ARAMCO Mechanical Inspector Ques.

Sr. No. Question Answer Answer

Reference
1. What are the To Conduct Inspection of all mechanical activities PQP
responsibilities of a To witness testing and monitoring of the product,
mechanical inspector? fabrication and installation process
Recordkeeping per SATIP
2. What is Schedule Q? Schedule Q is a part of contract agreement (between Sch. Q
Client and Contractor) that does contain client’s
minimum quality requirements for a specific project /
contract.
3. What is PQP? PQP stands for Project Quality Plan; it is the document PQP
which describes that how contractor will manage the
scope of work based their Quality System correlated to
Client’s Schedule Q.
4. What is NCR? NCR stands for Non Conformance Report; a NCR would
be issued to the culprit once non conformity is observed.
5. Who are authorized to All QA/QC personnel can issue NCR PQP
issue NCR?
6. What is the timeline for Contractor shall forward all INCR to Client within 48 Sch. Q
INCR (Internal NCR) to be hours of issuance.
forwarded to client?
7. What are the content of Description of Non-Conformity
NCR ? Root Cause Analysis(to find the cause of Non-
Conformity)
Corrective Action(action taken on the system / product
to debug the errors)
Preventive Action(Proactive measures to avoid the non-
conformity)
8. What is the timeline for Within 7 days of issuance Sch. Q
Root Cause Investigation
and initiate corrective
action?

9. What is the timeline to It must be responded in written within 48 hours Sch. Q

respond clients NCR?

10. What are the Inspection Surveillance: SATIP

levels / Responsibilities QA/QC organization to monitor work in progress without
during construction phase? notice from Construction Organization

Witness:
QA/QC organization shall be notified of the timing of
Inspection or test in advance. However, the inspection or
test shall be performed as scheduled if the QA/QC
organization representative is not present.
Hold:
QA/QC organization shall be notified of the timing of
inspection or test in advance. Inspection or test shall not
be carried out without the QA/QC organization
 representative in attendance.
11. What are the Inspection Level 0: SAER 1972
levels for contractor Documentation Requirement only; no vendor inspection
supplied materials per SAER required
1972? Level 1:
Only final inspection is required prior to shipping
Level 2:
Includes, as a minimum, pre inspection meetings, one or
more unspecified in progress surveillance / visits, all
witness and hold points, final inspection and release for
shipment
Level 3:
Same as Level 2, except that in progress surveillance shall
be on regular basis (Daily, Weekly or Bi-weekly)
Level4:
Resident Inspector continually monitoring the work
12. What are the SA-175 SA-175 forms establish minimum inspection and testing SAER 1972
forms? requirements for procured inspect-able material and
equipment.
13. What minimum amount of Actually it depends upon level of inspections; however
Documents do you need to below listed documents are the minimum requirements:
inspect a Material?
Related Drawing (IFC and Controlled)
Material Take off (IFC and Controlled)
Material Requisition and its approval
Purchase Requisition and its approval
Purchase Order
Packing List / Tally Sheet
Material Test Certificates
Vendor Inspection Report
Inspection Disposition Report / Inspection Release Note
Delivery Note
14. What is the timeline to Within 05 working days Sch. Q
award an ACD to LBE, NCR
and Worksheet?
15. List down the full forms of ASME: American Society of Mechanical Engineers
most frequently used ASTM: American Society for Testing of Materials
abbreviations. AISI: American Iron and Steel Institute
ANSI: American National Standard Institute
API: American Petroleum Institute
AWS: American Welding Society
AISC: American Institute of Steel Construction
ISO: International Organization for Standardization
SAES: Saudi Aramco Engineering Standards
SAEP: Saudi Aramco Engineering Procedures
SATIP: Saudi Aramco Typical Inspection Plan
SAIC: Saudi Aramco Inspection Checklist
SATR: Saudi Aramco Test Report
SASD: Saudi Aramco Standard Drawings
NCR: Non Conformance Report
ACD: Agreed Completion Date
PQI: Project Quality Index
QMIS: Quality Management Information System
 RFI: Request for Inspection
IIR: Internal Inspection Request
CAR: Corrective Action Report
CSD: Consulting Services Department
G. I.: General Instructions
PIP: Process Industry Practice
SIS: Safety Instruction Sheet
IFB: Issued for Bid
IFC: Issued for Construction
P& ID: Piping and Instrument Diagram
UG/AG: Under Ground / Above Ground
RSA: Responsible Standardization Authority
PQR: Procedure Qualification Record
16. What are the basic terms Code Break: The physical location on the piping system SAES-L-100
and definitions related to where the design Code changes from one Code to
piping and pipelines? another, such as from ASME B31.4 to ASME B31.3.
Critical Plant Equipment and Piping: A designation
imposed on equipment or piping system that will entail
extra design requirements with the objective to minimize
business interruption.
Cross-Country Pipeline: The pipeline and its
appurtenances used to transport fluids across the
country or offshore between isolated plant areas or
camps.
Design Agency: The agency responsible for designing the
piping system. It could be the design Contractor, the
Lump Sum Turn Key Contractor or in house design
organization of Saudi Aramco.
Design Conditions: All conditions (such as pressure,
temperature, ambient conditions, service, etc.) that
govern all or part of the design and selection of piping
components.
Design Factor: It is numerical multiplier used to calculate
the allowable stresses for transportation piping systems.
This factor is used by ASME B31.4 and ASME B31.8 Codes.
Flowlines: Pipelines connected to oil, gas or water wells
for production, injection or well testing.
Hazardous Service: Any fluid service other than Category
D as defined in ASME B31.3.
Maximum Allowable Operating Pressure (MAOP): This
term refers to the maximum pressure at which a piping
system can be operated within the provisions of the
applicable ASME B31.4 and or B31.8 codes. It is the
maximum internal pressure permitted in the piping
system for continued operation at the most severe
condition of coincident internal or external pressure and
temperature (minimum or maximum) expected during
service.
Normal Operating Conditions: The expected conditions
(such as pressure, flow, temperature, ambient conditions,
service, etc.) to occur during normal operation per
design.
Off-Plot: Off-plot refers to any area outside of the plot
 limits. Off-plot can include plant areas such as roads,
pipeways and open lots between plant units.
On-Plot: On-plot refers to any area inside the plot limit.
On-plot piping is generally, but not necessarily, designed
to ASME B31.3 code except in area(s) set aside for piping
within other code or government regulations.
Perimeter-Fence: The fence which completely surrounds
an area designated by Saudi Aramco for a distinct
function (plant or camp).
Plant-Area: The designated area engaged in the
production, processing, storage and transportation of
crude oil, gas, refined products and their derivatives. It
could be inside an onshore perimeter fence, or on the
decks of offshore structures.
Plant Piping: Pressure piping system, within an identified
plant-area.
Plant Utility Service: The supply of steam, water, air,
nitrogen or inert gas within a processing plant.
Plot Limit: The plot limit is a boundary, within the plant
area, which surrounds a single plant or function. The plot
limit may be physical such as a fence (not necessarily an
SSD fence), a wall, the edge of a road or pipe-way, chains
and posts or a boundary indicated on an approved plot
plan.
Production Pipelines: Those pipelines engaged in
transporting crude oil or gas from the producing wells to
the designated facility for processing. These include
flowlines, testlines, trunklines and transmission lines.
Process Piping: Pressure piping which is designed in
accordance with ASME B31.3. This piping is typically
found in petroleum refineries, chemical plants, cryogenic
plants, and related processing plants and terminals.
Power Piping: Pressure piping which is designed in
accordance with ASME B31.1 and typically found in
electric power generating plants.
Test lines: Flow lines that are used for testing an
individual producing well without affecting the operation
of the trunklines.
Transportation Piping: Pressure piping system that is
designed in accordance to ASME B31.4 or/and 31.8.
Typically, these pipelines transport hydrocarbon fluids or
others between processing plants or storage facilities to
export terminals and end users.
Trunklines: Pipelines to which two or more flowlines are
connected.
Well Head Piping: The piping system connecting the
wellhead to the flowline first isolation valve.
17. What are the Sections of ASME Section I: Rules for Construction of Power Boiler
ASME Boiler and pressure ASME Section II: Materials
vessel code? Part A: Ferrous Material
Part B: Non-Ferrous Material
Part C: Specifications for Electrodes and Filler Wire
Part D: Properties
 ASME Section IV: Rules for construction of heating Boiler
ASME Section V:Non Destructive Examination (NDE)
ASME Section VI:Recommended Rules for care and
operation of heating Boilers
ASME Section VII:Recommended Guidelines for care of
Power Boilers
ASME Section VIII:Rules for Construction of Pressure
Vessels
ASME Section IX:Welding and Brazing Qualification
18. What are the different ASME B 31.1:Power Piping
ASME Pressure Piping ASME B 31.2:Fuel Gas Piping
Codes for B31 series ASME B 31.3:Process Piping
ASME B 31.4:Pipeline Transportation System for Liquid
Hydrocarbon and other Liquids
ASME B 31.5:Refrigeration Piping
ASME B 31.8:Gas Transmission and Distribution Piping
System
ASME B 31.9:Building Service Piping
ASME B 31.11:Slurry Transportation Piping System
19. What are the different ASME B16 Series
ASME Codes for Material Flanges:
(ASME B16 and B36 series) ASME B16.1:Cast Iron Pipe Flanges and Flanged
Fittings(Classes 25, 125 and 250)
ASME B16.5:Pipe Flanges and Flanged Fittings (up-to 24
inches)
ASME B16.47:Large Diameter Steel Flanges (26 to 60)
ASME B16.49: Factory Made Wrought Steel But-welding
Induction Bends for Transportation and Distribution
Systems
But Welded Fittings:
ASME 16.9:But Welded Fittings
ASME 16.28: But welding short radius elbows and returns
bends.
Gaskets:
ASME 16.20:Metallic Gaskets for Pipe Flanges
ASME 16.21:Non-metallic Flat gaskets for pipe flanges
Socket and Threaded Fittings:
ASME 16.11:Forged fittings, socket welded and threaded
Valves:
ASME 16.10:Face to Face & End to End Dimensions of
Valves
ASME 16.34:Valves, Flanged , Threaded and Welding
Ends
ASME B36 Series
Pipes:
ASME 36.10:Welded and Seamless wrought steel pipe
ASME 36.19:Stainless Steel Pipe

20. What does ASTM describe? ASTM describes Standard Specifications of Materials
21. What are the ASTM Codes Pipe
for Materials? Carbon Steel:
ASTM A 53: Pipe, Steel, Black and Hot Dipped,Zinc
Coated, Welded and Seamless
ASTM A106:Seamless CS Pipe for High Temperature
Service
ASTM A 333:Seamless and welded steel pipe for low
temperature service
Stainless Steel
ASTM A312: Seamless, Welded, and Heavily Cold Worked
Austenitic Stainless Steel Pipes
Tube
Carbon Steel:
ASTM A 178:Electric-Resistance-Welded CS & Carbon-
Manganese Steel Boiler and Super heater Tubes
ASTM A 179:Seamless Cold-Drawn Low-Carbon Steel Heat-
Exchanger and Condenser Tubes
ASTM A 192:Seamless Carbon Steel Boiler Tubes for High-
Pressure Service
ASTM A 334:Seamless & Welded Carbon and Alloy-Steel
Tubes (Low-Temp)
Stainless Steel
ASTM A 213: Seamless Ferritic& Austenitic Alloy-Steel Boiler,
Super heater, & Heat-Exchanger Tubes
Wrought Iron Fittings
Carbon Steel:
ASTM A 234:Piping Fittings of Wrought CS & Alloy Steel for
Moderate & High Temp Service
ASTM A 420:Piping Fittings of Wrought CS and Alloy Steel for
Low-Temperature Service
Stainless Steel
ASTM A 403:Specification for Wrought Austenitic Stainless
Steel Piping Fittings
Forged Fittings
Carbon Steel:
ASTM A 181:Carbon Steel Forgings, for General-Purpose
Piping
ASTM A 105:Specification for Carbon Steel Forgings for Piping
Applications
ASTM A 350:Carbon & Low-Alloy Steel Forgings, Requiring
Notch Toughness Testing for Piping
Stainless Steel:
ASTM A 182:Forged or Rolled Alloy & SS Pipe Flgs, Forged
Fittings, Valves & Parts (Hi-Temp)
Cast Fittings
Carbon Steel:
ASTM A 216:Steel Castings, Carbon, Suitable for Fusion
Welding, for High-Temperature Service
ASTM A 352:Steel Castings, Ferritic& Martensitic, for
Pressure-Containing Parts, Suited for Lo-Temps
Stainless Steel:
ASTM A 217:Steel Castings, Martensitic Stainless & Alloy, for
Pressure-Containing Parts, Suited for High Temperature Service
ASTM A 351:Specification for Castings, Austenitic, for
Pressure-Containing Parts
Plates
Carbon Steel:
ASTM A 285:Pressure Vessel Plates, Carbon Steel, Low- and
Intermediate-Tensile Strength
 ASTM A 515:Pressure Vessel Plates, CS, for Moderate- and
Lower-Temperature Service
ASTM A 516:Pressure Vessel Plates, CS, for Moderate- and
Lower-Temperature Service
Stainless Steel:
ASTM A 240:Chromium & Chromium-Nickel SS Plate, Sheet, &
Strip for Press Vess& Gen Apps
Bolting Materials
Carbon Steel:
ASTM A307STD Specification for Carbon Steel Bolts and Studs,
60 000 PSI Tensile Strength

ASTM A194STD Spec-Carbon & Alloy Steel Nuts for Bolts for
High Press and/or High Temperature Service
ASTM A563 STD Spec – Carbon and Alloy Steel Nuts

Stainless Steel:
ASTM A193 STD Spec Alloy-Steel & SS Bolting Matls for High
Temp or High Pressure Service & Special Apps
ASTM A320 STD Spec – Alloy-Steel & SS Bolting Materials for
Low-Temperature Service

21. What are the different API API 5L:Specification for Line Pipe
Standards? API 6D:Pipeline Valves
API 526:Flanged Steel Pressure Relief Valve
API 594:Check Valves (Flanged, Lug, Wafer and But
Welding)
API 510: CONSTRUCTION OF PRESSURE VESSEL.
API 598:Valve Inspection and Testing
API 599:Metal Plug Valves, Flanged, Threaded and
Welding Ends
API 600:Bolted Bonnet steel gate valves for petroleum
and natural gas industries
API 602:Compact Steel Gate Valves Flanged, Threaded,
Welding and Extended Body Ends
API 603:Corrosion Resistant Bolted Bonnet Gate Valves,
Flanged and But Welding Ends
API 608:Metal Ball Valves, Flanged, Threaded and
Welding Ends
API 609:Butterfly Valves, Flanged, Lug and Wafer Type
API 620:Design and Construction of Large welded low
pressure storage tanks
API 650:Welded Steel Tanks for Oil Storage
API 653:Tank Inspection, Repair, Alteration and
Reconstruction
API 1104:Welding of Pipelines and Related Facilities
22. What is the AWS Standard AWS D1.1: Structural Welding Code-Steel
Reference for Structural
Steel Welding?
23. Define the Mechanical Compressive strength:Maximum stress a material can
Properties of Materials withstand before compressive failure (MPa).

Ductility:Ability of a material to deform under tensile load (%

elongation).
 Malleability:Abilty of material's to deform
under compressive stress.

Fatigue limit:Maximum stress a material can withstand

underrepeated loading (MPa)

Fracture toughness:Energy absorbed by unit area before the

fracture of material (J/m^2)

Hardness:Ability to withstand surface indentation (e.g. Brinell

hardness number)

Elasticity: it is the tendency of solid materials to return to

their original shape after being deformed

Plasticity (physics):Ability of a material to undergo

irreversible deformations

Shear strain:Change in the angle between two perpendicular

lines in a plane

Shear strength:Maximum shear stress a material can

withstand

Tensile strength:Maximum tensile stress a material can

withstand before failure (MPa)

Yield strength :The stress at which a material starts to yield

(MPa)
24. What is the Difference Pipe:Pipe is identified by NB and thickness is defined by Important
between Pipe and Tube? Schedule question
Tube:Tube is identified by OD& its thickness as BWG
(Birmingham wire gauge or 1/100 inch).
25. What is Hoop Stress?how Stresses which are generated circumferentially due to the Important
you calculate it? action of Internal pressure of pipe are calledHoop Stress. question
Hoop Stress (Sh) = Pdo/ 2t
Where P = Force Acting from Inside.
do= OD of Pipe.
t = Pipe Thickness
26. How can we classify the Pipe flanges are classified in different ways based on pipe
flanges? attachment, Pressure-Temperature (PT) rating, facing, face
finish.
27. Can Raised Face Flange Yes, it can be as far as the pressure and temperature ratings ASME B16.5
convert to Flat Face Flange? would remain unchanged. and ASME B
16.47
28. What are the flange types Flat face. (FF)
based on facing / mating Raised face. (R/F)
surfaces? Tongue and groove. (T/G)
Male and female. (M/F)
Ring type joint. (RTJ)
How can flanges be Smooth finish
classified based on face Serrated finish
finish?
What do you means by There are two series of flange dimensions.Series A specifies ASME B 16.47
Series A and Series B flange dimensions for general use flanges. Series B specifies
 Flanges? flange dimensions for compact flanges which, in general, have
smaller bolt circle diameters than Series A flanges. These two
series of flanges are not interchangeable. The user should
recognize that some flanged valves, equipment bolted between
flanges, and flanged equipment may only be compatible with
bolt circle diameter of one series of flanges.
29. How to check the OD of Flange, Thickness of Flange, Length through hub, Dia of ASME B 16.47
dimensions of the flanges? Hub, Raised Face Dia, Dia of Bolt Circle, Dia of Bolt hole, Fillet
Radius.
30. What are the flange types Slip on: The Slip-on type flanges are attached by welding inside
based on pipe as well as outside. These flanges are of forged construction.
attachments? Socket Weld: The Socket Weld flanges are welded on one side
only. These are used for small bore lines only.
Screwed: The Screwed-on flanges are used on pipe lines where
welding cannot becarried out.
Lap Joint: The Lap Joint flanges are used with stub ends. The
stub ends are welded with pipes & flanges are kept loose over
the same.
Welding Neck: The Welding neck flanges are attached by butt
welding to the pipe. These are used mainly for critical services
where the weld joints need radiographic inspection.
Blind: The Blind flanges are used to close the ends which need
to be reopened.
Reducing: The reducing flanges are used to connect between
larger and smallersizes without using a reducer. In case of
reducing flanges, the thickness of flange should be that of the
higher diameter.
Integral: Integral flanges are those, which are cast along with
the piping component or equipment.
31. Why do we make color Spiral Wound gaskets shall be marked with a color code that ASME B 16.20
coding on Spiral Wound identifies the windings and filler materials. A continuous color
Gasket and where it would around the outer edge of the centering ring shall identify the
be done on Gasket? winding metal. The color identifying the filler material for NPS
i’/* and larger shall have four intermittent stripes spaced
approximately 90 deg apart on the outer edge of the centering
ring. Smaller size gaskets shall have a minimum of two stripes
180 deg apart.
32. What are the Types of Full Face
Gasket based on Spiral Wound Metallic
Construction type? Ring Type
Metal Jacketed
Inside Bolt Circle
33. What are the Saudi Aramco SAES-A-004:General Requirements for Pressure Testing
Engineering Standards SAES-A-005:Safety Instruction Sheet
applicable for pipelines and SAES-A-007:Hydrostatic Testing Fluids and Lay-Up Procedures
Plant Piping? SAES-H-200:Storage, Handling and Installation of Externally
Coated Pipe
SAES-L-100: Applicable Codes and Standards for Pressure
Piping Systems.
SAES-L-101: Regulated Vendors List for Pipes, Fittings,
Flanges and Tubes.
SAES-L-102:Regulated Vendors List for Valves
SAES-L-105:Piping Material Specifications
SAES-L-108:Selection of Valves
SAES-L-109:Selection of Flanges, Stud Bolts and Gaskets
Piping Standards
SAES-L-125:Safety Instruction Sheet for Piping and
 Pipelines
SAES-L-150:Pressure Testing of Plant Piping and Pipelines
SAES-L-310:Design of Plant Piping
SAES-L-350:Construction of Plant Piping
SAES-L-410:Design of Pipelines
SAES-L-420:Scraper Trap Station and Appurtenances
SAES-L-440:Anchors for Buried Pipelines
SAES-L-450:Construction of On-Land and Near-Shore Pipelines
SAES-L-460:Pipeline Crossings Under Roads and Railroads
SAES-L-470:Trenchless Pipelines Construction Requirements
34. What are the Saudi Aramco SAES-D-001: Design Criteria for Pressure Vessels
Engineering Standards SAES-D-008: Repairs, Alterations, andRe-rating of Process
applicable for Tanks? Equipment
SAES-D-100: Design Criteria of Atmospheric and Low-
Pressure Tanks
SAES-D-101: Regulated Vendors List Managed
Commodities for Pressure Vessels and Storage Tanks
SAES-D-108: Repair, Alteration and Reconstruction of
Storage Tanks
SAES-D-109: Design of Small Metallic Storage Tanks
SAES-D-110: Design of Fiberglass-Reinforced Plastic (FRP)
Storage Tanks
SAES-D-116: Underground Storage Tank System
35. What are the Saudi Aramco SAES-G-005: Centrifugal Pump
Engineering Standards SAES-G-006: Positive Displacement Pumps - Controlled Volume
applicable for Centrifugal SAES-G-007: Submersible Pumps and Motors for Water Well
Pumps? and Offshore Service
SAES-G-101: Regulated Vendors List for Pumps and Mechanical
Seals
SAES-G-115: Lubrication, Shaft Sealing and Control Oil Systems
SAES-G-116: Cleanliness Standard for Lube/Seal Oil and Fluid
Power Systems
36. What are the Saudi Armco SAEP-20:Equipment Inspection Schedule
Engineering Procedures SAEP-29:General Instructions and Guidelines for Online Valve
involved in Pipelines and Preventive Maintenance
Piping? SAEP-35: Valves Handling, Hauling, Receipt Tests and Storage
SAEP-122:Project Records
SAEP-306: Assessment of Pipeline Defects
SAEP-302: Instructions for Obtaining a Waiverof a Mandatory
Saudi Aramco Engineering Requirement
SAEP-311:Installation of Hot Tapped and Stopple Connections
SAEP-310:Piping and Pipeline Repair
SAEP-327:Disposal of Waste water from Cleaning, Flushing and
Dewatering Pipelines and Vessels
SAEP-351:Bolted Flange Joints Assembly
SAEP-379:Quality Issues Notification
SAEP-381:Project Quality Issues Escalation Process
SAEP-1028:Chemical Cleaning and Flushing of Lube/Seal Oil
and Fluid Power Systems
SAEP-1160:Tracking and Reporting of Welding, NDT and
Pressure Testing for Capital Projects
SAEP-1150: Inspection Coverage on Projects
SAEP-1151:- REPLACEMENT OF SAER 1972
37. What are the SAMSS 01 SAMSS-024-: PIPEHandling and Nesting
involved in Pipelines, 01-SAMSS-022:Fracture Control Testing Procedures for Line
Piping, Valves and Fittings? Pipe
01-SAMSS-010: Fabricated Steel Piping

01-SAMSS-043 : Carbon Steel Pipes for On-Plot Piping

01-SAMSS-039:Induction Pipe Bends

01-SAMSS-046 : Stainless Steel Pipe

01-SAMSS-038 :Small Quantity Purchase of Pipe

from Stockist and Approved Pipe Mills

01-SAMSS-035:API Line Pipe

02-SAMSS-005 : Butt Welding Pipe Fittings

SAMSS-009: Design and Fabrication of Scraper Traps

04-SAMSS-001:Gate Valves
04-SAMSS-002:Globe Valves

04-SAMSS-003 :Additional Requirements for Low Temperature

Valves

04-SAMSS-005:Check Valves, Swing Type

04-SAMSS-035:General Requirements for Valves

04-SAMSS-041: Expanding Plug Valve

04-SAMSS-042: 4-Way Diverter Valve

04-SAMSS-047:High Performance Butterfly Valves (Including

Triple-Offset

04-SAMSS-048:Valve Inspection and Testing Requirements

04-SAMSS-049: Inspection and Testing Requirements

for API SPEC 6A, 10000 PSI Valves

04-SAMSS-050:Gate Valves, Through Conduit Type, APISPEC

6D

04-SAMSS-051: Ball Valves, API SPEC 6D

04-SAMSS-052:Ball Valves, API SPEC 6A

04-SAMSS-053:Steel Lubricated Plug Valves - Flanged and

Welding End
38. What do you mean by Hydrogen Induced Cracking (HIC) is the mechanism,
Hydrogen Induced Cracking related to hydrogen blistering, that produces subsurface
(HIC) cracks parallel to the surface and, sometimes, stepwise
cracks in the through-thickness direction.
39. What is HIC Resistant HIC resistant steel is manufactured via the electric arc
Material? furnace with desulphurisation, dephosphorisation, ladle
refining and vacuum degassing to provide ultra clean and
homogeneous steel. HIC steel is particularly suited for
pressure equipment where wet H2S corrosion can be a
problem.
40. What is the Difference Hydrostatic Test: A pressure test conducted using water SAES-A-004
between Hydrostatic test or other approved liquid as the test medium.
and Pneumatic Test? Pneumatic Test: A pressure test conducted using air or
other approved gas as the test medium or in conjunction
with liquid.

What do you mean by Strength Test: A pressure test at an internal pressure SAES-A-004
Strength and Tightness determined in accordance with this standard and the
test? applicable Code to verify the integrity of the piping
systems or equipment for service at the design pressure.
Tightness Test: A pressure test to ensure tightness of the
piping system (i.e., no leaks in the system) at the test
pressure.

41. What are the contents of  Flow Chart SAEP-1160

Hydrostatic test Package?  Reference the "Approved" Pressure Test
Procedure
 Pressure Test Diagram which shall include the
limits of piping (including test manifold) and
equipment included in each pressure test, high
points and low points (drain), locations of
pressure gauges, test pressures, test
temperature, test fluid, line flushing
requirements, and safety precautions
 Relief valve capacity, testing and installation
 Pressure gages and recorders calibration records
 COMPANY Safety Instruction Sheet (for critical
piping) and Pressure Test Report Form
 Copies of P&ID and isometric drawings of the
piping system to be pressure tested
 Piping spools control sheet with NDT extent and
results.
 Pre-pressure test check List
 Re-instatement procedure and Check List
 Flange set completion documentation for
permanent installations
 Identification of pressure testing SPC from
contractor
 Lay-up method to be applied
 Verification of chemical dosing calculations when
applicable
 Test manifold hydro test verification
 What is the formula for MAOP = (2*SMYS*WT*DF)/D SIS & ASME
Hydrostatic test pressure? Initial Test Pressure = (2*0.90*SMYS*WT)/D B31.8
&
At-least 1.25 times of MAOP for class location 1
At-least 1. 5 times of MAOP for class location 2, 3 and 4

42. What do you mean by Pre Punch list consists of the items to be done / rectified.
Test Punch list and how to A) Items must be cleared before pressure testing
identify Item A and B? B) Items could be cleared after pressure testing
43. What is the validity of Pressure Gauge: 01 Month SAES-A-004
Calibration of Pressure Relief Valve: 01 Week
Gauge, Relief Valve, Pressure Recorder: 01 Month
Pressure Recorder, Temperature Recorder: 01 Month
Test Manifold:Test Manifold for new construction shall be
Temperature Recorder and
revalidated for each new project & for operating facilities it is
Manifold? 60 months.
44. What is the Minimum No. A minimum of two pressure gauges are required for SAES-A-004
of Gauges required for the test system. One pressure gage shall be on the test
Hydrostatic Test? manifold and the other(s) on the test system. Their
accuracy shall be within 5% of one another.
How will you select a All gauges shall have a range such that the test SAES-A-004
suitable Pressure Gauge? pressure is within 30 to 80% of the full range.
45. What error is allowed Pressure Gauges accuracy shall be within 5% of one SAES-A-004
between pressure gauges? another.
56. What would be the Before employing the pressure testing manifold in the SAES-A-004
hydrostatic test pressure actual system pressure test, it shall be separately
for Manifold? pressure tested to at least 1.2 times the system test
pressure but not less than the discharge pressure of
the pump used for the pressure testing.
47. What is the set pressure of Pressure test relief valve(s) of adequate capacity set to SAES-A-004
Pressure Relief Valve relieve at 5% above the test pressure shall be installed
(PRV)? unless the test pressure is less than 85% SMYS at which
time it can be set at 10% above the test pressure.
48. What is the duration of The test pressure shall be maintained for a sufficient SAES-L-150
Hydrostatic testing of Plant time, but shall not be less than 30 minutes, to
Piping? determine that there are no leaks
49. What is the duration of The strength test pressure shall be maintained for SAES-A-004
Strength Test and Tightness 2hours.
test While Hydrostatic Tightness test shall be conducted at 95% of the
testing of aboveground strength test pressure, immediately after the
Pipeline? completion of the strength test. The tightness test
pressure shall be maintained as long as required for
the inspector to examine all exposed joints.

50. What is the duration of The strength test pressure shall be maintained for
Strength Test and Tightness
2hours.
test While Hydrostatic A 24-hour recorded tightness test shall be applied
testing of underground when the pipeline is buried or insulated, or is partially
Pipeline? buried or insulated for more than 300 m (1000 ft) or
10% of its total length whichever is less.
51. What should be the Water General: SAES-A-007
Quality for Hydrostatic
 test? What is the chlorine Water used for any part of the hydrotesting or
content? subsequent lay-up shall have a sulfate reducing
bacteria (SRB) count of 10³ per ml or less as
determined by the RapidChek II Method or alternative
test method approved by Supervisor,
CTU/ME&CCD/CSD. Water that has a higher bacteria
count may be accepted at the discretion of the
Supervisor, CTU/ME&CCD/CSD, after treatment with
biocide and retesting.

Water may be reused for hydrotesting, as in a pipeline

tested segment by segment. The water must meet the
requirements of Paragraph 4.2.3 and must have an
oxygen level of less than 20 ppb, or additional
chemical treatment will be required.

Carbon Steel and Low Alloy Steel Equipment:

Treatment of Hydrostatic Test Water When the equipment

contact time with hydrotest water may exceed 14 days,an
approved oxygen scavenger (see Appendix 1) shall be added to
the hydrostatic test water. Treat the water before it enters the
system. Use batching scrapers and/or a slug of nitrogen to
separate the air in the system from coming in contact with the
treated water, and then fill the system with water injecting
sufficient oxygen scavenger to maintain its residual
concentration at greater than 20 ppm and an oxygen
concentration of less than 10 ppb.

Stainless Steel Equipment

Type 300-series stainless steels shall be tested only with water SAES-A-007
that has very low chloride content in order to avoid pitting and
PARA 6.1
stress corrosion cracking. The maximum allowable chloride
concentration is 50 ppm. Verify the quality of the water
following the requirements of Paragraph 4.2.
What General Instruction GI-0002.102 Pressure Testing Safely
can be referred to conduct
pressure test safely?
52. What are the contents of
Tie-in Package?
53. What is Hot Tapping? Hot Tap Process is a mechanical procedure for tapping a
charged process line using special equipment without
shutting the line down.
54. What are the contents of
Hot Tap Package?
55. What are the Requirements 5.1 General Handling Requirements SAES-H-200
for Coated Pipe Storage, 5.1.1 The coated pipe shall be handled at all times in a
Handling, Transportation manner that prevents damage to the pipe walls, beveled
and stringing? ends, and to the coating (including internal coatings, if
applied).
5.1.2 All equipment, including field bending machines
and pipe cradles, that contact the coated surface of the
 pipe shall be padded. Slings shall be nylon or equivalent;
steel cables shall not be used.
5.1.3 Coated pipes shall not be rolled or dragged on the
ground. Coated pipes shall be protected by wrapping
polyethylene strings near the pipe ends.
5.1.4 Bevel protectors, when used, shall be firmly
attached to the pipe.
5.2 Stacking Requirements during Storage and
Transportation
5.2.1 During storage the coated pipes shall be placed at
least 150 mm off the ground on either rock-free sand
berms covered with polyethylene sheeting or on padded
skids spaced and leveled so that the pipes are supported
without damaging the coating.

5.2.2 FBE-Coated Pipes

FBE-coated pipes shall not be stacked directly against
each other at any time during storage or transportation.
They shall be separated by full encirclement,
noncompressible rubber padding or equivalent at least
10 mm thick.
5.2.2.1 Twelve meter (12 m) joints of pipe shall have at
least 3 full encirclement separation pads. Two (2) shall be
located 1 to 3 m from each end of the pipe and 1 in the
middle.
5.2.2.2 Twenty four meter (24 m) double-jointed pipe
lengths shall have at least 5 full encirclement separation
pads placed so that 2 of them are 1 to 3 m from the outer
ends of the pipe and 3 of them support the center section
of the pipe. Placement of the pads should be
approximately equidistant from each other.
5.2.2.3 Additional separation pads shall be used if
required to keep the coated pipes from touching each
other.
5.2.2.4 The separation pads shall be attached by some
mechanical means that ensures they will stay in place.
The FBE coated pipes shall be protected from direct
sunlight in order to prevent UV degradation. This shall be
done by covering the stacked pipes with tarpaulins or
similar protection. The tarpaulins must be maintained in
good condition for as long as the pipes are exposed to
direct sunlight. In case FBE coated pipes are stored
outdoors without appropriate cover for more than six
months, FBE coated film must be checked for premature
deterioration (see 09-SAMSS-091).
Stringing Requirements
Externally coated line pipe strung along the right-of-way
shall be supported on rock-free sand, sand bags, rubber
tires, or similar compressible material to prevent coating
damage. (See also the general handling requirements in
Paragraph 5.1.)
56. What are the Requirements B.1 Workmanship
for Pipeline Bending? B.1.1 At any point along a preformed bend, the pipe
 diameter shall not be reduced by more than 2-½% of the
nominal pipe diameter.
Bends shall not be made closer than 600 mm from edge
of the line pipe joint (location of the field circumferential
welds).
B.1.2 Preformed bends shall be made by welding into the
correct location of the string a length of pipe which has
been bent with a smooth stretch bending machine.
B.1.3 Bending of spiral wound line pipe shall be
conducted with proper tools and performed with skilled
operators because spiral wound pipe is more prone to
buckling. For example, a hydraulic bending mandrel and
polyurethane-lined bending dies should be used for
spiral-welded pipe.
B.1.4 For internally coated pipe, the bend angle per bite
may be reduced to minimize damage to the coating. (As a
minimum, the internal coatings shall withstand the bends
described in B.2).
B.1.5 For relatively thin wall spiral-welded pipe, the bend
angle per bite may need to be reduced (typically to 75%
of normal) to avoid wrinkling the pipe.
B.2 Preformed Bends Bites and Angle
B.2.1 The maximum permissible localized bend or “bite”
at one place on the pipe and the minimum spacing of
such bites are shown in Table B1.

Table B1 –
Maximum
Localized Bend
Nominal Pipe Minimum Bite Maximum Bend
Size Spacing Per Bite
Inch mm in Degrees
6 300 4.5
8 300 3.8
10 300 2.8
12 300 2.3
14 300 1.7
16 300 1.5
18 300 1.2
20 450 0.9
24 450 0.75
30 450 0.6
36 and larger 450 0.5

B.2.2 Wide Bends Radius

The wide bend radius of 210 meter can be achieved by
applying a maximum bend or “bite” at one place on the
pipe of 0.50 degrees and minimum spacing of such bites
of 0.9 m.
57. What are the Requirements 1: SAES-L-450
for Thrust Boring? 2:Thrust boring should not be used where open cut and trench
can be achieved
 3:
58. What are the Requirements
for Installation of
Sectionalizing Valves &
Jump-overs?
59. What are the Requirements
forInstallation of Scraper
trap Installation
60. What are the Requirements
for Pipeline Internal
Cleaning/Flushing/Scraping
61. What are the Requirements Gasket:
of Flanged Joint (Gasket 1: Size ,Class , ASME Stander, Approve Manufacture
Verification & Bolt Bolts ,Nuts
Tightening) 1:size,length,grade,approved Manufacture

62. What are the Requirements All spools,valves,bolts nuts,gaskets installation must bbe
for Pipeline Re-instatement compeleted
Inspection
63. What are the requirements
for Valve Hydrostatic
Testing?
64. What are the Requirements
of Pneumatic Testing?
65. How to witness fit-up of High Low: 3 mm maximum
pipes? What are the Root gap: 2 to 3 mm
tolerances? Bevel angle: 35degree +-2.5
Root face: per WPS

66. What does a SIS contains? SIS Contains Equipment Data and Operating Limits
67. What are the Different A. Isolation.
functions of valves? B. Regulation.
C. Non-Return.
D. Special purpose.
68. How to preserve a valve? 1:
Flanged valves NPS 2" and smaller shall be
fitted with UV resistant plastic covers.

2:
For other size, valve end flanges shall be fitted
with plywood covers.

3:
The cover shall be attached by machine bolts
with a nut & washer fitted on the inside of the
flange. There shall be four (4) bolts on valves
up to NPS 10 inch nominal size and eight (8)
bolts on valves
NPS 12 inch and larger.

4:
The raised face portion of the flange and the
ring joint groove shall be covered with a heavy
grease.
 5:
A heavy duty moisture-proof disc shall be
fitted between the greased flange face and the
cover.

6: The ends of threaded and socket weld end

valves shall be protected with tight fitting
plastic caps.

69. What are the Different 01: Gate valve.

types of valve? 02:Ball valve
03:Plug valve.
04:Piston valve.
05:Diaphragm Valve.
06:Butterfly valve.
07:Pinch valve.
08: Globe valve.
09: Needle valve
10: Check valve.
70. What are the Reducers and 1:Ecentric reducer.
its types? 2:concentric reducer.
71. What are the PSL-1 and PSL-1:-Provide a stander quality level for line pipe.
PSL-2 as per API 5L? PSL-2:-Has additional mandatory requirement for chemical
composition,notch toughness and strength properties and
additional NDE.
72. What is Pikotek Gasket and Pikotek is a non metallic gasket that is made with Teflon seal
where it is usually used? which is supported by glass reinforcement epoxy(gre)
laminated.
73. What is weep hole? Weep hole is provided in the supports to release hot gasses
during welding and it made down side of supports at 6 o clock
condition.
74. Is it possible to make weep No
hole after hydrostatic
testing?
75. How can flanges be A: Smooth finish.
classified based on face B: Serrated finish.
finish?
76. Why do we provide High HPV: For removing Air during Hydro-test.
Point Vent (HPV) and Low LPD : For draining water after conducting Hydro-test.
Point Drain (LPD) in piping?
77. What do you mean by
Jacketed Piping?
78. What are Weldolet and Weldolet and Sockolet are basically self-reinforced fittings.
Sockolet? And where they Weldolet:Weldolet is used for Butt weld branch
connection where standard tee is not available due to size
are used?
restrictions and the piping is of critical / high-pressure
service.
Sockolet:Sockolet is used for socket welding branch
connection, which require reinforcing pad.
79. How the valves are Valves are classified based on its method of operation as:
classified based on its A. Self- operated valves.
B. Operated valves
method of operation?
80. Describe different types of DESTRUCTIVE TEST: Bend test, Tensile test, Impact
destructive and non- test, and Hardness test.
NON-DESTRUCTIVE TEST: DPT, MPT, Radiography
destructive tests?
and ultrasonic test
81. What are the different 1: Brinell Hardness Test.
types of hardness tests 2: Rockwell Hardness Test.
3: Vicker Hardness Test
carried out?
82. What do you mean by Hoop Stresses which are generated circumferentially due to the Important
Stresses and how do you action of Internal pressure of pipe are called question
Hoop Stress. It is calculated by; -
calculate it?
Hoop Stress (Sh) = Pdo/ 2t
Where P = Force Acting from Inside.
do= OD of Pipe.
t = Pipe Thickness.
83. How does Hoop Stress As per membrane theory for pressure design of cylinders,
affect the system? as long as hoop stress is less than yield stress of Moc, the
design is safe. Hoop stress induced by thermal pressure
is twice the axial stress (SL). This is widely used for
pressure thickness calculation for pressure vessel.
84. What is stress? It is defined as the applied load per unit cross-section of
the specimen. The common unit are psi
(pound per square inch), kpa, Mpa, kg/cm2.
85. What is strain? For tensile load, it is the ratio of increase in length of the
specimen under constant sustained load to the original
length of the specimen before the load is applied. For
compressive load, it the ratio of decrease in length to the
original length under sustained load. Strain is thus an
observable and measurable quantity as the extension or
compression of the specimen can be directly measured. It
is a dimensionless quantity.
86 What is IAP? Inspection assignment package
87 Describe the difference Quality Control is the operational techniques
between QA & QC? (Inspection, Examination & Testing) that are used to
fulfill requirements for quality.

Quality Assurance is the system of action and

planning needed to provide confidence that a
Product or Service will satisfy quality requirements

88 Definition of Procedure, Procedure: A specified way to perform an activity.

Standard, and Specification, Standard: Document, established by consensus, and
code,Code of approved by a recognised body, that provides, for
practice,Instruction, common and repeated use, rules, guidelines or
Normative document, characteristics for activities or their results, aimed at the
Regulation, Technical achievement of the optimum degree of order in a given
specification? content.
Specification: The document that advises the
requirements with which the product or service has to
conform. NB. A specification should refer to or include
drawings, patterns or other relevant documents and
should also indicate the means and the criteria where
byconformity can be checked.
Code of practice: Document that recommends practices
or procedures for the design, manufacture, installation
maintenance or utilisation of equipment, structures or
products
Instruction: Provision that conveys an action to be
performed.
Normative document:A document that provides rules
 guidelines or characteristics for activities or their
results.
Regulation: A document providing binding legislative
rules that is adopted by an authority.
Technical specification: A document that prescribes
technical requirements to be fulfilled by a product,
process or service. NB. A technical specification should
indicate, where ever appropriate, the procedure(s) by
means of which it may be determined whether the
requirements given are fulfilled. A technical
specification may be a standard, a part of a standard or
independent of a standard

89 Describe Pre assembly 1:The gasket shall be verified for correct type, rating, SAEP-351
inspection before flange dimension and compatibility with the flange facing. PARA:
joint? 2:Bolts, nuts and washers shall be visually checked for 4.1 TO 4.7
proper size, grade, dimension and for any physical
damage to shanks or threads which would affect the
bolt assembly or performance.
3:The flange facing, particularly the seating area, shall
be visually examined for cleanliness and ensure that no
damage, such as scratches exist.
4:For ring joint type flanges, the ring and the ring groove
shall be free of damage and dirt.
5:Proper lubricant for bolts and nuts shall be used.
Lubricant for bolts and nuts shall be Jet-Lube SS-30 or
other acceptable lubricants listed in Table-SAEP-351-01.
6:Tightening tools shall be checked for adequacy,
performance and calibration, if required.
7:Lubricant shall not be used in the gasket and the
gasket seating area.
8:Flange shielding shall be installed/reinstalled when
required.

90 If Leaks Occur During 1: Depressurize the piping system SAEP-351

Pressure Testing what you 2: If leak does not stop after re-torquing has been PARA:8
will do? performed, disassemble the flange joint
3: Inspect stud bolts and nuts for defects or damage to
threads or improper cleaning of threads
4: Inspect flange faces for damage, misalignment
5: Inspect gasket for damage or defects.
91 Which Torquing Tools are 6.1: There are various types of tools available toachieve SAEP-351
used for bolt torquing? the proper torque value. Selection of the proper tool PARA:6.1-6.3
depends on the stud bolt size, physical location of the
flanged joint, and criticality of the flange. Identifying the
proper tools shall be resolved between Contractor,
SAPMT, Proponent and Inspection prior to commencing
the erection of the piping.
6.2: The manufacturer's instructions shall be followed for
 the operation, limitation and maintenance of all torque
wrenches used to perform flange bolts tightening.
6.3: Torque wrench calibration shall be performed in
accordance with manufacturer's recommendations
92 DESCRIBE MECHANICAL IMPACT TEST :
IMPECT TEST AND DWTT
(DROP WEAR TEAR TEST )? DWTT TEST :
93 What we need in pipe 1: Purchase Order number 01-SAMSS-035
marking? 2: Item Number
3: heat number
4: 9COM or 9CAT stock number
5: if 9com or 9cat number are not so marked "01-
SAMSS-035
94 How much hardness Maximum acceptable hardness for all grades is 250 HV 01-SAMSS-035
require for all grades? using 5 or 10 kg load.
95 What is ISO drawing? show the exact routing of every pipe two inches and above in
diameter. Sometimes the drawings to provide further detail
contain a plan and elevation .

96 What is P&ID drawing? for engineers, operators and instrument people, shows
instruments, piping and vessels or equipment.

97 How you will do work by

using PFD drawing
98 What you know about
hydrotestdiagrame?
99 Why you use SIS sheet in
Hydrotest package?
100 If you found a dent in a
pipe what you will do?
101 What you are check before When we are going to hydrotest we must have the
hydrotest? approved hydrotest package and hydrotest procedure
with us.
1:internel cleaning and water flushing must be done
before hydrotest.
2:apre test punch listing must be done before
hydrotest and all a item must be clear.
3:the area where we are going to test must be
barigate and sign bord putting there for safety resin.
4:the water use in test must be treated or plant
process water and its water analyses report must be
on site.
5:allgauges,reliefvalve,testheader,manifold must
have the valid certificate.
6:gaskets which are used in hydrotest must be from
approved manufacture and must be same class.
7:bolttorqning done before hydrotest as per
saep 351.