!ec7 2al2e.
+. Special purpose
1. Multi- Port 2al2e.
'. <lus! Bottom 2al2e.
*. <loat 2al2e.
(. <oot 2al2e.
,. 0ine "lin 2al2e.
7. Anife %ate 2al2e.
*. ;ow the 2al2es are classified 4ased on its ethod of operation&
Answer: -
>al2es are classifie "ase on its met!o of operation as' -
A. Self- operate 2al2es.
). 9perate 2al2es.
(. 5ae the Self H operated & operated 2al2es&
Answer: -
Mainly t!e c!ec7 2al2es are self-operate an all ot!er 2al2e types comes uner operate 2al2es.
,. ;ow the 2al2es are classified 4ased on end connection&
Answer: -
>al2es are classifie "ase on en connection as' -
A. Screwe ens.
). Soc7et ens.
C. <lange ens.
+. Butt wel ens.
E. ?afer type ens.
-. Buttress ens.
En connection means arrangement of attac!ment of t!e 2al2e wit! t!e equipment or t!e piping.
7. What are the types of chec/ 2al2es&
Answer: -
(!ec7 2al2es are i2ie into two types "ase on c!ec7 mec!anism as' -
A. 0ift c!ec7 2al2e.
). Swing c!ec7 2al2e.
!age 16 of 7*
<. What do you ean 4y special purpose 2al2es&
Answer: -
>al2es t!at perform uties ot!er t!an t!e two-way isolation8 control an c!ec7 are calle special
purpose 2al2es.
=. What are .landless piston 2al2es& Where these are used&
Answer: -
%lanless piston 2al2es are regulating 2al2es use in steam ser2ices.
Questions related to Welding8 Weld defects8!ost heating8!ost weld heat treatent8
Electrode8-iller wire.
1. What do you ean 4y following type of welding&
A. SMAW ). 0$.
Answer: -
A. SMA? ' - S!iele Metal Arc ?eling.
). T6% ' - Tungsten 6nert %as ?eling.
'. Mention the contents of 0$. welding set&
Answer: -
A. Torc! ' (onsist of !ose for argon gas 5 weling lea 5 ceramic noGGle5 collet 5 tungsten ro as
cat!oe to create arc.
B. Fegulator wit! Pressure %auge *@P # 0P. # flow meter.
(. Argon cyliner C %r., 5 %r.1 epening upon requirements of t!e Eo".
1. Transformer 5 Fectifier.
E. <iller wire
*. While welding of pipe trunion to pipe8reinforceent pad you ha2e to put a hole or lea2e
soe
portion of welding why&
Answer:
<or 2enting of !ot gas w!ic! may get generate ue to weling.
(. What is the thu4 rule to calculate Current reAuired for Welding&
Answer:
(urrent *Amp. I O1iameter of Electroe *mm. P 44Q ,4
,. What is the iniu thic/ness of cs pipe that reAuires stress relie2ing to 4e done as
per
)*1.*&
Answer: - 13.4) mm t!7.
7. Which is the Electrode & filler wire used for welding of following aterials&
A. Alloy steel
$. AS0M A**,!$
$$. AS0M A**,!'
$$$. AS0M A**,!11
$1. AS0M A**,!,
1. AS0M A**,!>
). Stainless steel
$. AS0M A*1'0!*6(
$$. AS0M A*1'0!*6(9
$$$. AS0M A*1'0!*6(;
$1. AS0M A*1'0!*6=
!age 11 of 7*
1. AS0M A*1'0!*16
1$. AS0M A*1'0!*17
1$$. AS0M A*1'0!*179
1$$$. AS0M A*1'0!*17;
$I. AS0M A*1'0!*'1
I. AS0M A*1'0!*'1;
Answer: -
Co2ered Electrode )are electrode
Alloy Steel
$. ASTM A33)P6 E/41$ E/4 S-1B
$$. ASTM A33)P, E$41$-B1 ---
$$$. ASTM A33)P11 E$41$-B, EF)1)
$1. ASTM A33)P) E)4, EF)4,
1. ASTM A33)P3 E)4) EF)4)
Stainless Steel
$. ASTM A31,TP344 E34$ EF34$
$$. ASTM A31,TP3440 E34$0 EF34$0
$$$. ASTM A31,TP344@ E1&-&-, EF1&-$-,
$1. ASTM A31,TP34$ E343 EF343
1. ASTM A31,TP314 E314 EF314
1$. ASTM A31,TP31& E31& EF31&
1$$. ASTM A31,TP31&0 E31&0 EF31&0
1$$$. ASTM A31,TP31&@ E1&-$-, EF1&-1$-,
$I. ASTM A31,TP3,1 E34/ EF34/
I. ASTM A31,TP3,1@ E1&-&-, EF1&-$-,
<. What are the coon welding defects&
Answer: -
A. 0ac7 of penetration.
). 0ac7 of fusion.
C. +nercut.
+. Slag inclusion.
E. Porosity.
-. (rac7.
.. <aulty wel siGe # profile.
;. 1istortion.
A. 9ac/ of penetration.
T!is efect occurs at t!e root of t!e Eoint w!en t!e wel metal fails to reac! it or wel metal fails
to fuse completely t!e root faces of t!e Eoint. As a result8 a 2oi remains at t!e root Gone8 w!ic!
may contain slag inclusions.
Cause: -
A. +se of incorrect siGe of electroe in relation to t!e form of Eoint.
B. 0ow weling current.
(. <aulty fit-up an inaccurate Eoint preparation.
). 9ac/ of fusion.
0ac7 of fusion is efine as a conition w!ere "ounaries of unfuse metal e=ist "etween t!e
?el metal # "ase metal or "etween t!e aEacent layers of wel Cmetals.
Cause: -
A. Presence of scale8 irt8 o=ie8 slag an ot!er non-metallic su"stance w!ic! pre2ents
t!e wel metal to reac! melting temperature.
B. 6mproper eslagging "etween t!e wel pass.
!recaution: -
A. Aeep t!e wel Eoint free from scale8 irt8 o=ie8 slag an ot!er non- metallic su"stance.
B. +se aequate weling current.
(. 1eslag eac! wel pass t!oroug!ly.
1. Place wel passes correctly ne=t to eac! ot!er.
!age 1' of 7*
C. Cndercut
T!is efect appears as a continuous or iscontinuous groo2e at t!e toes of a wel pass an is
locate on t!e "ase metal or in t!e fusion face of a multipass wel. 6t occurs prominently on t!e
ege of a fillet wel eposite in t!e !oriGontal position.
Cause: -
A. E=cessi2e weling current.
B. Too !ig! spee of arc tra2el.
(. ?rong electroe angle.
#ectification: -
T!e efect is rectifie "y filling t!e unercut groo2e wit! a wel pass. 6f unercut is eep #
contains slag8 it s!oul "e c!ippe away "efore reweling.
+. Slag $nclusion
;onCmetallic particles of comparati2ely large siGe entrappe in t!e wel metal are terme
as slag inclusion.
Cause: -
A. 6mproper cleaning of slag "etween t!e eposition of successi2e passes.
B. Presence of !ea2y mill scale8 loose rust8 irt8 grit # ot!er su"stances present on t!e
surface of "ase metal.
!recaution: -
A. (lean t!e slag t!oroug!ly "etween t!e wel pass.
B. Aeep t!e Eoint surface *especially gas cut surface. an "are filler wire perfectly clean.
(. A2oi unercut # gaps "etween wel pass.
1. +se proper weling consuma"les.
E. !orosity
T!e presence of gas pores in a wel cause "y entrapment of gas uring soliification is
terme as porosity. T!e pores are in t!e form of small sp!erical ca2ities eit!er clustere locally
or scattere t!roug!out t!e wel eposit. Sometimes entrappe gas gi2e rise to a single large
ca2ity calle Blow!oles.
Cause: -
A. (!emically imperfect weling consuma"les8 for e=ample8 eficient in eo=iiser.
B. <aulty composition of "ase material or electroe8 for e=ample8 !ig! sulp!ur content.
(. Presence of oil8 grease8 moisture an mill scale on t!e wel surface.
1. E=cessi2e moisture in t!e electroe coating or su"merge-arc flu=.
E. 6naequate gas s!ieling or impure gas in a gas Cs!iele process.
<. 0ow weling current or too long an arc.
%. Ruic7-freeGing of wel eposit.
-. Crac/
<racture of t!e metal is calle crac7. Two types of crac7s' - (ol crac7 # @ot crac7.
(ol crac7 usually occur in @AK of t!e "ase metal w!en t!is Gone "ecomes !ar an "rittle ue
to rapi cooling after t!e wel metal !as "een eposite # sufficient !yrogen !as "een
a"sor"e "y t!e wel metal from t!e arc atmosp!ere.
!recaution: -
A. +se of low car"on equi2alent materials.
B. @ig!er !eat input uring weling.
(. Pre!eating.
1. +se of low !yrogen electroe.
.. -aulty weld si@e and profile
A wel is consiere faulty if it !as lac7 of reinforcement8 e=cessi2e reinforcement or irregular
Profile.
!age 1* of 7*
;. +istortion
Because a welment is locally !eate *"y most weling processes.8 t!e temperature
istri"ution in t!e welment is not uniform an c!anges ta7e place as weling processes.
Typically8 t!e wel metal an t!e "ase metal !eat-affecte Gone immeiately aEacent to it are
at a temperature su"stantially a"o2e t!at of t!e unaffecte "ase metal. As t!e molten pool
soliifies an s!rin7s8 it "egins to e=ert s!rin7age stresses on t!e surrouning wel metal an
!eat-affecte Gone area. ?!en it first soliifies8 t!is wel metal is !ot8 relati2ely wea78 an can
e=ert little stress. As it cools to am"ient temperature8 !owe2er8 t!e s!rin7age of t!e wel metal
e=erts increasing stress on t!e wel area an e2entually reac!es t!e yiel point of t!e "ase
metal an t!e !eat-affecte Gone. Fesiual stresses in welments !a2e two maEor effects. <irst8
t!ey prouce istortion8 an secon8 t!ey may "e t!e cause of premature failure in welments.
1istortion is cause w!en t!e !eate wel region contracts nonuniformly8 causing s!rin7age in
one part of t!e wel to e=ert eccentric forces on t!e wel cross section.
T!e istortion may appear in "utt Eoints as "ot! longituinal an trans2erse s!rin7age or
contraction8 an as angular c!ange *rotation. w!en t!e face of t!e wel s!rin7s more t!an t!e
root.
1istortion in fillet wels is similar to t!at in "utt wels' trans2erse an longituinal s!rin7age as
well as angular istortion results from t!e un"alance nature of t!e stresses in t!ese wels.
!age 1( of 7*
=. What is ean 4y J!W;0G& Why it is reAuired&
Answer: -
DP9ST ?E01 @EAT TFEATME;T- T!is is one to remo2e resiual stress left in t!e Eoint w!ic!
may
cause "rittle fracture.
>. Why pre-heating is done on soe pipe 4efore starting welding&
Answer: -
To slow own t!e cooling rate.
16. Why post-heating is done on soe pipe after the welding is o2er&
Answer: -
To maintain uniform !omogeneous structure.
11. What is the pre-heat teperature for car4on steel a4o2e 1>.6,MM th/.
Answer: -
Pre C!eat temperature for car"on steel a"o2e 13.4) mm is $4_(.
1'. $s post heating reAuired for car4on steel aterial a4o2e 1>.6,MM th/.
Answer: -
;o. Post !eating is not require for car"on steel material of any t!ic7ness.
1*. What is the soa/ing teperature during stress reli2ing for car4on steel aterial&
Answer: -
Soa7ing temperature for car"on steel material uring stress reli2ing is &,4_(. *,4_(.
1(. What is the soa/ing period during stress reli2ing for car4on steel aterial&
Answer: -
Soa7ing perio for car"on steel material uring stress reli2ing is 1!r.
1,. What is the rate of heating & cooling during stress reli2ing for car4on steel aterial&
Answer: -
T!e rate of !eating # cooling for car"on steel material uring stress reli2ing is 1)4_c5!r.
17. What is the pre-heat teperature during stress reli2ing for alloy steel aterials&
Answer: -
Pre-!eat temperature for AS materials is 1$4_(.
1<. What is the soa/ing teperature during stress reli2ing for alloy steel aterial&
Answer: -
Soa7ing temperature for alloy steel material is /,4_(*,4_(..
1=. What is the soa/ing period during stress reli2ing for alloy steel aterial&
Answer: -
Soa7ing perio for alloy steel material is ,!rs.
1>. What is the rate of heating & cooling during stress reli2ing for alloy steel aterial&
Answer: -
T!e rate of !eating # cooling for alloy steel material is 144_(5!r.
'6. What is the post heat teperature for alloy steel aterial&
Answer: -
Post !eat temperature for alloy steel material is 344_(.
!age 1, of 7*
'1. What is a four or fi2e digit coding for electrode as per AWS classification S-A ,.1&
Answer: -
E P P P P P
P P P P
T!e minimum +TS of ?eling position. Type of coating
t!e unilute wel metal an current conition.
in psi. * +TS C +ltimate tensile strengt!..
''. Where the use of electrode E<61= is recoended&
Answer: -
T!e use of electroe E/41$ is recommene for weling t!e following' -
A. <or !ig! strengt! steel.
B. <or !ig! t!ic7ness car"on steel plates.
(. @ig!er car"on equi2alent material.
'*. Why the electrode E<61= is called low hydrogen electrode&
Answer: -
T!e low !yrogen electroes !a2e in t!eir coating ingreient8 w!ic! prouces car"on i-o=ie
uring
melting. T!is (9, gi2es a gaseous s!ieling for t!e metal an pre2ents atmosp!eric !yrogen
from
entering in arc atmosp!ere. By t!is way t!e wel metal !as low le2el of !yrogen.
'(. What should 4e the content of chlorine in water while conducting hydrotest for CS &
SS
pipes&
Answer: -
<or (S C ,)4 PPM.
<or SS C 34 PPM.
',. +raw the stress-reli2ing diagra for car4on steel & Alloy steel aterial&
Answer: -
Soa7ing perio * 1!r. for (.S # ,!rs. for AS.
"5ote: - 0he stress reli2ing diagra reain sae
for 4oth AS & CS. 0he difference is only
in soa/ing teperature.%
0ie
0eperature
!age 17 of 7*
'7. What is the test positions for fillet & groo2e welding in case of plate & pipes&
Answer: -
0est positions for -illet welds: -
Plate positions' -
A. <lat Position 1< ' - Plates so place t!at t!e wel is eposite wit! its a=is !oriGontal # its
t!roat 2ertical. Fefer s7etc! *a..
B. @oriGontal Position ,< ' - Plates so place t!at t!e wel is eposite wit! its a=is !oriGontal on
t!e upper sie of t!e !oriGontal surface an against t!e 2ertical
surface. Fefer s7etc! *"..
(. >ertical Position 3< ' - Plates so place t!at t!e wel is eposite wit! its a=is 2ertical. Fefer
s7etc! *c..
1. 92er!ea Position 4< ' - Plates so place t!at t!e wel is eposite wit! its a=is !oriGontal on
t!e unersie of t!e !oriGontal surface an against t!e 2ertical surface.
Fefer s7etc! *..
Pipe positions' -
A. <lat Position 1< ' - Pipe wit! its a=is incline at 4)_to !oriGontal an rotate uring
weling so t!at t!e wel metal is eposite from a"o2e an at t!e point
of eposition t!e a=is of wel is !oriGontal an t!e t!roat 2ertical. Fefer
s7etc! *a..
B. @oriGontal Position ,< ' - Pipe wit! its a=is 2ertical so t!at t!e wel is eposite on t!e upper
sie of t!e !oriGontal surface an against t!e 2ertical surface. T!e a=is
of t!e wel will "e !oriGontal an t!e pipe is not to "e rotate uring
weling. Fefer s7etc! *"..
(. @oriGontal Position ,<F' - Pipe wit! its a=is !oriGontal an t!e a=is of t!e eposite wel in t!e
2ertical plane. T!e pipe is rotate uring weling. Fefer s7etc! *c..
1. 92er!ea Position 4< ' - Pipe wit! its a=is 2ertical so t!at t!e wel is eposite on t!e
unersie
of t!e !oriGontal surface an against t!e 2ertical surface. T!e a=is of
t!e wel will "e !oriGontal an t!e pipe is not rotate uring weling.
Fefer s7etc! *..
E. Multiple Position )< ' - Pipe wit! a=is !oriGontal an t!e a=is of t!e eposite wel in t!e
2ertical Plane. T!e pipe is not to "e rotate uring weling. Fefer
s7etc! *e..
!age 1< of 7*
0est positions for .roo2e welds: -
Plate positions' -
A. <lat Position 1% ' - Plate in a !oriGontal plan wit! t!e wel metal eposite from a"o2e.
Fefer s7etc! *a..
B. @oriGontal position ,% ' - Plate in a 2ertical plane wit! t!e a=is of t!e wel in !oriGontal.
Fefer s7etc! *"..
(. >ertical position 3% ' - Plate in 2ertical plane wit! t!e a=is of t!e wel 2ertical. Fefer s7etc! *c..
1. 92er!ea Position 4% ' - Plate in a !oriGontal plane wit! t!e wel metal eposite from
unerneat!. Fefer s7etc! *..
Pipe Positions' -
A. <lat Position 1% ' - Pipe wit! its a=is !oriGontal an rolle uring weling so t!at t!e wel
metal is eposite from a"o2e. Fefer s7etc! *a..
B. @oriGontal Position ,% ' - Pipe wit! its a=is 2ertical an t!e a=is of wel in a !oriGontal plane.
Pipe s!all "e not "e rotate uring weling. Fefer s7etc! *"..
(. Multiple Position )% ' - Pipe wit! its a=is !oriGontal an t!e weling groo2e in 2ertical plane.
?eling s!all "e one wit!out rotating t!e pipe. Fefer s7etc! *c..
1. Multiple Position &% ' - Pipe wit! its a=is incline at 4)_to !oriGontal. ?eling s!all "e one
wit!out rotating t!e pipe. Fefer s7etc! *..
!age 1= of 7*
'<. +raw the .roo2e details for 7. position in pipe&
<,_' K_
1 MM 6., MM
'.,MM 1 MM
Doint details for 7. !osition.
'=. +raw the .roo2e details for '. & *. position in case of plates&
Answer: -
76_to <6_
16 MM 0;B."MaF.%
' 0? *.'MM
' 0? *.' MM
(,_ 'MM
76_to <6_ *MM
1' MM 0;B. & A4o2e.
' 0? *.'
' 0? *.' MM
Doint details for *. !osition Doint details for '. !osition
"2ertical 3oint%. ";ori@ontal Doint%.
!age 1> of 7*
'>. What is the affect if the Auantity of hydrogen induced in weld etal is ore&
Answer: -
? !en !yrogen is more in wel metal8 it tens to ma7e t!e material "rittle # su"sequently leas
to
crac7ing. T!ese crac7s are calle !yrogen inuce crac7ing or elaye crac7. To a2oi t!is t!e
electroe "efore using is "ac7e at ,)4_( to 344_( for one !our in mot!er o2en # t!en coole
own
to 144_( in t!e same o2en # finally transferre to porta"le o2en for use w!ere temperature is
maintaine at &4_to /4_.
Questions related to pipes supports: -
1. What are the Criteria for !ipe Supporting&
Answer: -
<ollowing are t!e points8 w!ic! s!oul "e ta7en into account for proper supporting' -
A. 0oa of "are pipe S flui S insulation *if any..
B. 0oa of "are pipe S water fill.
(. 0oa of 2al2es an online equipment an instrument.
1. T!ermal loas uring operation.
E. Steam out conition8 if applica"le.
<. ?in loas for piping at !ig!er ele2ation8 if require.
%. <orce 2i"ration ue to pulsating flow.
@. Bare pipe wit! siGe a"o2e 1,- s!all "e supporte wit! Pa or S!oe.
'. What is the 4asic span of supports for 'L87L816L8'(L pipe&
Answer: -
Basic Span is ).)m 5 3m 5 11.)m 5 1)m respecti2ely.
*. What is the function of pro2iding the anchor: cross guide and guide for piping&
Answer: -
Anc!or is pro2ie to restrict all t!e a=ial an rotational mo2ements of pipe8 w!ereas cross guie
is
pro2ie to restrict isplacements of pipe along wit! t!e a=is perpenicular to its centerline an
%uie
is pro2ie to restrict t!e longituinal mo2ements of pipes along wit! its a=is.
(. ;ow is piping to 0an/ inlet no@@le is supported and why&
Answer: -
Piping to Tan7 ;oGGle is supporte wit! spring type support *first support from ;oGGle. in orer to
ma7e t!e noGGle safe from t!e loas w!ic! occurs ue to t!e isplacement of pipe
* 1isplacement
may "e ue to t!ermal e=pansion of pipe8 tan7 material8 tan7 settlement etc..
,. What are the types of fleFi4le spring hangers&
Answer: -
1. (onstant Spring @anger ,. >aria"le Spring @anger.
7. What is the purpose of pro2iding .raphite !ads in supports 4elow shoes&
Answer: -
To reuce t!e friction factor. T!e co-efficient of friction for %rap!ite Pas is 4.1
<. Where do you pro2ide Anchor and Slotted Support of ;eat EFchanger&
Answer: -
Anc!or support of @eat e=c!anger is pro2ie on t!e sie from w!ic! Tu"e "unle will "e pulle
out
for t!e purpose of maintenance wor7 also it is "ase on t!e growt! of t!e connecting piping as
e=c!anger s!oul grow wit! t!e piping.
!age '6 of 7*
=. What should 4e the aterial of shoes for supporting AS pipes & why&
Answer: -
6f (S s!oes are use t!en pa in contact wit! t!e pipe s!all "e of Alloy steel to a2oi issimilar
weling at pipe. To a2oi alloy steel weling an issimilar weling8 fa"ricate clamps eit!er of
(S or
SS can "e use.
>. What are sway 4races&
Answer: -
Sway "races are essentially a ou"le acting spring !ouse in a canister. T!eir purpose is to limit
t!e
unesira"le mo2ement. +nesira"le mo2ement means mo2ement cause "y win loaing8 rapi
2al2e closure8 relief 2al2e opening8 two p!ase flow or eart!qua7e.
16. What is the difference 4etween 2aria4le spring hanger and constant spring hanger&
Answer: -
>aria"le spring @anger' -
As t!e name itself inicates t!e resistance of t!e coil to a loa c!anges uring compression.
(onstant spring @anger' -
(onstant spring !anger pro2ies constant support force for pipes an equipment su"Eecte to
2ertical
mo2ement ue to t!ermal e=pansion.
Questions related to #adiography technology: -
1. What are the types of radiation eitted 4y isotopes&
Answer: -
T!ere are t!ree types of raiation as' -
A. Alp!a particle *- particle..
). Beta particles *_- particle..
C. %amma ray *_- ray..
'. What is the charges on - particle: _- particle and _- ray & copare their relati2e
penetration&
Answer: -
(!arges on raiation are' -
A. Alp!a particle *- particle. ' - Positi2e c!arge # less penetrating in comparison to _- particle
#
_- Fay. T!ey can "e stoppe "y a t!in s!eet of paper.
B. Beta particles *_- particle. ' - ;egati2e c!arge # !a2e efinite range of penetration. Easily
a"sor"e in t!e matter.
(. %amma ray *_- ray. ' - ;o c!arge # !ig!ly penetrating.
*. 5ae the isotopes: which eits gaa ray&
Answer: -
%amma ray source are' -
A. 6riium C 13,
B. (o"alt C &4
(. (esium C 13/
1. T!ulium C 1/4
(. 5ae the gaa ray source used for industrial radiography wor/&
Answer: -
A. 6riium C 13,
B. (o"alt C &4
!age '1 of 7*
,. What is the depth of penetration in steel 4y co4alt H 76: cesiu H 1*<: $ridiu H 1>' &
0huliuH 1<6.
Answer: -
Penetration in steel "y' -
A. (o"alt C &4 ' - 3 inc!.
B. (esium C13/ ' - 3 M inc!.
(. 6riium C 13, ' - 3 inc!.
1. T!uliumC1/4 ' - M inc!.
7. What do you ean 4y photographic +ensity&
Answer: -
6t is t!e quantitati2e measurement of film "lac7ness. 6t is e=presse as' -
1 I 0og I0/It T. T w!ere8 1 is ensity.
I4 - 0ig!t intensity incient on t!e film.
It - 0ig!t intensity transmitte t!roug! t!e film.
<. 5ae the instruent used for easuring density of photographic or radiographic fil&
Answer: -
1ensitometre is an instrument for measuring t!e ensity of p!otograp!ic an raiograp!ic film.
=. What are the factors on which the density of radiographic fil depends&
Answer: -
T!e ensity of raiograp!ic films epens upon t!e following' -
A. Total amount of raiation emitte "y P-ray or gamma ray.
B. Amount of raiation reac!ing t!e specimen.
(. T!e amount of raiation passing t!roug! t!e specimen.
1. 6ntensifying action of t!e screen if use.
>. ;ow the intensity of source is related with fil distance&
Answer: -
6ntensity of P-ray or gamma ray 2aries in2ersely wit! t!e square of t!e istance from focal spot or
source of lig!t. T!is relation is 7nown as t!e 6n2erse square law.
Mat!ematically8 it is e=presse as' -
I1 = D2
2
I2 D1
2
M ?!ere I1 an I2 are intensities at t!e istance D1 and D2 respectively.
16. What are the go2erning factors for eFposure fro particular radioisotopes&
Answer: -
T!ere are t!ree factors for go2erning t!e e=posure wit! a gi2en 7ilo2oltage for P- ray or wit! t!e
gamma ray from particular raioisotopes.
A. Milliamperage *P-ray. or source strengt! *for %amma ray..
B. <ocal spot to film istance or source to film istance.
(. Time of e=posure.
!age '' of 7*
11. What is the relation 4etween Milliaperage "source strength% and fil distance&
Answer: -
T!e Milliamperage *M. is irectly proportional to t!e square of t!e focus to film istance *1.. T!e
equation is e=presse as' -
M1 D12
M2 D22
M?!ere8 M1 an M2 are t!e Milliamperage.
D1 an D2 are t!e istance from focus to film.
1'. What is the relation 4etween eFposure tie & fil distance&
Answer: -
T!e e=posure time *T. is irectly proportional to t!e square of t!e focus to film istances *1..
T!e equation is e=presse as '
T1 D12
T2 D22
1*. What is the relation 4etween Source strength & eFposure tie&
Answer: -
T!e Milliamperage *M. is in2ersely proportional to t!e time of e=posure *T.. T!e equation is
e=presse as' -
M1 T2 or M1 T1 M2 T2
M2 T1
M?!ere8 M1 an M2 are t!e Milliamperage.
T1 an T2 are t!e time of e=posure.
;ote' T!e a"o2e relation is also calle Feciprocity law an is true for irect P-ray or gamma ray
wit!
lea screen e=posure. T!e a"o2e relation is not quit accurate for e=posure to lig!t.
1(. ;ow the source strength of radiographic isotopes eFpressed&
Answer: -
T!e source strengt! of raiograp!ic isotopes e=presse in terms of (urie.
1,. What do you ean 4y eFposure&
Answer: -
6t is efine as t!e quantity of P or gamma raiation t!at prouces in air 8 ions carrying 1 coulom"
*(.
of c!arge * of eit!er sign. per Ag of air. T!e unit of e=posure is (5Ag.
17. What do you ean 4y #oentgen&
Answer: -
Foentgen is t!e ol unit for e=posure. 6t is efine as t!e amount of P or gamma raiation w!ic!
li"erates 1e s u of c!arge of eit!er sign in 1 (. ( of air at S T P.
1F I 1e s u 5 ( ( of air at STP.
I ,.)$ P 144 (5 Ag air.
!age '* of 7*
1<. What is +ose eAui2alent&
Answer: -
1ose Equi2alent I Ruality factor P a"sor"e ose.
Ruality factor generally consiere as'
A. 1 for P8 _or _.
B. 3 for T!ermal neutrons.
(. ,4 for - particles.
T!e unit of ose equi2alent is Sie2ert *S>..
<ormerly8 t!e unit of ose equi2alent was 1 rem.
1 Sie2ert I 144rem * Foentgen..
1=. What is the function of radiographic screens&
Answer: -
6t intensifies t!e raiograp!ic images on t!e film.
1>. What are the types of radiographic screens generally used&
Answer: -
Types of raiograp!ic screens generally use are' -
A. 0ea screen.
B. <luorescent screen or salt screens.
'6. What are the types of 9ead screens&
Answer: -
Types of 0ea screens are' -
A. 0ea foil screen.
B. 0ea o=ie screen.
'1. What do you ean 4y intensification factor " $-%&
Answer: -
E=posure time require to prouce require film ensity wit!out screen.
6ntensification factor I
E=posure time for same ensity using screen.
6n t!e a"o2e efinition it is assume t!at same film an raiation source use for t!e "ot! t!e
e=posure.
''. What are the factors upon which the intensification factor depends&
Answer: -
6ntensification factor ue to metallic screens epens on t!e following' -
A. Metal of foil.
B. T!ic7ness of foil.
(. Energy of raiation.
1. Specimen t!ic7ness.
'*. ;ow the intensification factor depends on etal of foil&
Answer: -
<or a gi2en raiation source8 t!e num"er of electrons prouce epens on t!e nature of t!e
metal
foil. 6ntensification factor increases wit! atomic num"er of t!e metal. <or gamma ray raiograp!y
generally 0ea screen are use.
!age '( of 7*
'(. ;ow the intensification factor depends on thic/ness of foil&
Answer: -
T!e intensification factor increases wit! t!e increase in t!e t!ic7ness of t!e foil. 6ntensification
increases ma=imum corresponing to t!e range of p!otoelectron in t!at metal. After furt!er
increase it
remains practically constant. 6f t!e t!ic7ness furt!er increase8 greater num"er of gamma
p!otons will
"e attenuate an t!is will reuce t!e prouce of p!otoelectrons.
',. ;ow the intensification factor depends on energy of radiation&
Answer: -
More is t!e energy of raiation8 more is t!e intensifying action.
'7. ;ow the intensification factor depends on thic/ness of the specien&
Answer: -
A specimen place in "etween t!e source an film performs following two functions' -
A. 6t filters t!e primary raiation.
B. %i2es low energy scattere raiation.
T!e raiograp!ic screen can !a2e ifferent sensiti2ities for primary raiation an t!e raiation
gi2en
"y t!e a"o2e two effects. @ence t!e c!ange in intensification factor wit! o"Eect t!ic7ness is
e=pecte.
T!e intensification of low energy scattere raiation is more t!an t!e intensification of !ig! energy
filtere raiation.
'<. Where the fluorescent screen finds its use&
Answer: -
T!e fluorescent screens are wiely use for meical purpose to reuce t!e e=posure time.
'=. What are the ain constituents of a radiographic fil&
Answer: -
T!e raiograp!ic films consist of t!e following' -
A. Base material.
B. Su""ing layer.
(. Emulsion an
1. Protecti2e layer5 Super coat.
'>. What is the different 4ase aterial tried so far for radiographic fil&
Answer: -
T!e materials so far trie for "ase is' -
A. %lass.
B. (ellulose ;itrate.
(. (ellulose Acetate.
1. (ellulose Triacetate.
E. Polyester * Most suita"le material to "e use as "ase material..
*6. What is the function of Su44ing aterial: Eulsion & protecti2e layer in radiographic
fil&
Answer: -
Su44ing aterial : - 6t pro2ies t!e stic7y action to t!e emulsion8 as t!e emulsion oes not
a!ere irectly on t!e "ase material.
Eulsion : - 6t contains sil2er "romie gelatin * %enerally animal "one marrow.
!rotecti2e 9ayer : - 6t is coate on emulsion in orer to protect t!e same from p!ysical
amage8 a"rasion an stress mar7.
!age ', of 7*
*1. ;ow the #adiographic fils are classified&
Answer: -
T!e Faiograp!ic films are classifie as' -
A. (lass C 6 ' - @ig!est contrast8 0owest spee.
B. (lass C 66 ' - @ig! contrast8 0ow spee.
(. (lass C 666 ' - Meium contrast8 Meium spee.
1. (lass C 6> ' - 0ow contrast8 @ig! spee.
*'. What is the 4asis of classification of radiographic fil&
Answer: -
(lassification of Faiograp!ic film is one on t!e "asis of grain siGe of Sil2er Bromie *Sil2er
Bromie
(rystals.. <iner t!e grain siGe of Sil2er Bromie in emulsion8 slower will "e t!e spee. %enerally
use
crystal siGe is 4.,,8 4.),8 4.&$8 4.$4 an 1 micron.
**. What is speed with reference to #adiography fil&
Answer: -
6t can "e efine as t!e ensity recors on t!e film resulting from a gi2en e=posure. 6t is in2erse
of
e=posure require to prouce on raiograp! of particular ensity uner t!e specifie conitions. A
film requires less e=posure to ac!ie2e particular ensity is calle fast film an more e=posure
calle
slow film.
*(. What type of fil is generally used for #adiography&
Answer: -
(lass C 666 type * 1)81/ C Agfa ma7e. film is generally use for raiograp!y.
*,. What type of fil is not used for industrial purpose "Csed for Medical purpose%&
Answer: -
(lass C 6> type * 114 C Agfa ma7e. film is not use for inustrial purpose.
*7. What do you ean 4y fil processing&
Answer: -
? !en t!e film is e=pose to t!e raiation8 creates latent image or in2isi"le image "y con2erting
t!e
sil2er "romie present in t!e emulsion into metallic sil2er. T!e e=pose film w!en processe
con2erts
latent image into 2isi"le image.
*<. What are the ain steps in fil processing&
Answer: -
Main steps in film processing are' -
A. 1e2eloping
B. Stop "at!.
(. <i=ture.
1. ?as!ing
E. 1rying.
*=. What are the ingredients of +e2eloper&
Answer: -
A. 1e2eloping Agent ' - Metol8 @yroquinone an Pencilone.
B. Accelerator ' - Soium car"onate.
(. Festrainer ' - Potassium Bromate.
1. Preser2ati2e ' - Soium Sulp!ate.
!age '7 of 7*
*>. What is the function of Accelerator present in +e2eloper&
Answer: -
6t encourages t!e e2eloper to supply more electrons.
(6. What is the function of #estrainer present in +e2eloper&
Answer: -
6t opposes to reuce t!e une=pose sil2er "romie. 6t acts as antifogging agent.
(1. What is the function of !reser2ati2e present in +e2eloper&
Answer: -
6t pre2ents o=iation.
('. What is the affect of teperature on +e2eloper&
Answer: -
T!e 1e2eloper supplies more electrons at !ig! temperature an reuces t!e e2eloping time.
9pposite is t!e case w!en t!e temperature is lower.
(*. What is the ideal de2eloping teperature&
Answer: -
Below 1$_( an a"o2e ,4_(8 e2eloping is not recommene.
((. What is the de2eloping tie generally recoended&
Answer: -
) to $ minutes. 0arger e2eloping time increases t!e fog ensity. T!e e2eloping time "elow 3
minutes is not recommene as t!e require ensity s!all not "e ac!ie2e an may miss minor
iscontinuities.
(,. What is the ingredient of Stop )ath&
Answer: -
,B Acetic Aci.
(7. What is the function of Stop )ath&
Answer: -
Stops t!e 1e2eloping action "y neutralising t!e al7aline e2eloper.
(<. What are the ingredients of -iFer&
Answer: -
<i=ing Agent A. Soium t!iosulp!ate commonly 7nown as @ypo. (ommonly use fi=ing agent.
B. Ammonium t!iosulp!ate. +se as rapi fi=ing agent.
(=. What is the function of -iFer&
Answer: -
6t remo2es all une=pose sil2er grains an cloue film starts to "ecome clear.
(>. What is the recoended tie for -iFer&
Answer: -
%eneral recommenation is ) to 1) minutes.
,6. What is #adiographic sensiti2ity&
Answer: -
6t is t!e com"ination of Faiograp!ic contrast an Faiograp!ic efinition. T!e Faiograp!ic
sensiti2ity is Euge "y 6mage quality 6nicator *6R6.8 also 7nown as penetrametre. :uging t!e
qualitati2e # quantitati2e quality of raiograp!8 a penetrametre is require. T!e image of 6R6 on
t!e
raiograp! is t!e e2ience t!at t!e raiograp!ic inspection was conucte uner proper conition
an ac!ie2e t!e require sensiti2ity.
Minimum 2isi"le wire iameter.
B Sensiti2ity I P 144
T!ic7ness of t!e Eo".
!age '< of 7*
,1. What is the general reAuireent of #adiographic Sensiti2ity&
Answer: -
%eneral requirement of Faiograp!ic sensiti2ity are' -
",B *0ess t!en two percent. C %oo.
,B *More ten two percent. C ;ot accepta"le.
,'. What are the coonly used $Q$&
Answer: -
(ommonly use 6R6 are' -
A. ?ire type Penetrametre.
B. Plate type Penetrametre.
(. Step type Penetrametre.
1. Step- @ole type Penetrametre.
,*. What are the criteria for selection of $Q$ or !enetraetre&
Answer: -
Penetrametre s!oul "e mae of same material as t!at of t!e specimen.
T!e selection of 6R6 s!oul "e mae as' -
A. <or car"on Steel # 0ow Alloy Steel ' - (ar"on Steel 6R6.
B. <or @ig! Alloy Steel # Stainless Steel ' - Stainless Steel 6R6.
(. <or Aluminum # Aluminum Alloy ' - Aluminum 6R6.
1. (opper # copper Alloy ' - (opper 6R6.
,(. 5ae soe $Q$&
Answer: -
? ire types 6R6 ' - 1-6S9-/8 &-6S9-1,814-6S9-1&
,,. What do you ean 4y #adiographic contrast&
Answer: -
1ensity ifference "etween t!e two aEacent areas of t!e raiograp! is 7nown as contrast.
Faiograp!ic contrast is t!e com"ine effect of t!e following.
A. Su"Eect contrast.
B. <ilm contrast.
,7. What is su43ect contrast&
Answer: -
T!e factor of t!e specimen8 w!ic! affects t!e contrast8 is 7nown as su"Eect contrast.
,<. What is fil contrast&
Answer: -
T!e factor of t!e film8 w!ic! affects t!e contrast8 is 7nown as <ilm contrast.
,=. What are the factors: which affects su43ect contrast&
Answer: -
Su"Eect contrast affecte "y' -
A. T!ic7ness ifference in t!e specimen.
+niform t!ic7ness of t!e specimen s!ows no contrast "ut t!ic7ness ifference in t!e specimen
sows goo contrast.
B. Faiation Ruality.
Best contrast is ac!ie2e "y ray of suita"le low 7ilo2oltage *Soft Faiation.. By increasing t!e
7ilo2oltage *@arer Faiation. penetration will increase "ut ecrease t!e su"Eect contrast.
(. Scattere Faiation.
By reucing t!e scattere raiation *internal8 sie an "ac7 scatters. using iap!ragm8 mas7s8
<ilters8 an lea screens increase t!e su"Eect contrast.
!age '= of 7*
,>. What are the factors: which affects the fil contrast&
Answer: -
<ilm contrast affecte "y' -
A. Type of film.
%rain siGe of t!e film controls t!e film contrast. <iner t!e grains *lower spee . of t!e film !ig!er
t!e film contrast.
B. <ilm processing.
6ncreasing t!e e2eloping time increases t!e ensity as well as fog ensity an ecreases t!e
film
contrast. Processing of film in fres! e2eloper gi2es !ig!er contrast t!en t!e e=!auste
e2eloper.
(. <ilm 1ensity.
At !ig!er film ensity8 t!e film contrasts is more an at low ensity t!e film contrast is less.
76. Where the $Q$ "!enetraetre% is placed&
Answer: -
T!e 6R6 or penetrametre s!oul "e place as possi"le on t!e source sie of t!e raiation. ?!en it
is
not possi"le as in case of ou"le wall single image raiograp!y8 it can "e place on t!e film sie
wit!
a lea letter U < U near t!e 6R6. T!e 6R6 s!oul "e place in most unfa2oura"le location wit!
respect to
t!e raiation "eam.
71. What are the different types of #adiography or EFposure techniAue&
Answer: -
1ifferent types of Faiograp!y tec!niques are' -
A. Single wall single image *Panoramic E=posure..
B. 1ou"le wall single image.
(. 1ou"le wall ou"le image.
Question related to EAuipent and piping 9ayout: -
1. What are the steps in2ol2e in !lant design&
Answer: -
T!e mec!anical esign an e2elopment of t!e plant !as t!ree maEor steps as' -
A. (onceptual layout esign.
). Equipment layout esign.
C. Piping layout esign.
'. What is conceptual layout design&
Answer: -
6t is t!e part of "asic engineering pac7age. 6t consists of following information' -
A. Essential process esign requirement suc! as !oriGontal # 2ertical relations!ip of equipment.
). Space allocation for "asic plant requirement *space require for la"oratories8 office8 storage
etc..
C. Planning for control room8 motor control center room etc.
*. What is EAuipent layout design&
Answer: -
6t is t!e etailing of conceptual layout. 6t is t!e "asic ocument of mec!anical engineering esign
or in
ot!er wors t!is ocument is t!e "asis for e2elopment of construction rawing "y all isciplines.
6t is
sometimes also referre as plot plan for large outoor plant.
6t consists of following information' -
A. <loor space neee for t!e equipment an ot!er facilities are s!own.
). Access8 remo2al space8 cleaning area8 storage space an !anling facilities are outline.
(. What are the essential data8 docuents reAuired for preparation of eAuipent layout&
Answer: -
T!e essential ata or ocuments require for preparation of equipment layout is as' -
A. !rocess flow diagras "!-+% and !iping & instruent +iagras "!& $+%.
P<15 P# 61 inicates t!e interconnecti2ity of eac! equipment8 information regaring soli
!anling8 gra2ity fee8 line slopes8 loop siGes8 2enting requirement8 special piping materials etc.
w!ic! in turns go2erns t!e equipment location to a great e=tent.
!age '> of 7*
). !ro3ect design data.
T!is consists of following information as' -
%eograp!ic location8 pro=imity to roas an railway8 topograp!y an local coes an
regulations8
weat!er conitions suc! as rainfall recors8 seasonal temperature ifferences8 win irection8
outlet points for rains etc.
T!e a"o2e information suc! as win irection influences t!e location of cooling towers8
furnaces8
stac7s etc. Similarly8 t!e information regaring outlet rain points affects t!e esign of storm
water
rains an requirements of enclosures.
C. EAuipent si@es and )uilding.
T!is inclues fa"ricate equipment suc! as 2essels8 @eat E=c!angers8 Feactors8 Tan7s an
proprietary equipment li7e pumps8 (ompressors8 <urnaces etc. <or locating t!e a"o2e8 t!e
equipment is groupe to !a2e optimum location for minimum pipe run as well as fallow t!e
process
flow sequence.
,. What are the two 4asic configurations for the eAuipent layout "unit plot plan%&
Answer: -
T!e equipment layout can "asically "e i2ie into two configurations'
A. T!e %rae Mounte @oriGontal arrangement as seen in t!e refineries an petroc!emical
plants.
). T!e 2ertical Arrangement as seen in many c!emical process inustries.
7. What is .rade ounted ;ori@ontal Arrangeent of eAuipent layout&
Answer: -
6n t!e %rae mounte @oriGontal Arrangement8 t!e equipment is place on t!e eit!er sie of t!e
central pipe rac7 wit! au=iliary roas. A2antage of t!is arrangement is t!at t!e equipment is
locate
at grae le2el8 w!ic! ma7es it easier to construct8 operate an maintain. 1isa2antage is t!at it
ta7es
lot of groun area.
<. What is 1ertical arrangeent of eAuipent layout&
Answer: -
T!e structure mounte 2ertical arrangement !as equipment locate at multile2el in steel or
concrete
structure. T!is coul "e inoor or outoor. A2antage is of small co2erage area an a"ility to
!ouse
t!e facility to suit process requirement or climate conitions.
=. What are the 4asic principles of locating the EAuipent irrespect of the type of
arrangeent&
Answer: -
T!e certain "asic principles to "e followe w!ile locating t!e equipment is as' -
A. Econoic piping :
6n orer to minimiGe t!e cost of piping8 t!e equipment s!oul "e locate in process sequence an
close enoug! to suit safety nees8 access requirements an fle=i"ility. T!e equipments are
ientifie
w!ic! forms t!e su"system wit!in t!e unit. T!e component wit!in t!e su"system to "e arrange
to
!a2e most economical piping an t!e w!ole su"system to "e arrange wit!in t!e unit to !a2e
most
economic interconnection.
). !rocess #eAuireent:
T!e equipment layout s!oul support requirement li7e minimum pressure rop8 gra2ity fee an
loop.
C. Coon operation:
T!e equipment t!at requires common maintenance facilities8 common utility an continuos
operator
attention s!all "e locate t!e same area.
+. Cnderground -acilities:
Before eciing t!e equipment location8 t!e facilities suc! as storm water rain8 effluent rain8 fire
water8 cooling water to "e place unergroun.
>. What is 9ine #outing +iagra&
Answer: -
A line routing iagram is a sc!ematic representation of all process an utility-piping system rawn
on
a copy of plot plan. T!is iagram oes not s!ow t!e e=act locations8 ele2ations or interference "ut
it
locates t!e most congeste area.
!age *6 of 7*
16. ;ow do you calculate the width of !ipe rac/&
Answer: -
? I *f P n P s. S A S B.
T?!ere8 f : Safety <actor
I 1.) if pipes are counte from P<1.
I 1., if pipes are counte from P#61.
n : num"er of lines in t!e ensest area up to siGe 4)4;B.
I 344 mm *Estimate a2erage spacing.
I ,,) mm *if lines are smaller t!an ,)4 ;B.
A : Aitional ?it! for' C
: V 0ines larger t!an 4)4 ;B.
' <or instrument ca"le tray 5 uct.
' <or Electrical ca"le tray.
s : 344 mm *estimate a2erage spacing.
' ,,) mm *if lines are smaller t!an ,)4 ;B.
) : future pro2ision
I ,4B of *f P n P s. S A
11. Cp to what liit the width of pipe #ac/ is restricted& What type of arrangeent shall 4e
done
if the width of rac/ calculated is ore then the restricted liited&
Answer: -
;ormally pipe Fac7 wit! is limite to &.44 Mtrs. 6f t!e wit! of rac7 calculate is more t!en t!e
arrangement s!all "e one in multiple layers. T!e arrangements aopte are' -
A. Single column Fac7 UTW type.
). 1ou"le column Fac7 wit! a single tier.
C. 1ou"le column Fac7 wit! a ou"le tier.
1'. ;ow uch space is /ept in 4etween colun of pipe rac/&
Answer: -
;ormally8 ) to & Mtrs. spacing is 7ept in "etween t!e column of pipe rac7.
1*. At which location the wide spacing "spacing ore than the noral% in 4etween the
colun is
necessary&
Answer: -
? ie spacing is necessary at roa crossing or w!ere loaing or access space is neee.
1(. ;ow uch ;eadroo clearance is reAuired under the following type of crossing&
A. Structures8 pipe lines inside operating area.
). -ro top of the #ail.
C. A4o2e crest of road for crane o2eent.
+. A4o2e crest of road for 0ruc/ o2eent.
E. A4o2e crest of road 4etween process units.
Answer: -
T!e @earoom normally pro2ie is as' -
A. Structures5 pipe lines insie operating area. ' ,,44
). <rom top of t!e Fail. ' /444
C. A"o2e crest of roa for crane mo2ement. ' /444
+. A"o2e crest of roa for Truc7 mo2ement. ' &444
E. A"o2e crest of roa "etween process units. ' 4)44
1,. What sort of drawing8 layout is reAuired for piping layout&
Answer: -
T!e following 1rawing5 0ayout are require for piping layout.
A. Piping # instrumentation 1iagram *P# 61..
). Equipment 0ayout.
C. Piping Specification.
+. Equipment 1rawing.
E. >enor Fequirement for proprietary equipment.
!age *1 of 7*
17. What care shall 4e ta/en while routing piping for instruents&
Answer: -
<ollowing points s!all "e ta7en care of w!ile routing piping for instruments.
A. <low measuring instrument nees certain straig!t lengt! on upstream # ownstream of t!e
instruments. ;ormally8 1)1 on t!e upstream an )1 on t!e ownstream is 7ept.
). T!e pipe line in w!ic! flow meters suc! as magnetic flow meters8 2orte= meters8 tur"inemeters
etc
are locate s!all "e route in suc! a way t!at t!e line must "e fille wit! liqui all t!e time. T!e
pipe line s!all "e supporte wit! ro"ust support on "ot! sie of t!e meter.
C. (ontrol 2al2es are locate at grae e.g. at a"out )44mm !eig!t from finis!e groun to
pro2ie
con2enient access for operation an maintenance. Bloc7 an "ypass 2al2e s!all "e locate to
!a2e easy operation5 access from t!e grae. 0ocating control 2al2e on t!e 2ertical line s!all "e
a2oie.
+. 6solation 2al2es for le2el gauges an pressure gauges s!all "e mae accessi"le. All primary
an
seconary inicators of pressure8 temperature8 flow8 le2el8 positioners etc s!all "e 2isi"le from t!e
operating area.
E. Fotameter s!all "e place on 2ertical line an t!e inlet s!all "e from t!e "ottom of t!e
instrument.
Question #elated to Mechanical +esign -undaentals:-
1. What are the -ailures with reference to the structural design&
Answer:-
<ailure of a structural part can occur "y'-
A. E=cessi2e elastic eformation.
). E=cessi2e non-elastic eformation.
C. <racture.
Any esign !as to guar against t!ese percei2e failures.
'. What are the factors upon which the echanical properties of aterial are dependent&
Answer:-Mec!anical properties of any material of construction are epenent on'-
A. (!emical composition of t!e material.
). Met!o "y w!ic! t!e material is manufacture.
*. What is stress&
Answer:-
6t is efine as t!e applie loa per unit cross-section of t!e specimen. T!e common unit are psi
*poun per square inc!.8 7pa8 Mpa8 7g5cm, .
*. What is strain&
Answer:-
<or tensile loa8 it is t!e ratio of increase in lengt! of t!e specimen uner constant sustaine loa
to
t!e original lengt! of t!e specimen "efore t!e loa is applie. <or compressi2e loa8 it t!e ratio of
ecrease in lengt! to t!e original lengt! uner sustaine loa. Strain is t!us an o"ser2a"le an
measura"le quantity as t!e e=tension or compression of t!e specimen can "e irectly measure.
6t is
a imensionless quantity.
(. +raw the Stress- Strain cur2e showing the 4eha2ior of the specien under stress&
Answer:-
Cpper yield points.
Stress 9ower yield points.
Strain
!age *' of 7*
?!en t!ere is no loa8 t!ere are no stresses an no strain. ?!en a small tensile loa is applie8
t!e
strain can "e measure an stress eri2e. 6f t!e loa is remo2e8 t!e specimen returns to its
original
s!ape. T!at is t!ere is no resiual or permanent strain in t!e specimen. T!is situation continues
up to
a certain le2el of stress. A stress strain cur2e in t!is region is a straig!t line i.e. stress is
proportional
to strain. T!is region of cur2e is calle t!e elastic region8 as t!e M9(Xs "e!a2ior is elastic li7e a
ru""er.
As t!e tensile loa uring t!e test is increase furt!er8 a situation arises w!en t!e specimen oes
not
return to t!e original imension e2en w!en t!e loa is wit!rawn. T!is is also t!e le2el or stress
le2el
at w!ic! t!e stress strain cur2e "egins to e2iate from t!e elastic straig!t- line "e!a2ior as s!own
in
t!e grap!. T!us8 t!e metal 5 specimen are unergoing plastic eformation in aition to elastic
eformation. ?!en t!e loa is wit!rawn8 t!e elastic eformation is reco2ere "ut t!e plastic
eformation stays.
,. What is upper yield point with reference to a4o2e stress-strain .raph "Cltiate 0ensile
Strength%&
Answer:-
T!e !ig!est stress t!at t!e metal can wit!stan uner sustaine loa wit!out continuing to
elongate
uner same loa is calle t!e upper yiel point.
7. What is lower yield point with reference to a4o2e stress- strain .raph&
Answer:-
<. What is the effect on the specien when su43ected to a sustained load with higher
teperatures&
Answer:-As t!e temperature of t!e test increases8 specimen of t!e same material woul elongate
more for t!e
same loa as compare to specimen teste at lower temperature. 6t means t!at t!e material
"ecomes
softer as it is su"Eecte to !ig!er an !ig!er temperatures.
Stress-strain cur2es are different for different aterials and at different teperatures for
the
sae aterials.
Stress
$ncreasing 0eperature
Strain
Stress- strain cur2es at different 0eperatures.
=. What is Allowa4le Stress&
Answer:-
6t is efine as ultimate tensile strengt! i2ie "y factor of safety. T!e safety factor is o"2iously
greater t!an 1. 1esign w!ic! ensure t!at t!e stress 2alue anyw!ere in t!e structure is less t!an
t!is
allowa"le stress are consiere safe as t!ey o not allow t!e structure element to come
anyw!ere
close to t!e point w!ere plastic insta"ility leaing to isruption or isintegration of element woul
set
in.
!age ** of 7*
>. What is the 2alue of allowa4le stress if yield stress or 6.'N proof stress 2alue is
a2aila4le at
design teperature&
Answer:-
6f t!e yiel stress or 4.,B proof stress 2alue is a2aila"le at esign temperature8 t!e same s!all "e
i2ie "y a safety factor of 1.) to get allowa"le stress.
16. What is the 2alue of allowa4le stress if the yield stress is not a2aila4le at design
teperature
4ut is a2aila4le at roo teperature&
Answer:-
6f t!e yiel stress is not a2aila"le at esign temperature "ut is a2aila"le at room temperature8 t!e
same s!all "e i2ie "y safety factor of 3.4 to get allowa"le stress.
11. What is the 2alue of allowa4le stress if the stress 2alue for rupture due to static fatigue
or
creep failure is a2aila4le at design teperature&
Answer:-
6f t!e stress 2alue for rupture ue to static fatigue or creep failure is a2aila"le at esign
temperature8
t!e same s!all "e i2ie "y safety factor of 1.) to get allowa"le stress.
5ote: 0he safety factor considered a4o2e is recoended for car4on steel and low alloy steel.
1'. ;ow uch design teperature shall 4e considered for the structural parts which are
heated
4y stea: theric fluid etc&
Answer:-
1esign temperature s!all "e t!e !ig!est e=pecte temperature of t!e !eating meia or !ig!est
e=pecte "oy part temperature plus 14_(. @ere8 14_( is t!e safety margin.
1*. What shall 4e the safety argin "teperature related% considered for fired 2essel parts
which
are shielded "4y #efractory% and the parts which are unshielded&
Answer:-
Safety margin for s!iele parts ' ,4_(.
Safety margin for uns!iele parts ' )4_(.
5ote: 0he a4o2e safety argins are 3ust guidelines. What should 4e the safety argin would depends upon the
se2erity of operation
1(. +efine !roof Stress&
Answer:-
6t is also calle 4.,B proof stress. 6t is t!e stress for 4.,B strain. 6n simpler terms8 it is t!e stress
2alue for strain 2alue of 4.44, on t!e stress strain cur2e.
1,. ;ow the proof stress in a aterial is altered "increased arginally%&
Answer:-
-
+
.
C
Stress
E Strain
$ncrease in proof stress due to cold wor/.
(onsier a stress strain cur2e as s!own a"o2e. 0et a fres! specimen "e su"Eecte to graually
increasing tensile loas. A 4.,B proof stress can "e mar7e on t!e cur2e as t!e stress 2alue
corresponing to point ( on t!e cur2e. 0et t!e loa "e increase "eyon t!is point up to point 1
on
!age *( of 7*
t!e cur2e. T!e specimen !as surely passe t!e elastic range an crosse o2er to plastic
eformation.
9n wit!rawal of t!e loa8 t!e specimen woul return "ac7 to point E wit! a resiual permanent
strain
as s!own a"o2e. Tensile loa test can now "e conucte on t!is specimen w!ic! !as seen
plastic
eformation or col wor7 pre2iously. T!e specimen woul now follow a stress- strain cur2e wit!
strain
Gero at point E. Along t!is stress strain cur2e *E%<.8 4.,B proof stress correspons to point %
w!ic!
is !ig!er t!an t!e proof stress for t!e fres! specimen.
0he aterial in the a4o2e case sees to ha2e hardened with its eFperience of stress
earlier.
Most aterial shows this arginal increase in their proof stress due to cold wor/.
17. What are the types of failures encountered in !iping&
Answer: -
1. (atastrop!ic <ailure. '. <atigue <ailure.
1<. +efine catastrophic failure&
Answer:-
T!e failures w!ic! occurs suenly as soon as t!e loa crosses t!e t!res!ol *+ltimate tensile
strengt!.. T!ese failures ta7e place on t!e first occurrence of t!e loas in e=cess of yiel stress.
1=. What is fatigue failure&
Answer:-
T!e failure w!ic! occurs ue to amaging of t!e grain structure of t!e specimen su"Eecte to
prolonge application of sustaine loa an or tensile Ccompressi2e loa cycle.
1=. What are the types of -atigue failure&
Answer:-
Types of fatigue failure are'-
A. Static <atigue.
). (yclic <atigue.
1>. What is Static -atigue&
Answer:-
T!e specimen w!ic! fails uner sustaine loa su"Eecte to consiera"le lengt! of time. T!e total
time for w!ic! t!e loa was applie is important. ?!et!er it is applie continuously or in
installments
is not important.
'6. What is cyclic fatigue&
Answer:-
T!e specimen w!ic! fails uner a loa cycle su"Eecte to consiera"le num"ers of times. T!e
total
num"ers of cycles for w!ic! t!e loa was applie is important. ?!et!er t!e cycle was frequent or
infrequent is not important.
'1. EFplain the failure of the specien su43ected to cyclic load&
Answer:-
(onsier a specimen su"Eecte to a tensile loa increasing from Gero to P an t!en t!is loa is
graually wit!rawn till it is Gero. ;ow compressi2e loa applie graually till it is P an t!en it is
rawn till t!e loa is Gero. T!is comprises a cycle an is repeate again an again. ?it! eac!
cycle8
t!e grains in t!e material get isplace relati2e to eac! ot!er an get more an more interloc7e.
?it! eac! cycle8 t!e material loses its uctility in small increments. A time comes w!en t!e grains
are
so "aly interloc7e t!at t!ey cannot allow eformation to wit!stan loa an a small crac7
e2elops.
T!is crac7 grows wit! furt!er cycles an failure occurs.
''. What is creep failure&
Answer:-9ccurrence of static fatigue failure w!en t!e material is uner prolonge sustaine loa
couple wit!
!ig! temperature is calle creep failure.
'*. Write the seAuence of stress 2alues at failures for solid rod: sphere and cylinders&
Answer:-A typical sequence of stress 2alues at failure for soli ros an two most important
s!apes in process
inustry namely8 sp!ere an cyliner is Fo Y Sp!ere Y (yliner.
!age *, of 7*
Questions #elated to pipe under stress:-
1. What are !riary loads& Mention soe of !riary 9oads&
Answer:-
T!ese are typically steay or sustaine types of loas. T!ese loas !a2e t!eir origin in some
force
acting on t!e pipe causing tension8 compression8 torsion etc leaing to normal an s!ear stress.
Primary loas are not self limiting. Some of t!e primary loas are as'-
A. 6nternal flui pressure
). E=ternal pressure.
C. %ra2itational forces acting on t!e pipe suc! as weig!t of t!e pipe # flui.
+. <orces ue to relief or "low own.
E. Pressure wa2es generate ue to water !ammer effects.
'. What do you ean 4y self liiting&
Answer:-
6t means t!at t!e stresses continue to e=ist as long as long t!e loa persists an eformation
oes
not stop "ecause t!e system !as eforme into a no-stress conition "ut "ecause strain
!arening
!as come into play.
*. What are secondary loads& Mention soe of the secondary loads&
Answer:-Seconary loas are cause "y isplacement of some 7in. Some of t!e seconary
loas are as'-
A. <orce on piping ue to tan7 settlement.
). >essel noGGle mo2ing up ue to e=pansion of 2essel.
C. Pipe e=pansion or contraction.
+. >i"ration ue to rotational equipment.
(. What is the ost used choice of co-ordinate syste for defining the stresses&
Answer: -
6n a pipe su"Eecte to internal pressure or any ot!er loa8 t!e most use c!oice of co-orinate
system
is as'
A. A=ial or 0ongituinal irection.
). (ircumferential or @oopeWs irection.
C. Faial irection.
T!e stresses in t!e pipe wall are e=presse as a=ial*S0.8 @oopeWs *S@. an Faial *SF..T!ese
stresses w!ic! stretc! or compress a grain5 crystal are calle normal stress "ecause t!ey are
normal
to t!e surface of t!e crystal.
,. What do you ean 4y ;oop Stresses and how do you calculate it&
Answer: -
Stresses w!ic! are generate circumferentially ue to t!e action of 6nternal pressure of pipe are
calle
@oop Stress. 6t is calculate "yX -
@oop Stress *S!. I Po 5 ,t
?!ere P I <orce Acting from 6nsie.
o I 91 of Pipe.
t I Pipe T!ic7ness.
7. ;ow does ;oop Stress affect the syste&
Answer: -
As per mem"rane t!eory for pressure esign of cyliners8 as long as !oop stress is less t!an
yiel
stress of Moc8 t!e esign is safe. @oop stress inuce "y t!ermal pressure is twice t!e a=ial
stress
*S0.. T!is is wiely use for pressure t!ic7ness calculation for pressure 2essel.
!age *7 of 7*
<. What are the other stresses against which the design of piping is safe guarded&
Answer:-A. Principal stress.
). S!ear stress.
Apart from t!e stress w!ic! is normal to t!e surface of t!e crystal as mentione in question ;o. 48
t!e
grains woul !a2e "een oriente in t!e pipe wall in all possi"le orientations. T!e a"o2e stresses
*A=ial8 (ircumferential an Faial stress. !a2e stress component in irection normal to faces of
ranomly oriente crystal. Eac! crystal t!us faces normal stresses. 9ne of t!ese orientations
must "e
suc! t!at it ma=imiGes one of t!e normal stresses. ;ormal stresses for suc! orientation
*ma=imum
normal stress orientation. are calle principal stresses an are esignate as S1 *ma=imum.8 S,
an
S3 *minimum..
!rincipal stresses are way of defining the worst case scenario as far as the noral
stresses
are concerned.
6n aition to t!e normal stresses8 a grain can "e su"Eecte to s!ear stresses as well. T!ese
stress
act parallel to t!e crystal surface. T!e s!ear stresses occur if t!e pipe is su"Eecte to torsion8
"ening
etc. :ust as t!ere is an orientation for w!ic! normal stresses are ma=imum8 t!ere is an orientation
w!ic! ma=imiGes s!ear stress. T!e ma=imum s!ear stress in a 3-1 state of stress can "e s!own
to
"e as'-
ma= I *S1-S3.5,
i.e. !alf of t!e ifference "etween t!e ma=imum an minimum principal stresses.
=. What does the solid echanics states regarding the 5oral stresses&
Answer:-Soli mec!anic states t!at t!e sum of t!e t!ree normal stresses for all orientation is
always t!e same
for any gi2en e=ternal loa as'-
S0S S@ S SF I S1 S S, S S3
>. Which coponent of noral stress is considered negligi4le&
Answer:-
6n most pipe esign cases8 t!e raial component of normal stresses *SF. is negligi"le as compare
to
t!e ot!er two component *S@ an S0..
16. ;ow the two principal stresses and aFiu shear stress are calculated&
Answer:-
+se of Mo!rWs circle allows calculating t!e two principal stresses an ma=imum s!ear stress as'-
S1 I *S0 S S@.5, S _ZS0 - S@[5, `, S ,_4.)
S, I *S0 S S@.5, - _ZS0 - S@[5, `, S ,_4.)
ma= I 4.) _ZS0 C S@.,S 4 ,_4.)
T!e t!ir principal stress *minimum i.e. S3. is Gero.
11. What are the potential loads faced 4y pipes during noral operation& Write their
relationship
to the stresses de2eloped&
Answer:-
T!e potential loas face "y a pipe are'-
A. A=ial loa.
). 6nternal5 E=ternal pressure loa.
C. Bening loa.
+. S!ear loa.
E. Torsional loa.
!age *< of 7*
A. AFial 9oad:-
do di
-9
!ipe under AFial load "0ensile%
A pipe may face an a=ial force *<0. as s!own in figure. T!e loa may "e tensile or compressi2e. 6n
figure only tensile loa acting on pipe is s!own. T!e loa *<0. leas to normal stress in a=ial
irection
*S0.. T!e loa "earing cross-section is t!e cross-sectional area of t!e pipe wall normal to t!e loa
irection8 Am.T!e stress e2elope is gi2en "y'-
S0 I <0 5 Am
T!e loa "earing cross- section is calculate as'-
Am I *o
, C i
,.54 *rigorous.
I *o S i. t5, *"ase on a2erage 1iameter..
I o t *"ase on outer 1iameter..
Some e=amples of cause of a=ial loa are as'-
1. T!e metal cross- section at t!e "ase of t!e column is uner t!e weig!t of t!e column section
a"o2e it incluing t!e weig!t of ot!er column accessories suc! as insulation8 trays8 laers etc.
'. Sometimes t!e pipe is intentionally cut a little s!ort t!an t!e en- to- en lengt! require. 6t is
t!an connecte to t!e noGGle "y forci"ly stretc!ing it. T!e pipe as assem"le is uner a=ial
tension. ?!en t!e !ot fluis starts mo2ing t!roug! t!e pipe8 t!e pipe e=pans an t!e
compressi2e stresses are generate. T!e col tensile stresses are t!us nullifie.
). $nternal 8 EFternal pressure 9oad:-
A pipe use for transporting flui is su"Eecte to t!e internal pressure loa. T!is internal or
e=ternal pressure inuces stresses in t!e a=ial as well circumferential *@oopeWs. irections. T!e
pressure also inuces stresses in t!e raial irection "ut is often neglecte.
AFial Stress
T!e internal pressure e=erts an a=ial force equal to pressure times t!e internal cross-section of
pipe as'-
<0 I P _i
,54_
T!is t!en inuces a=ial stress calculate as'-
S0 I Po54t
*9uter iameter is use for calculating metal cross-section as well as pipe cross- section..
!age *= of 7*
;oopeGs or Circuferential Stress
T!e internal pressure also inuces stresses in t!e circumferential irection as s!own in figure.
S;
ro r
ri
!
S;
;oopeGs Stress +ue to $nternal !ressure.
T!e stresses are ma=imum for grains situate at t!e inner raius an minimum for t!ose situate
at t!e outer raius. T!e @oopeWs stress at any point in "etween raial position *r. is gi2en as'-
S@ at r I P Zri
, S ri
,ro
,.5 ro
, C ri
,. ----------------- *0ameWs equation.
<rom mem"rane t!eory8 S@ is calculate as'-
S@ I Po5 ,t or Pi5 ,t
#adial Stress
<or t!in walle pipes8 t!e raial stress 2ariation can "e neglecte.
Faial stresses are also inuce ue to internal pressure as s!own in figure.
Patm or Pe=t
PP
#adial Stresses +ue to $nternal !ressure.
At t!e outer s7in8 t!e raial stress is compressi2e an equal to t!e atmosp!eric pressure *Patm. or
e=ternal pressure *Pe=t. on t!e pipe. At t!e inner raius8 it is also compressi2e "ut equal to
a"solute flui pressure *Pa"s.. 6n "etween it 2aries. But it is often neglecte.
C. )ending 9oad:-
Pipe "ening is cause mainly ue to two reasons'
A. +niform weig!t loa
). (oncentrate weig!t loa.
Pa"s
!age *> of 7*
Cnifor Weight 9oad.
A pipe span supporte at two ens woul sag "etween t!e supports ue to t!e following'
A. Self weig!t of t!e pipe an weig!t of t!e insulation w!en not in operation.
). Self weig!t an weig!t of !yrostatic test flui uring !yrostatic test.
C. Self weig!t8 weig!t of insulation an weig!t of flui it is carrying uring operation.
All t!ese weig!ts are istri"ute uniformly across t!e unsupporte span an lea to ma=imum
"ening moment eit!er at t!e centre of t!e span or at t!e en points of t!e span.
0et t!e total weig!t of t!e pipe8 insulation an flui "e ? an t!e lengt! of unsupporte span "e 0
as s!own in figure.
Pinne Support.
Total 0oa
?
<i=e Support.
Cniforly +istri4uted 9oad.
T!e weig!t per unit lengt!8 w I ?50
T!e ma=imum "ening moment *Mma=. w!ic!
occurs at t!e centre for t!e pinne support. Mma=. I w0,5$
<or fi=e support8 t!e ma=imum "ening
moment occurs at t!e en. Mma= I w0,51,
T!e pipe configuration an support use in process inustry o not confirm to any of t!e a"o2e
ieal support an is consiere somew!ere in "etween. T!e common practice is to use t!e
following a2erage formula to calculate "ening moment for practical pipe configuration.
Mma=. I w0,514
Concentrated Weight 9oad.
T!e e=ample of concentrate loa is a 2al2e on a pipe run.
!ointed load
!inned Support
a 4
9
a 4 -iFed support.
9
T!e loa is acting at t!e centre of gra2ity of t!e 2al2e an t!e ma=imum "ening moment occurs
at
t!e point of loaing for pinne support is gi2en "y'
Mma=. I ? a " 5 0
<or rigi support8 t!e ma=imum "ening moment occurs at t!e en nearer to t!e pointe loa an
is
gi2en "y'
Mma=. I ?a,"50, *UaW is ta7en as t!e longer of two arm in using t!e formula..
T!e "ening moment in t!e a"o2e case can "e reuce to Gero "y ma7ing eit!er UaW or U"W Gero i.e.
locating one of t!e supports rig!t at t!e point w!ere t!e loa is acting. 6n actual practice8 it woul
mean supporting t!e 2al2e itself. As it is not possi"le8 t!e common practice is to locate one of t!e
supports as close to t!e 2al2e *or any ot!er pointe an significant loa.. By t!is8 t!e "ening
moment ue to pointe loa is minimal an can "e neglecte.
!age (6 of 7*
AFial Stress due to )ending
MaFiu copressi2e stress.
M4
5atural AFis
MaFiu 0ensile stress.
?!ene2er t!e pipe "ens8 t!e s7in of t!e pipe wall e=periences "ot! tensile an compressi2e
stresses in t!e a=ial irection as s!own in t!e figure. T!e a=ial stress c!anges from ma=imum
tensile
on one sie of t!e pipe to ma=imum compressi2e on t!e ot!er sie. 9"2iously8 t!ere is natural
a=is
along w!ic! t!e "ening moment oes not inuce any a=ial stress. T!is is also t!e a=is of t!e
pipe.
T!e a=ial tensile stress for "ening moment M" at location c as measure from natural a=is is
gi2en
"y'
S0 I M" c 5 "
"is t!e moment of inertia of t!e pipe cross-section. <or a circular cross-section pipe8 "is gi2en
"y'
"I *o
4 C i
4. 5 &4
T!e ma=imum tensile stress occurs w!ere c is equal to t!e outer raius of t!e pipe an is gi2en
"y'
S0 at outer raius I M" ro 5 "I M"5K
?!ere K *I"5ro. is t!e section moulus of t!e pipe.
+. Shear 9oad:- 1
Shear -orce on a pipe
S!ear force *>. acting on t!e pipe is s!own in t!e figure. 6t causes s!ear stresses w!ic! are
ma=imum along t!e pipe a=is an minimum along t!e outer s7in of t!e pipe. T!is is e=actly
opposite
of t!e a=ial stress pattern cause "y "ening moment. T!ese stresses are small in magnitue
!ence
not ta7en in account in pipe stress analysis. 6f necessary t!ese are calculate as'
ma=. I>R5Am w!ere8 R is s!ear form factor an Am is metal cross-section.
E. 0orsional 9oad:-
r M0
T!is loa causes s!ear stresses. T!e s!ear stress cause ue to torsion is ma=imum at
outer pipe raius. T!e Torsional moment is gi2en "y'
*at r Iro. I MT ro 5FT I MT ro 5*,6. I MT5 , K
w!ere8 FT is t!e Torsional resistance I twice t!e moment of inertia.
ro
r
ri
!age (1 of 7*
1'. What are the 0heories of failure&
Answer:-
6mportant t!eories in common use are'-
A. Ma=imum Stress T!eory or Fan7ine T!eory.
). Ma=imum S!ear T!eory or Tresca T!eory.
C. 9cta!eral S!ear T!eory or >on Mises T!eory.
1*. What is MaFiu stress theory&
Answer:-Accoring to t!is t!eory8 failure occurs w!en t!e ma=imum principal stress in a system
*S1. is greater
t!an t!e ma=imum tensile principal stress at yiel in a specimen su"Eecte to unia=ial test. 6n
unia=ial
test8 t!e applie loa gi2e rise to a=ial stress *S0. only an @oopeWs stress *S@. # Faial stress
*SF.
as well as t!e s!ear stress are a"sent. 6n a specimen uner unia=ial tension test at yiel t!e
following
!ols.
S0 I S\8 S@ I 48 SF I 4
S1 I S\8 S, I 48 an S3I 4
T!e ma=imum tensile principle stress at yiel is t!us equal to t!e con2entionally reporte yiel
stress
*loa at yiel 5 cross- sectional area of specimen.
0he #an/ine theory thus says that the failure occurs when the aFiu principal stress
in a
syste "S1% is ore than the yield stress of the aterial "SE%.
1(. What is MaFiu Shear 0heory&
Answer:-
Accoring to t!is t!eory t!e failure occurs w!en t!e ma=imum s!ear stress *ma=. is greater t!an
t!e
ma=imum s!ear stress at yiel in a specimen su"Eecte to unia=ial tension test.
ma=. I 4.) _*S0 C S@., S 4,_4.)
Since8 in t!e unia=ial tension test S@ an is Kero. T!us8
ma= I S05, I S\5,
0he 0resca 0heory thus says that the failure occurs when the aFiu shear stress in a
syste "aF% is ore than half the yield stress of the aterial.
1,. What is ?ctahedral Shear 0heory&
Answer:-
Accoring to t!is t!eory8 t!e failure occurs w!en t!e octa!eral s!ear s!ear stress in a system
*oct..
is greater t!an t!e octa!eral s!ear stress at t!e yiel in a specimen su"Eecte to unia=ial tension
test. T!e octa!eral s!ear stress is gi2en "y'
oct I 153 _*S1 - S,., S *S, C S3., S *S3 C S1., _4.)
T!e octa!eral s!ear stress at yiel in t!e specimen su"Eecte to unia=ial tension test is gi2en "y'
oct I ,53 S\
4.)
Questions #elated to Stress Analysis:-
1. What is the o43ecti2e of stress analysis&
Answer: -
A. To ensure t!at t!e stresses in piping components in t!e system are wit!in allowa"le limits.
). To sol2e ynamic pro"lems e2elope ue to mec!anical 2i"ration8 flui !ammer8 pulsation8
relief
2al2es8 etc.
C. To sol2e pro"lems associate ue to !ig!er or lower operating temperature as' -
$. 1isplacement stress range.
$$. ;oGGle loaing on connecte equipment.
$$$. Pipe isplacements.
$1.0oas # moments on supporting structure.
!age (' of 7*
'. What are the steps in2ol2ed in stress analysis "or any stress pac/age carries out%&
Answer: -
A. 6entify t!e potential loas t!at t!e piping system woul encounter uring t!e life of t!e plant.
). Felate eac! of t!ese loas to t!e stresses an strains e2elope.
C. %et t!e cumulati2e effect of t!e potential loas in t!e system.
+. 1ecie t!e allowa"le limits t!e system can wit!stan wit!out failure as per coe.
E. After t!e system is esigne to ensure t!at t!e stresses are wit!in safe limits.
*. ;ow the loads are classified in stress analysis pac/age&
Answer: -
A. Sustaine 0oas ' T!ose ue to forces present uring normal operation.
). 9ccasional 0oas ' T!ose present uring rare inter2als of operation.
C. 1isplacement 0oas ' T!ose ue to isplacement of pipe.
*Self-limiting stresses ue to t!ermal effects..
(. What are the sources of sustained load generated in piping syste&
Answer: -
A. 6nternal flui pressure.
). 1ea weig!t of Pipe wit! flui an its attac!ments.
Sustaine loa is calculate as' -
?eig!t of Pipe wit! <lui S 6nternal flui pressure loa S 0oa ue to springs *?SP1..
,. What are the $nputs reAuired for stress analysis of a piping syste&
Answer: -
A. Pipe SiGe.
). <lui Temperature.
C. Pipe Material.
+. Moel.
E. 1esign pressure.
-. 6nsulation T!ic7ness.
.. Specific gra2ity.
;. <riction coefficient.
7. ;ow do you calculate the operating load&
Answer: -
? SP1ST1
T1 C 0oa ue to t!ermal e=pansion.
<. .i2e soe EFaples for occasional 9oads.
Answer: -
A. ?in loa.
). Seismic loa.
C. <orces ue to relief or "low own.
+. Pressure wa2e generate ue to water !ammer effects.
=. What is the failure theory su4scri4ed under ASME )*1.*&
A. MaFiu principal stress theory "#an/ines 0heory%.
). MaFiu Shear 0heory.
C. ?ctahedral Shear 0heory.
Answer: - A. Ma=imum principal stress t!eory or Fan7ines t!eory.
>. Select the failure stress range for fatigue failure due to theral eFpansion as per )*1.*&
A. SA O "ScP Sh% 1.7f
). SA O 1.', "SC P Sh%
C. SA O "1.', ScP6.',Sh%f
Where: SA O Allowa4le EFpansion stress #ange.
Sc and Sh O )asic Allowa4le aterial stress in cold & hot conditions respecti2ely.
f O Stress range reduction factor "1 for <666 cycles.%
Answer: - (
!age (* of 7*
16. What is the desired life cycle for !iping in operation&
Answer: -
1esire life cycle for Piping in operation is ,4 \ears */444 (ycles..
T!e normal no. of cycles for w!ic! t!e isplacement or t!ermal stresses are esigne is /444
cycles.
11. ;ow do you calculate the stress de2eloped due to theral eFpansion&
Answer: -
Stress e2elope8 _I E = 8 *I 050.
TT. ?!ere8 E I \oungWs Moulus.
0 I 6ncrease in lengt! ue to t!ermal e=pansion.
0 I 9riginal 0engt! of t!e pipe.
1'. ;ow do you calculate the theral eFpansion in a pipe&
Answer: -
0 I = T = 0
6n t!e coes an many reporte calculations8 is use as inclusi2e of T. T!us t!e a"o2e
formula is
written as'-
0 I = 0
?!ere8 I (oefficient of t!ermal e=pansion from am"ient to operating temperature.
0 I 0engt! of t!e pipe.
1*. What do you ean 4y Stress $ntensity -actor "S$-%& .i2e soe eFaples.
Answer: -
Stress 6ntensity <actor *S6<. is t!e ratio of ma=imum stress intensity to normal stress. 6t is use
as
safe factor to account for t!e effect of localise stress on piping uner respecti2e loaing. 6n
piping it
is applie to wels8 fittings8 "ranc! connections etc w!ere stress concentration an possi"le
fatigue
failuremay occur.
E=ample' - S6< for Feucer an ?elnec7 <lange is 1.4
S6< for soc7et wel flange is 1.3
1(. ;ow uch should 4e the pressure for ;ydro-0est&
Answer: -
@yrotest pressure s!oul "e calculate as follow e=cept as pro2ie against point ;o 1.
A. 1.) Times of 1esign Pressure.
). <or a esign temperature a"o2e t!e test temperature8 minimum test pressure can "e
calculate as'
Pt I *1.) P P P St. 5 S
TTT..?!ere8 Pt ' Minimum Test Pressure.
P ' 6nternal esign pressure.
St' Allowa"le stress at test temperature.
S ' Allowa"le stress as esign temperature.
.
C. 6f a test pressure as per a"o2e woul prouce a stress in e=cess of t!e yiel strengt! at test
temp.t!e test pressure may "e reuce to ma=imum pressure t!at will not e=cee t!e yiel
strengt! at test temp.
1. 6f t!e test pressure of piping e=cees t!e 2essel pressure an it is not consiere practica"le
to
isolate piping from 2essel8 t!e piping an 2essel may "e teste toget!er at test pressure of t!e
2essel w!en appro2e "y owner an pro2ie t!e test pressure for 2essel is not less t!an 11)B
of
piping esign pressure aEuste for temperature as per point ;o.B.
1,. ;ow do you calculate the pipe spacing&
Answer: -
Pipe Spacing *mm. I *1o S 1t. 5 , S ,)mm S T!ic7ness of 6nsulation *mm..
?!ere' 14 ' 91 of Small siGe Pipe *mm..
1t ' 91 of <lange of 0arge siGe Pipe *mm..
!age (( of 7*
17. Which fluid is used in ;eat EFchanger in shell side and tu4e side&
Answer: -
%enerally corrosi2e flui is use from t!e tu"e sie *as tu"e can "e easily replace. an cleaner
flui
is use from s!ell sie. Sometimes @ot flui is also use from t!e s!ell sie.
1<. What is #eynolds nu4er and what is the 2alue of #eynolds nu4er upto which the
flow is
lainar&
Answer: -
6tWs a imensionless num"er to classify t!e nature of flow.
Fe I a 2 5 f
TTT?!ere8 Fe ' FaynolWs no.
a ' 1ensity of flui.
' 1iameter of Pipe.
2 ' A2erage 2elocity of flui.
f ' >iscosity of flui.
<low is laminar upto FeI,144
1=. Why do we pro2ide +rip 9eg in Stea 9ine&
Answer: -
To remo2e conensate w!en t!ere is a rise of same in t!e pipe along t!e flow irection. 6f rip leg
is
not pro2ie in steam line8 t!e conensate w!ic! forms insie t!e pipe will result in ?ater
@ammer
effect causing amage to piping system.
1>. What is the design standard followed for the calculation of allowa4le forces 8 Moents
in
no@@les of centrifugal copressor & Stea tur4ines no@@le&
Answer: -
T!e strain sensiti2e equipment piping to "e route an supporte to limit noGGle loaing an
moment
in equipment wit!in allowa"le limits furnis!e "y respecti2e 2enors or in a"sence of 2enor ata
AP6
)&45&145&1)5&,15&&1 # ;EMA SM,3. *Feferre "y AP6 &1/. is use for compressor # steam
tur"ine
noGGle.
'6. What is the ill tolerance to 4e considered for the thic/ness of pipe during stress
analysis as
per ASME )*1&
*i% 1N
ii% '.,N
"iii% <.,N
i2% 1'.,N
Answer : i2
'1. +ifferentiate 4etween static load and dynaic load&
Answer: -
Static loas are t!ose w!ic! are applie slowly enoug! so t!at t!e system !as time to react an
internally istri"ute t!e loas8 t!us remaining in equili"rium. 6n equili"rium8 all forces an
moments
are resol2e *i.e.8 t!e sum of t!e forces an moments are Gero.8 an t!e pipe oes not mo2e.
1ynamic loas are t!ose w!ic! c!anges quic7ly wit! time. T!e piping system may not !a2e time
to
internally istri"ute t!e loas8 so forces an moments are not always resol2e # resulting in
un"alance loas8 an t!erefore pipe mo2ement. Since t!e sum of forces an moments are not
necessarily equal to Gero8 t!e internally inuce loas can "e ifferent eit!er !ig!er or lower t!an
t!e
applie loas.
''. .i2e different types of dynaic loads with eFaple&
Answer: -
A. Fanom C ?in8 Eart!qua7e.
). @armonic C Equipment >i"ration8 Pulsation8 Acoustic >i"ration.
C. 6mpulse C <lui @ammer8 relief 2al2e opening8 slug flow.
!age (, of 7*
'*. What is +ynaic Analysis and why it is used&
Answer: -
1ynamic analysis is performe for all two p!ase lines in orer to ensure t!at t!e line supporte is
safe
from 2i"rations loas w!ic! may occur uring normal operation as well as in start up or any upset
conition. *1iesel mi=e wit! !yrogen in 1@1T process..
'(. What areW#C 16< 8 W#C '><&
Answer: -
0ocalise stresses at ;oGGle to S!ell is calculate "y ?F( 14/ 5 ,3/ an t!ese compute stress
2alues s!all "e limite in accorance wit! ASME Sec >666 for Pressure >essels.
',. Why loop is pro2ided in piping syste&
Answer: -
To aEust t!ermal e=pansion.
'7. What is the aFiu eFpansion a4sor4ed in loops in noral design&
Answer: -
14 6nc!es.
'<. What is the allowa4le stress range for CS pipes&
Answer: -
,4/4 7g5cm,.
Question related to 5on- destructi2e 0esting: -
1. +escri4e different types of destructi2e and non-destructi2e tests&
Answer: -
1ESTF+(T6>E TEST' Ben test8 Tensile test8 6mpact test8 an @arness test.
;9;-1ESTF+(T6>E TEST' 1PT8 MPT8 Faiograp!y an ultrasonic test.
'. What are the different types of hardness tests carried out&
Answer: -
Brinell @arness Test.
Foc7well @arness Test.
>ic7er @arness Test.
*. What is the relation 4etween )rinell ;ardness 5o. and #oc/well ;ardness 5o.&
Answer: -
,, @F( *Foc7well @arness. I ,3$ B@; *Brinell @arness ;o. @arer.
Questions related to wrapping & coating8 insulation8 cathodic protection: -
1. What is the procedure for application of wrapping and coating&
Answer: -
Proceure for application of (oating an wrapping' -
A. Prior to application of wrapping # coating8 t!e surface of pipe s!oul "e mae free from all
loose
Mill scale8 irt8 rust8 grease8 moisture an ot!er foreign material. T!is is ac!ie2e "y "last
cleaning to grae Sa , M .
). T!e pipe e=terior surface or "last surface s!all "e coate wit! primer wit!in four !ours of s!ot
"lasting. T!e primer s!all not "e applie w!en t!e pipe surface temperature is "elow /_( an
a"o2e /4_(. w!en moisture is present on t!e surface8 t!e same is !eate for sufficient time to
ry
t!e surface.
C. T!e pipe after priming s!all "e coate wit! two-floo coat of !ot enamel incorporating t!e
simultaneous application of inner # outer wrapping.
'. What is the content of prier applied on the pipe surface 4efore coating&
Answer: -
T!e primer consists of processe coal C tar pitc! an refine coal C tar oil.
!age (7 of 7*
*. What is the enael applied on the pipe surface for coating&
Answer: -
T!e enamel is plasticise coal tar pitc! suita"le for !ot application an fille wit! inert mineral
filler
w!ic! !a2e minimum tenency to settle own in flui state.
(. Which aterial is used as inner and outer wrapping&
Answer: -
<i"re glass tissue consisting of a uniformly porous mat of c!emically resistant "oro C silicate
glass
containing not less t!en )B B,93.
,. What should 4e the iniu thic/ness of enael on any point on pipe&
Answer: -
T!e enamel s!all !a2e minimum t!ic7ness of ,.4 mm w!en measure on top of t!e wel wit! an
o2erall t!ic7ness of 4mm.
7. ;ow uch should 4e the depth of pulling of inner -i4re H glass tissue into the hot
enael&
Answer: -
T!e inner wrap of <i"re C glass tissue pulle in suc! a manner t!at t!e same is im"ee !alf
way
into t!e enamel wit!out touc!ing t!e steel surface.
<. What should 4e the o2erlap 4etween inner & outer wrap&
Answer: -
T!e inner an outer wraps s!all "e o2erlappe "y ,)mm.
=. What should 4e the iniu staggering of inner & outer wraps8
Answer: -
T!e o2erlaps of t!e inner an outer wraps s!all "e staggere from eac! ot!er "y minimum
istance
of 144mm.
>. What is cold type of wrapping&
Answer: -
P>( "ac7e "ituminous compoun tape use for fiel wrapping is calle col wrapping.
16. What is the iniu o2erlap of field wrapping "cold 0ape% on shop wrapping&
Answer: -
? rapping s!all start an finis! to gi2e a minimum /)mm o2erlap onto t!e aEoining s!op coating.
11. What is the aterial applied on the flanges or 2al2es to o4tain sooth surface for
application
of cold 0ape&
Answer: -
Mouling compoun s!all "e !an applie to o"tain t!e smoot! surface for application of col
tape on
flanges 5 2al2es.
1'. What is the de2ice used to locate the defects on surface of coating & wrapping&
Answer: -
@oliay 1etector.
1*. ;ow uch crest 2oltage of ;oliday +etector shall 4e set&
Answer: -
T!e crest 2oltage of @oliay 1etector s!all "e set as !ig! as practical.
1(. What is the test to ensure the proper thic/ness: adhesion and the position of inner
wrap&
Answer: -
A square of ,)mm P ,)mm s!all "e cut from wrapping for etermination of t!ic7ness8 a!esion
an
position of t!e inner wrap. T!is s!all "e carrie out at t!e rate of one pipe per )4 coate.
1,. What are different types of Anodes used in cathodic protection&
Answer: -
1ifferent types of Anoes are Magnesium8 Kinc8 @ig! Silicon 6ron8 Aluminum etc.
!age (< of 7*
17. What are $nsulating .as/et Bits&
Answer: -
6nsulation gas7et 7its are esigne to restrict t!e effects of corrosion often foun in flange pipe
systems. T!e most common e=ample is fire water line running insie t!e groun an turne
upwar
on a"o2e groun wit! flange connection.
6t consists of following 7its' -
A. %as7et ' - ;eoprene face P!enolic 5%lass Feinforce Epo=y *%14..
). 6nsulation slee2e ' - Feinforce P!enolic5;ylon5Polyet!ylene5*%14..
C. 6nsulation was!er ' - Feinforce P!enolic5;ylon5Polyet!ylene5*%14..
+. Plate ?as!er ' - Electro plate steel was!er.
1<. What is the teperature liit for application of insulation for personnel protection&
Answer: -
6nsulation for personnel protection s!all "e require w!en t!e line operating temperature e=cees
&4_(.
1=. What short of paint is applied on the inside surface of Aluiniu etal Dac/ets for
pipe
insulation&
Answer: -
All pipe insulation s!all "e pro2ie wit! an Aluminum metal Eac7et wit! site applie moisture
"arrier
of "ituminous paints.
1>. Which aterial is used for secureent of insulation on pipe&
Answer: -
<or securement of insulation following material are applie'
A. Stainless steel wire *SS C344. of 1 mm t!ic7ness wit! ,,) mm inter2als.
B. Aluminium "ans of 4.& P ,4 mm wit! ,,) mm inter2als.
'6. What shall 4e layers of insulation for different thic/ness&
Answer: -
T!e insulation s!all "e single layer up to /)mm t!ic7ness an ou"le layer at 34mm t!ic7ness
an
greater.
'1. What care shall 4e ta/en 4efore applying insulation&
Answer: -
T!e surface to "e insulate s!all "e free from oil8 grease an all ot!er foreign matter an s!all "e
free
from moisture prior to t!e application of any insulation.
''. What is the iniu circuferential lap of etal 3ac/et applied on the insulation&
Answer: -
Questions related to !up8 Alignent8 pup piping: -
1. What are different types of pups&
Answer: -
Basically t!ere are two types of pumps.
A. (entrifugal Pump.
). Positi2e 1isplacement pump.
'. What are the different types of centrifugal pup&
Answer: -
1ifferent types of (entrifugal Pump are' -
A. Single Stage or
). Multi-stage
*. What is the 4asic difference 4etween single stage and ulti-stage centrifugal pup&
Answer: -
T!e Single stage pump !as one impeller an multi-stage pump !as two or more impellers in
series.
T!e isc!arge of one impeller is t!e suction of t!e ne=t one an t!e !ea e2elope in all t!e
stages
are totale.
!age (= of 7*
(. ;ow any types of centrifugal pup are a2aila4le 4ased on the Suction and +ischarge
arrangeent&
Answer: -
Base on t!e suction an isc!arge arrangement8 t!e type of centrifugal pumps a2aila"le is' -
A. En Suction Top 1isc!arge.
). Top Suction Top 1isc!arge.
C. Sie Suction Sie 1isc!arge.
,. What are the ain coponents of a centrifugal pup&
Answer: -
A centrifugal pump !as two main components as'-
A. A rotating component comprise of an impeller an a s!aft.
). A stationary component comprise of a casing8 casing co2er8 an "earings.
T!e general components8 "ot! stationary an rotary are s!own in <igure B.41.
!age (> of 7*
7. What are the different types of casing&
Answer: -
(asings are generally of two types' 2olute an circular. T!e impellers are fitte insie t!e casings.
<. +efine the wor/ing echanis of centrifugal pup&
Answer: -
A centrifugal pump is one t!e simplest pieces of equipment in any process plant. 6ts purpose is to
con2ert energy of prime mo2er *an electric motor or tur"ine. first into 2elocity or 7inetic energy
an
t!en into pressure energy of a flui t!at is "eing pumpe. T!e energy c!anges occur "y 2irtue of
two
main parts of t!e pump8 t!e impeller an t!e 2olute or iffuser. T!e impeller is rotating part t!at
con2erts ri2ers energy into t!e 7inetic energy. T!e 2olute or iffuser is t!e stationary part t!at
con2erts t!e 7inetic energy into pressure energy.
=. ;ow the centrifugal force generated in the centrifugal pup&
Answer: -
T!e process liqui enters t!e suction noGGle an t!en into t!e eye *center. of t!e re2ol2ing e2ice
7nown as an 6mpeller. ?!en t!e impeller rotates8 it spines t!e liqui sittings in t!e ca2ities
"etween
t!e 2anes outwar an pro2ies centrifugal acceleration. As t!e liqui lea2es t!e eye of t!e
impeller a
low C pressure area is create causing more liqui to flow towars t!e inlet. Because t!e impeller
"laes are cur2e8 t!e flui is pus!e in a tangential an raial irection "y centrifugal force. T!e
figure "elow epicts a sie cross-section of a centrifugal pump inicating t!e mo2ement of t!e
liqui.
!age ,6 of 7*
>. ;ow the /inetic energy created 4y centrifugal force is con2erted to pressure energy&
Answer: -
T!e energy create "y centrifugal force is 7inetic energy. T!e amount of energy gi2en to t!e liqui
is
proportional to t!e 2elocity at t!e ege or 2ane tip of t!e impeller. T!e faster t!e impeller re2ol2es
or
t!e "igger t!e impeller is t!en t!e !ig!er will "e t!e 2elocity of t!e liqui at t!e 2ane tip an t!e
greater t!e energy imparte to t!e liqui. T!is 7inetic energy of t!e liqui coming out of an
impeller is
!arnesse "y creating a resistance to t!e flow. T!e first resistance is create "y t!e pump 2olute
*casing. t!at catc!es t!e liqui an slows it own. 6n t!e isc!arge noGGle8 t!e liqui furt!er
ecelerates an its 2elocity is con2erte to pressure accoring to BernoulliWs principle.
T!erefore8 t!e !ea *pressure in terms of !eig!t of t!e liqui. e2elope is appro=imately equal to
t!e
2elocity energy at t!e perip!ery of t!e impeller e=presse "y t!e following formula as' -
@ I 2,5 ,g
?!ere8
@ I Total !ea e2elope in feet.
> I >elocity at perip!ery of impeller in ft5sec.
% I Acceleration ue to gra2ity-3,.,ft5sec,
<ormula for calculating perip!eral 2elocity'
> I ;P 1
,,3
?!ere8
> I Perip!eral 2elocity in impeller in ft5sec.
; I T!e impeller rpm *Fe2olution per minute.
1 I 6mpeller iameter in inc!es.
?ne fact that ust always 4e ree4ered: A pup does not create pressure: it only
pro2ides
flow. !ressure is a 3ust an indication of the aount of resistance to flow.
16. What do you ean 4y Ca2itation in !up&
Answer: -
A pump is esigne to !anle liqui8 not 2apor. T!e satisfactory operation of pump requires t!at
2aporiGation of t!e liqui oes not occur at any conition of operation. T!is is so esire "ecause
w!en a liqui 2aporiGes its 2olume increases 2ery muc!. <or e=ample8 1 ft3 of water at room
temperature "ecomes 1/44 ft3 of 2apor at t!e same temperature. T!e 2aporiGation "egins w!en
2apor pressure of t!e liqui at t!e operating temperature equals t!e e=ternal system pressure8
w!ic!
in an open system is always equal to atmosp!eric pressure. Any ecrease in e=ternal pressure or
rise
in operating temperature can inuce 2aporiGation. T!e 2apor pressure occurs rig!t at t!e impeller
inlet w!ere a s!arp pressure rop occurs. T!e impeller rapily "uils up t!e pressure8 w!ic!
collapses 2apors "u""les causing ca2itation an amage t!e pump internals. T!is is a2oie "y
maintaining sufficient ;PS@. *(a2itation implies ca2ities or !oles in t!e flui we are pumping.
T!ese
!oles can also "e escri"e as "u""les8 so ca2itation is really a"out t!e formation of "u""les an
t!eir collapse. Bu""les form w!ene2er liqui "oils. 6t can "e a2oie "y pro2iing sufficient
;PS@..
11. What do you ean 4y 5!S; or 5!S;r&
Answer: -
? !en t!e liqui passes from t!e pump section to t!e eye of t!e impeller8 t!e 2elocity increases
an
t!e pressure ecreases. T!ere are also pressure losses ue to s!oc7 an tur"ulence as t!e liqui
stri7es t!e impeller. T!e centrifugal force of t!e impeller 2anes furt!er increases t!e 2elocity an
ecreases t!e pressure of t!e liqui. T!us8 t!e ;et positi2e suction @ea require *;PS@r. or
sometimes in s!ort as ;PS@ is t!e total !ea at t!e pump section to o2ercome t!ese pressure
rops
in t!e pump an maintain t!e maEority of t!e liqui a"o2e its 2apor pressure.
T!e term D;ET- refers to t!e actual pressure !ea at t!e pump section flange an not t!e static
section !ea. ;PS@ require is a function of t!e pump esign an is etermine "ase on actual
pump test "y 2enor.
!age ,1 of 7*
1'. What do you ean 4y 5!S;a "5et positi2e suction head a2aila4le%&
Answer: -
;et Positi2e Suction @ea A2aila"le is a function of t!e system in w!ic! t!e pump operates. 6t is
t!e
e=cess pressure of t!e liqui in feet a"solute o2er its 2apor pressure as it arri2es at t!e pump
suction8
to "e sure t!at t!e pump selecte oes not ca2itate. 6t is calculate "ase on system or process
conitions. ;PS@a calculation is state "elow'
;PS@aS I !ps S !s C !2ps - !fs
?!ere8
@ps I Pressure @ea i.e. Barometric pressure of t!e suction 2essel con2erte to !ea.
!s I Static Suction @ea i.e. t!e 2ertical istance "etween t!e eye of first stage impeller
centerline an suction liqui le2el.
!2ps I >apor pressure @ea i.e. 2apor pressure of liqui at its ma=imum pumping
temperature con2erte to @ea.
!fs I <rication @ea i.e. friction an entrance pressure losses on suction sie con2erte to
@ea.
;ote'
1. 6t is important to correct for t!e specific gra2ity of t!e liqui an to con2ert all terms to units of
Jfeet
a"soluteJ in using t!e formula.
,. Any iscussion of ;PS@ or ca2itation is only concerne a"out t!e suction sie of t!e pump.
T!ere
is almost always plenty of pressure on t!e isc!arge sie of t!e pump to pre2ent t!e flui from
2aporiGing.
NPSHa in a nutshell
6n a nuts!ell8 ;PS@ a2aila"le is efine as'
;PS@a I Pressure !ea S Static !ea - >apor pressure !ea of t!e prouct - <riction !ea loss
in
t!e piping8 2al2es an fittings. DAll terms in feet a"solute-
6n an e=isting system8 t!e ;PS@a can also "e appro=imate "y a gauge on t!e pump suction
using
t!e formula'
NPSHa = hpS - hvpS & hgS + hvS
`VhpS = Barometric pressure in feet absolute.
`VhvpS = Vapor pressure of the liquid at maximum pumping temperature, in feet absolute.
`VhgS = Gauge reading at the pump suction expressed in feet (plus if above atmospheric,
minus if below atmospheric) corrected to the pump centerline.
`VhvS = Velocit head in the suction pipe at the gauge connection, expressed in feet.
Significance of NPSHr and NPSHa
T!e ;PS@ a2aila"le must always "e greater t!an t!e ;PS@ require for t!e pump to operate
properly. 6t is normal practice to !a2e at least , to 3 feet of e=tra ;PS@ a2aila"le at t!e suction
flange
to a2oi any pro"lems at t!e uty point.
!age ,' of 7*
1*. What care shall 4e ta/en while doing layout for pup piping&
Answer:-
T!e following point s!all "e ta7en care of w!ile oing layout for pump piping.
A. Pump location affects t!e piping routing an its supporting. Pumps eicate for !yrocar"on
ser2ices an carrying materials a"o2e ,34_( s!all not "e locate "elow pipe rac78 structures8 air
fin coolers an 2essels. Pumps w!ic! are eicate for non C flamma"le ser2ice may "e locate
"eneat! t!e pipe rac7 wit!out o"structing t!e access "ay an ot!er maintenance requirements of
t!e respecti2e process unit.
). Pump s!all "e locate as close to t!e source of suction in orer to minimiGe pressure rop in
t!e
system.
C. A preliminary piping layout *stuy layout. s!all "e mae to etermine t!e requirement of
spacing
"etween pumps especially in case of sie suction5 sie isc!arge8 top suction5 top isc!arge
pumps
w!ere straig!t lengt! requirement5 platform 5(PS requirement etc !a2e to "e consiere.
+. Eccentric reucer in pump suction lines s!all "e flat on top sie in orer to pre2ent ca2itation.
E. Feucers in pump suction lines s!all "e as close as possi"le to t!e pump suction noGGle.
-. ;ormally reucers in pump isc!arge s!all "e concentric type. Eccentric reucers may "e use
in
"ot! suction an isc!arge piping for top suction5 top isc!arge pump in orer to o"tain clearance
"etween suction an isc!arge piping.
.. Piping for lu"e oil an seal oil system of pump s!all "e suc! t!at it s!all not "loc7 access to
t!e
pump seal an "earing. <or 2ery large pumps t!ese may "e separate on s7is.
;. As per 9S61- 11$ *9il inustries Safety 1irectorate stipulation. t!ere s!all "e minimum 1 meter
spacing "etween pumps e. g a minimum space of 1 meter must "e pro2ie in "etween t!e
pumps
an any potential o"structions *large "loc7 2al2es8 steam tur"ine piping an tee type support from
grae..
$. Au=iliary piping s!all "e suc! t!at it s!all not o"struct inspection co2ers8 "earing caps8 upper
!al2es
of casing or any ot!er items w!ic! require access for operation or maintenance. Piping for
lu"ricating oil8 seal oil etc s!all not "e route in t!e 2icinity of !ot process or !ot utility pipes in
orer
to a2oi fire !aGar.
D. (ooling water lines to pumps an compressors s!all not "e less t!an ,4;B. Pipes ,);B or
less
s!all !a2e t!e ta7e-off connection from t!e top of t!e !eaer in orer to pre2ent plugging uring
operation.
B. E2ery efforts must "e mae to minimiGe maintenance o"structions "y running t!e piping eit!er
outsie t!e area irectly o2er t!e pump or at !ig! enoug! ele2ation to permit t!e remo2al of t!e
pump or ri2er.
9. T!e pump s!all "e place in suc! a manner t!at t!e suction noGGle ele2ation is always "elow
t!e
2essel 5tan7 noGGle an suction pipe s!all "e route to pre2ent any poc7ets in t!e line.
M. Pump in t!e 2acuum ser2ice operates at a negati2e pressure an 2ery !ig! temperature s!all
"e
locate 2ery close to t!e suction source. T!is is often irectly "elow t!e tower or immeiately
outsie t!e tower support column. Pumps locate irectly "eneat! t!e tower can "e mounte on
a
special spring "ase.
!age ,* of 7*
1(. What care shall 4e ta/en while doing layout for End section H 0op discharge ;ori@ontal
type
Centrifugal pup piping&
Answer: -
T!e following point s!all "e ta7en care of w!ile oing layout for En section- Top isc!arge pump
piping.
A. (lear access in "etween t!e 2al2e !anle an pump s!all "e ensure. T!e 2al2e in suction
line
s!all "e installe wit! t!e stem in t!e !oriGontal position i.e. install 2al2e in t!e 2ertical run of pipe.
). Suction Strainer s!all "e locate at grae to ease easy maintenance an remo2al for cleaning.
T!e
rain connection from strainer assem"ly s!all !a2e a "rea7 up flange immeiately after t!e
isolation
2al2e an t!e rain line s!all "e route in suc! way t!at t!e strainer can "e remo2e wit! ease
for
maintenance.
C. 1isc!arge piping s!all "e ta7en to grae for ma7ing 2al2e accessi"le.
+. 1o not route t!e suction an isc!arge piping a"o2e prim mo2er ot!erwise it may create
!inrance
w!ile ismantling t!e same.
E. Small "ore piping s!all "e route in suc! a manner t!at tripping !aGars are a2oie.
-. (are s!all "e ta7en w!ile routing isc!arge line not to "loc7 access to couplings. 4
.. Some e=amples of en suction- top isc!arge pump piping are s!own in s7etc!es 48 ) # &.
1(. What are the different types of isalignent with regards to rotating achinery&
Answer: -
1ifferent types of misalignment are'-
A. Parallel or FaialMisalignment ' T!e centre line of two s!afts is parallel "ut o not lie on t!e
same
line. 6t is also calle offset misalignment.
). Angular or A=ial Misalignment ' (onition w!ic! escri"es t!e angularity "etween t!e
centerline
of t!e two s!afts. 6t can "e correcte "y rotating a s!aft a"out t!e
centre of t!e coupling face.
C. (om"ine Angular an Parallel
Misalignment ' 6t occurs w!en t!e centerline of t!e two s!afts is not lying along
t!e common centerline an t!e one coupling face is not parallel
to ot!er coupling face in any of t!e plane8 !oriGontal or 2ertical. 6t
is t!e com"ination of t!e a"o2e two.
1,. What are the pre- alignent chec/s to 4e carried out in aligning rotating achinery&
Answer:-
T!e pre- alignment c!ec7s in2ol2e in aligning rotating mac!inery are'-
A. (!ec7 t!e mac!ine is properly secure to founation.
). (!ec7 for e=cessi2e run- out conitions i.e. Eccentric coupling "ore8 Bent S!aft.
C. Mac!ine to "ase plate interface pro"lems i.e. soft foot.
+. Ensure t!at no piping loas are coming on t!e mac!ine.
1<. What are the 4asic steps in2ol2ed in aligning rotating achinery&
Answer:-
T!e "asic steps in2ol2e in aligning rotating mac!inery are'-
A. (arry out pre-alignment c!ec7s as mentione a"o2e.
). Arrange all t!e necessary alignment tools # measuring tools.
C. (ollect necessary ata for t!e equipment to "e aligne as'
Any special tools neee to measure t!e alignment.
Any ata a2aila"le on s!aft mo2ement from position of rest.
Tolerance on alignment.
+. 6nspect t!e coupling for any amage or worn out component.
E. Measure s!aft or coupling !u" run out.
-. Mount t!e alignment tools # measuring instruments8 rotate t!e s!aft.
.. Fecor one set ata # etermine t!e s!aft positions wit! respect to eac! ot!er. (ompare t!e
s!aft
positions wit! esire s!aft positions. 6f s!aft positions are wit!in tolerance no furt!er mo2ement
of
mac!ine is require.
!age ,( of 7*
1=. What is soft foot as indicated in pre-alignent chec/s&
Answer:-
?!en rotating mac!inery is set in place on its "ase frame5 sole plate8 one or more t!an one of t!e
UfeetW
may not ma7e goo contact at t!e Ufoot pointsW on t!e frame. T!is is ue to "owe5 warpe
frames8
improper mac!ining of feet.
1>. What are the steps in2ol2ed to detect & correct the soft foot pro4le&
Answer:-
A. Before installation of t!e mac!ine on t!e "ase frame8 ensure t!at all mounting pas on t!e
"ase
frame are flat enoug!. *(!ec7 wit! straig!t ege across t!e pas # no gap unersie of t!e
straig!t
ege.. 6f pa is not flat enoug!8 correction can "e one "y mac!ining t!e frame.
). (lean t!e mounting area # install t!e mac!ine on t!e "ase frame.
C. <ully tig!tene all t!e mounting "olts. Place ial inicator at one of t!e feet near t!e "olt!ole
wit!
stem resting on frame. 0oose all "olts one "y one # o"ser2e t!e ial mo2ement8 if is not
e=ceeing
4.4)mm8 no correction is require # no soft foot e=ists.
+. 6n case of !ig!er mo2ement of ial inicator8 mar7 t!e feet. (!ec7 t!e gap "etween t!e feet #
mounting pa. 6f t!ere is gap # it is uniform t!en insert s!im plate of t!ic7ness equal to t!e gap. 6f
t!e gap is not uniform8 it s!all "e correcte.
'6. What is )lue atching with reference to the alignent of rotating achinery&
Answer:-
6t is a type of c!ec7. By t!is met!o8 t!e flatness of t!e mounting pa is c!ec7e. 6n t!is met!o
"lue
colour *Blue mi=e wit! oil. is applie wit! t!e !elp of "rus! on to surface of a glass of suita"le
siGe.
T!e glass wit! t!e painte surface pointing towars t!e mounting pa is place on to t!e mounting
pa
an is rotate wit! little pressure. ;ow t!e glass is remo2e from t!e mounting pa. T!e surface
of
mounting pa w!ic! is slig!tly up is now clearly 2isi"le as t!e "lue colour stic7 on t!ese portions.
;ow
t!ese coloure surfaces s!all "e flattene "y using rotating isc. Fepeat t!e a"o2e proceure till
$4B
of t!e mounting pa surface gets coloure.
'1. What are the 0ools reAuired for easuring the shaft centre line during alignent&
Answer:-
<ollowing Tools are require for measuring t!e s!aft centre line.
A. Straig!t ege.
). <eeler%auge.
C. Taper%auge.
+. Measuring Tape # Fuler.
E. Alignment Brac7et.
-. >ernier caliper.
.. 1ial 6nicator.
''. ;ow the +ial $ndicator reading is interpreted& Mention ethod of easureent 4y +ial
indicator&
Answer:-
T!e inwar mo2ement is inicate "y cloc7wise mo2ement of inicator or in *S. irection. T!e
outwar
mo2ement is inicate "y anti-cloc7wise mo2ement or in *C. irection.
1ifferent measurement met!os are'-
A. >ertical Mo2e ' T!e figure s!ows !ow t!e 2ertical offset of 4.4,mm of a s!aft wit! respect to
t!e ot!er s!aft will "e isplaye.
). Sweep Feaing ' Sweeping reaing is o"taine "y Geroing t!e ial at t!e top position on t!e
coupling to "e inicate. Slowly rotate t!e s!aft so t!at t!e ial inicator is
rotate "y 3&4_in 34_increment. 9"tain reaing at top *T.8 "ottom *B.8 rig!t *F.
an left *0.. Fefer figure./
C. @oriGontal mo2e ' T!e figure */. isplays !ow t!e alignment of two s!aft !a2ing 4.4,mm
2ertical offset an 4.4,mm !oriGontal offset will loo7 ali7e.
!age ,, of 7*
Machine A is 6.6' lower with respect to the achine A
''. What are the different alignent techniAues adopted for aligning rotating achinery&
Answer:-
<ollowing alignment tec!niques are aopte for aligning rotating mac!inery.
A. Straig!t ege # feeler gauge Met!o.
). S!aft alignment using ial inicator.
1.6 <ace-rim met!o.
1.1 Two inicator met!o.
1.' T!ree inicator met!o.
'.6 Fe2erse inicator met!o.
'.1 <ace- <ace- 1istance met!o.
C. 0aser Alignment met!o.
'*. +escri4e J-ace-?+ ethod using 0wo +ial $ndicator&
Answer:-
6t is t!e most wiely use met!o for alignment. 6n t!is met!o a "rac7et is attac!e to one of t!e
s!aft
an e=tens near t!e coupling !u" on t!e ot!er s!aft. 1ial inicators are attac!e to t!e "rac7et
wit!
t!e stem of one inicator resting on 91 or rim of opposite coupling !u" # ot!er stem resting on
face of
same coupling !u". 9ffset of t!e s!aft or parallel misalignment is etermine "y t!e 91 reaing
w!ereas angularity is etermine "y UfaceW reaing. ;ormally "ot! t!e s!afts are rotate toget!er
to
eliminate errors ue to face an rim irregularities.
Machine A
Machine )
!age ,7 of 7*
'(. Write the procedure for recording the indicator reading and its interpretation 4y 0wo
indicator
ethod&
Answer:-
A. 1ial 6nicator wit! t!e pointer inicating Gero to "e mounte on t!e "rac7et first.
). Fotate "ot! t!e s!afts simultaneously in cloc7wise irection.
C. ;ote t!e reaing in top8 "ottom8 left an rig!t position of t!e s!aft.
+. 6nterpret t!e final reaing an o t!e require aEustment.
4-
4-44
>L
*6L
5?#0;
#A+$A9 6 AI$A9 6
- 6.'' P 6.6< P 6.6( - 6 - 6.16
- 6.1( - 6.6<
$nterpretation: $nterpretation:
0P ) O SPS 0P ) O SPS
0P ) O - 6.1(: SPS O - 6.1, "o/% 0P ) O - 6.6<: SPS O - 6.67 "o/%
Machine to 4e aligned w.r.t the stationary M8C is: Machine to 4e aligned w.r.t the stationary
M8C is:
A. ;igher O - 6.1(P 6.6* "sag% O - 6.118' O 6.6,, A. -ace distance is 6.6< wider.
). ;ori@ontal ?ffset: ). ;ori@ontal .ap:
- 6.''- 6.6< "change sign% O -6.'>8' O - 6.1(,. P 6.6( P 6.16 "change sign% O P 6.1(
5ote: 5ote:
$n hori@ontal offset: the total deflection in +ial $n hori@ontal gap: the total deflection in +ial
indicator fro P6.6< to - 6.'' is -6.11.Change indicator fro P6.6( to - 6.16 is
P6.1(.Change
of sign is 3ust to read the total deflection only. of sign is 3ust to read the total deflection
only.
!CM!
S0A0$?5A#E MAC;$5E
M?0?#
MAC;$5E E9EME50 0?
)E A+DCS0E+.
!age ,< of 7*
',. Write the procedure for recording the indicator reading and its interpretation 4y 0hree
indicator
ethod&
]
4-
4-44
>L
*6L
5?#0;
6 $5$0$A9 #EA+$5. - 6.6*
P 6.6* - 6.6( - 6.61 - 6.6'
-$5A9 #EA+$5.
- 6.6, 6 6
- 6.6(- "- 6.61% O -6.6*8' O - 6.61,MM
P 6.6*- "-6.6'% O - 6.6,8'O P 6.6',MM
- 6.6, H "- 6.6*% O - 6.6'8' O - 6.61
$nterpretation:
0P ) O SPS
0P ) O - 6.61: SPS O - 6.61 "o/%
Machine to 4e aligned w.r.t the stationary M8C is:
A. -ace distance is 6.61 wider
). ;ori@ontal .ap:
P 6.6', P 6.61, "change sign% O P 6.6(
5ote:
$n hori@ontal gap: the total deflection in +ial indicator fro P6.6', to - 6.61, is
P6.6(.Change
of sign is 3ust to read the total deflection only. ;ere two dial indicator is used to note aFial
reading.
0he final aFial reading is the a2erage of the two indicator reading.
AI$A9 -1 AI$A9- '
AI$A9
!CM!
S0A0$?5A#E MAC;$5E
M?0?#
MAC;$5E E9EME50 0?
)E A+DCS0E+.
!age ,= of 7*
Question #elated to 5ors & Assuptions -or !iping & Structural Wor/:-
1. Write the estiation for welding consua4les for piping wor/ ".roo2e& -illet welding%&
Answer:-
!age ,> of 7*
!age 76 of 7*
!age 71 of 7*
'. What are the consuption nors for grinding8cut-off wheel&
Answer:-
<or piping wor7'-
A. %rining w!eel for fa"rication ' 4.43) ;um"ers5 inc! ia.
). %rining ?!eel for Eoint grining for +T ' 4.41, ;um"ers5 inc! ia.
<or structural wor7'-
A. %rining ?!eel A% / */J^/MM. ' 4./) ;um"ers5 MT.
). %rining ?!eel A% ) *)J^)MM. ' 4.,) ;um"ers5 MT.
<or support fa"rication at s!op'-
A. %rining ?!eel ' , ;um"ers5 MT.
*. What are the consuption nors for +issol2ed Acetylene and ?Fygen&
Answer:-
<or piping wor7'-
A. 1issol2e Acetylene *1.A.. ' 4.4144 (u-M5 inc! ia.
). 9=ygen *9,. ' 4.4)14 (u-M5 inc! ia.
<or structural wor7'-
A. 1issol2e Acetylene *1.A.. ' ,., (u-M5 inc! ia.
). 9=ygen *9,. ' $.4 (u-M5 inc! ia.
<or support fa"rication at s!op'-
A. 1issol2e Acetylene *1.A.. ' 3.) (u-M5 inc! ia.
). 9=ygen *9,. ' 1, (u-M5 inc! ia.
!age 7' of 7*
(. What are the anpower deployent nors for structural steel wor/&
Answer:-
<or fa"rication of 1 MT of structural steel per ay8 t!e manpower require is as'-
A. ?eler ' 4,
). <itter ' 4,
C. %as cutter ' 41
+. %riners ' 41
E. Figgers ' 4,
-. @elpers # ot!ers ' 4,
<or erection of 1 MT of structural steel per ay8 t!e manpower require is as'-
A. ?eler ' 4./)
). <itter ' 41
C. %as cutter ' 41
+. %riners ' 4.)
E. Figgers ' 43
,. What are the anpower deployent nors for piping erection wor/&
Answer:-
;ormally8 34 to 1,4 6M is erecte per ay per gang. 9ne gang comprises t!e following'
A. ?eler ' 41
). <itter ' 41
C. %as cutter ' 4.)
+. %riners ' 4.)
E. Figgers ' 44
7. What is the producti2ity of the welder for plant piping and for off-site piping&
Answer:-
!$!E S$QE -?# !9A50 !$!$5. -?# ?---S$0E !$!$5.
+pto 1ia. 1 M D 14 615weler5ay 1, 615weler5ay
1ia. ,- to 1,- 1& 615weler5ay 1$ 615weler5ay.
1ia. $- to 1,- 1$ 615weler5ay ,4 615weler5ay
1ia.14- # a"o2e ,4 615weler5ay ,, 615weler5ay
<. ;ow any pipe 3oints for plant piping & for offsite piping are assued&
Answer:-
!$!E S$QE -?# !9A50 !$!$5. -?# ?---S$0E !$!$5.
+pto 1ia. 1 M D 1:T5MTF. 1:T5,MTFS.
1ia. ,- to &- 1:T51.)MTF 1:T54MTFS
1ia. $- to 1,- 1:T5,MTF 1:T54MTFS
1ia.14- # a"o2e 1:T5,.)MTF 1:T54MTFS
!age 7* of 7*
=. What are the consuption nors for Electrodes & -iller wire&
Answer:-
!age 7( of 7*

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