S No Question Brief Answer
1 What is the difference between SA 515 & SA 516 a) SA 515- Intermediate and high temperature service and coarse Grain steel
b) SA 516- Moderate and low temperature service and fine Grain steel. Aluminium added in SA516 steel
to refine the grain.
2 What is fine grain and Coarse grain Coarse Austenitic Grain—the grain size number determined shall being in the range of 1 to 5 (inclusive).
Fine Austenitic Grain: Grain size number above 5
3 What is the orientation of Tensile test coupon of Carbon or low alloy steel Transfer to rolling direction
plate (Refer SA20)
4 Number of Tensile test specimen required for Carbon or low alloy steel plate a) Two/ Plate, if Plate is Quenched and Tempered.
(Refer SA20) b) For other than Quenched and Tempered steel- one/ plate.
5 What is the meaning for LTV, G & MT marking on Carbon and Low alloy • LTV - Impact tested (low temprature V-Notch Tests).
steel-Plate (Refer SA 20) • G - If Heat Treatment not performed by Plate Manufacturer and to be carried out by Vessel
manufacturer.
• MT - If Heat Treatment performed by Plate Manufacturer. (material treateded)
6 What is Simulation Heat Treatment of Mechanical Test Coupon. Prior to testing, the test coupons representing the plate for acceptance purposes for mechanical
properties shall be thermally treated to simulate a post-weld heat treatment to be performed during
Manufacturing of Pressure Vessel. Temperature range, time, and cooling rates shall be specified in the
purchase order. For tests using specimens taken from such heat treated test coupons, the test results
shall meet the requirements of the applicable product specification. This addition to Heat treatment
required for Plate as per Material specification.
7 Is Carbon Equivalent to be reported for ASTM Carbon and Low Alloy steel No. It is only supplementary requirement.
plates used for Pressure Vessel.
8 What is the difference between Heat/Cast Number and Plate Number Heat/Cast Number: Identification of Heat number of cast from which steel is rolled
marked on Plate. Plate Number: Identification of Plate after Rolling (Both Heat Number and Plate Number has to be
marked on Plate. In Material Test certificate, Chemical Analysis reported against heat number and
Mechanical Values against Plate Number)
9 What is acceptance criteria difference between SA435 and SA 578 SA 435-
Any discontinuity indication causing a total loss of back reflection which cannot be contained within a
circle, the diameter of which is 3 in. [75 mm] or one half of the plate thickness, whichever is greater, is
unacceptable.
SA578-
Any area where one or more discontinuities produce a continuous total loss of back reflection
accompanied by continuous indications on the same plane (within 5 % of plate thickness) that cannot be
encompassed within a circle whose diameter is
Level A- 75 mm or 1⁄2 of the plate thickness, whichever is greater, is unacceptable.
Level B- 75 mm or 1⁄2 of the plate thickness, whichever is greater, is unacceptable + In addition, two or
more discontinuities smaller than described above shall be unacceptable unless separated by a minimum
distance equal to the greatest diameter of the larger discontinuity or unless they may be collectively
encompassed by the circle described above.
Level C- 25 mm is unacceptable.
10 What is the Permissible variation under specified thickness for Carbon Steel Permissible variation under specified thickness, 0.254mm.
& low alloy steel Plates
11 Is hydro test mandatory requirements for Pipes manufactured under SA As an alternative to the hydrostatic test at the option of the manufacturer or where specified in the
106, SA333, SA 312, SA335. purchase order as an alternative or addition to the hydrostatic test, the full body of each pipe shall be
tested with a non destructive electric test.
12 What is the Permissible variation under specified thickness for Pipes 12.5% of specified thickness.
manufactured under SA 106.
13 Type of Heat Treatment generally used in Pressure Vessels • Stress reliving- Heating below lower critical temperature.
• Normalising- Heating above upper critical temperature and cooling in Still Air
• Quenching- Heating above upper critical temperature and cooling in liquid medium and followed by
tempering.
• Solution Annealing- Mostly performed for Austenitic stainless steel. Heating around 1000 deg C and
cooling rapidly by quenching in solution from soaking temperature or cooling in furnace up to 850 Deg C
and cooling rapidly at sensitization temperature range (850 to 530 deg C)
• PWHT- All above Heat treatment selected depending upon Material as specified in ASME Sec VIII.
14 What is Sensitization Temperature of Stainless steel Material. Sensitization involves the precipitation of chromium carbides along the grain boundaries of austenitic
(300 series) and ferritic/martensitic (400 series) stainless steels when they are exposed for significant
periods of time in the temperature range of about 540°C to 845°C.
15 What are all the type of Stainless steel generally used in Pressure Vessel a) Austenitic stainless steels : They contain a maximum of 0.15% carbon, a minimum of 16% chromium
and sufficient nickel and/or manganese to retain an austenitic structure at all temperatures from the
cryogenic region to the melting point of the alloy.
Grade 316, 304, 321
b) Ferritic stainless steels: are highly corrosion resistant, but far less durable than austenitic grades and
cannot be hardened by heat treatment. They contain between 10.5% and 27% chromium and very little
nickel. Grade 430, 409
c) Martensitic stainless steels :are not as corrosion resistant as the other two classes, but are extremely
strong and tough as well as highly machineable, and can be hardened by heat treatment. Martensitic
stainless steel contains chromium (12-14%), molybdenum (0.2-1%), no nickel, and about 0.1-1% carbon
(giving it more hardness but making the material a bit more brittle). Grade 410, 410S
d) Duplex stainless steels: have a mixed microstructure of austenite and ferrite, the aim being to produce
a 40:60 mix. Duplex steel have improved strength over austenitic stainless steels and also improved
resistance to localised corrosion particularly pitting, crevice corrosion and stress corrosion cracking.
Grade: UNS 33205
16 What is Stress corrosion cracking Stress corrosion cracking is a rapid and severe form of stainless steel corrosion. It forms when the
material is subjected to tensile stress and some kinds of corrosive environments, especially chloride-rich
environments (sea water) at higher temperatures.
17 What is intergranular corrosion cracking Stainless steel are prone to intergranular corrosion when exposed to certain environments. When heated
to around 700 °C, chromium carbide forms at the intergranular boundaries, depleting the grain edges of
chromium, impairing their corrosion resistance. Steel in such condition is called sensitized.
18 What is Sulphide stress cracking Sulphide stress cracking is an important failure mode in the oil industry, where the steel comes into
contact with liquids or gases with considerable hydrogen sulphide content, e.g., sour gas. It is influenced
by the tensile stress and is worsened in the presence of chloride ions. Very high levels of hydrogen
sulphide apparently inhibit the corrosion. Rising temperature increases the influence of chloride ions, but
decreases the effect of sulphide, due to its increased mobility through the lattice; the most critical
temperature range for sulphide stress cracking is between 60-100 °C.
19 What are all types of test to deduct Susceptibility to Intergranular corrosion
as per ASTM A 262 • Practice A- Oxalic Acid Etch Test for Classification of Etch Structures of Austenitic Stainless Steels- to be
carried out before carrying any of the below test.
• Practice B- Ferric Sulfate–Sulfuric Acid Test
• Practice C—Nitric Acid Test
• Practice E—Copper–Copper Sulfate–Sulfuric Acid Test
20 Difference between SA 263, SA 264, SA 265
• SA263- Specification for Chromium Steel Clad plate (Clad Material- Straight Chrome steel. Base Material
-Carbon or low alloy steel)
• SA264- Specification for Stainless Chromium – Nickel Steel Clad plate (Clad Material- Austenitic
Stainless steel. Base Material -Carbon or low alloy steel)
• SA265- Specification for Nickel & Nickel- Base Alloy- Clad steel plate (Clad Material- Nickel and Nickel
Alloys. Base Material -Carbon or low alloy steel)
21 When Cladding Material is not included in Tensile test of Clad steels
If the cladding is for corrosion allowance only, the cladding need not be included in the tensile test. The
tensile properties thus determined shall meet the base steel requirements.
22 Is test for strength of bonding in clad plate is Mandatory as per Specification
SA263, SA 264, SA 265
No Tests for strength of the bond, when required, must be specified by the purchaser
23 Mechanical test for Bond strength of Clad Plates Shear Strength and Bend Test
24 What is the NDT required as mandatory to carried out on Clad Plates as per
specification • Visual- when total composite thickness less than 10mm
• UT as per SA578- when total composite thickness 10mm & more.
25 What is difference between heat analysis and product analysis.
• Heat Analysis- Chemical analysis of cast/heat used for making the Products like plate, forging, pipes,
tubes etc
• Product Analysis- Chemical analysis of products.
26 What is through thickness tensile test
Through thickness tensile test is test carried out on specimen drawn perpendicular to the rolled surface.
(Refer SA 770)
27 Why through thickness test carried out on Pressure Vessel Material. The principal purpose of the testing is to provide a measure of the resistance of a steel plate to lamellar
tearing.
29 What is the meaning of terminology "examination" used in ASME Inspection activity carried out by Vessel Manufacturer
30 What is the meaning of terminology "Inspection" used in ASME Inspection activity carried out by Authorised Inspector
31 Is Mechanical test coupon of Flanges and fitting exempted from Simulation
Heat Treatment.
Yes, if they are manufactured to ASME standards like B16.5, etc
32 What is the Joint Category for Shell Flange to Shell weld Category C
33 What is the Joint Category for Hemispherical Dish to Shell weld Category A
34 What is the Joint Category for Nozzle to Flange weld Category C
35 What is the Joint Category for Nozzle Neck to Nozzle Neck weld Category B
36 For what all joint Category, Vessel production test coupon required.
For Category A welds & for Category B welds, if WPS used is different from Category A
37 When Production Test coupon is required as per ASME. If WPS used, requires impact test.
38 When welding procedure requires to be qualified with impact test. If Material used requires to be Impact tested.
39 What all test required on Production Test Coupon as per ASME VIII Impact Test
40 How much out of roundness or ovality permitted for pressure vessel as per
ASME Sec VIII Div.1. The difference between the maximum and minimum inside diameters at any cross section shall not
exceed 1% of the nominal diameter at the cross section under consideration. At opening location shall
not exceed 2%.
41 Is deviation from true circle has to be measured for Vessel with internal
pressure.
Not required. Required only for Vessel with external pressure.
42 What is the limit on out of shape for Dish ends
shall not deviate outside of the specified shape by more than 1-1/4% of nominal diameter nor inside the
specified shape by more than 5/8% of nominal diameter.
43 What is the graduation range required for Dial indicating Pressure gauge
used for Pressure testing Dial indicating pressure gages used in testing shall be graduated over a range of about double the
intended maximum test pressure, but in no case shall the range be less than 1-1/2 nor more than 4 times
that pressure.
44 Is Digital Pressure Gauge permitted
Yes, Digital reading pressure gages having a wider range of pressure may be used provided the readings
give the same or greater degree of accuracy as obtained with dial pressure gages.
45 What is the frequency of Calibration required for Pressure Gauges used for Gages shall be recalibrated at any time that there is reason to believe that they are in error. All gages
testing Pressure vessel manufactured to ASME Sec VIII Div.1 shall be calibrated against a standard dead ‐weight tester or a calibrated master gage.
46 What is the meaning of Markings RT1, RT2, RT3, RT4 in Name Plate
• RT1- Full Radiography (Refer UW 11a)
• RT 2-Spot Radiography +RT of T Joints (when the complete vessel satisfies the requirements of UW-
11(a)(5) and when the spot radiography requirements of UW-11(a)(5)(-b) have been applied)
• RT3- Spot Radiography (Refer UW11 b)
• RT4 when only part of the complete vessel has satisfied the Full radiographic requirements (RT1) or
where none of the markings “RT 1,” “RT 2,” or “RT 3”are applicable.
47 What is the meaning of Markings HT & PHT in Name Plate HT- Vessel fully PWHT, PHT- Part of the Vessel PWHT
48 Is painting permitted as per ASME before Hydro test No Unless permitted by Vessel User for vessel not used in lethal service.
49 What should be the metal Temperature during Hydrotest. 17 deg C above MDMT.
50 How much should be the minimum length of staggering required between
long seams of adjacent courses. 5 times the thickness. This requirement can be waived off, if longitudinal joints are radiographed 4 in.
(100 mm) each side of each circumferential welded intersection.
51 Can nozzle holes opened on shell Seams. Permitted on head‐to‐shell or Category B or C butt welded joints, provided the weld meets the
radiographic requirements in UW-51 for a length equal to three times the diameter of the opening with
the centre of the hole at midlength
52 What is the minimum overlap required when heat treating the Vessel in
more than one heat. 1.5Meter
53 How rate of heating calculated for PWHT
222 DegC divided by maximum metal thickness in inches. However it shall not exceed 222 Deg C
54 How rate of cooling calculated for PWHT
280 DegC divided by maximum metal thickness in inches. However it shall not exceed 280 Deg C
55 How much is the maximum temperature difference accepted during Holding
period of PWHT 83 Deg C (except limited in tables of USC56)
56 At what condition heat treatment required for formed products like shell, • For P. No.1 Gr.1&2- if extreme Fiber elongation exceeds 40% or 5% and any of the clause specified in
dish, Fabricated Nozzle neck etc. USC 79 d 1to5 exist.
• For other than [Link].15E & P. No.1 Gr.1&2- if extreme Fiber elongation exceeds 5%
57 Types of Dished Head hemispherical, ellipsoidal, semi-ellipsoidal, conical, torispherical, toriconical, flat
58 What is MAWP Maximum Allowable Working Pressure
59 What is MDMT Minimum Design Metal Temperature
60 At what temperature Impact test to be carried out Minimum Design Metal Temperature
61 Tensile test fails outside weld during welding procedure qualification test. Is Accepted, provided the strength is not more than 5% below the minimum specified tensile strength of
it acceptable the base metal
62 Two Material of different strength 70KSI & 60KSI used for welding
procedure qualification coupon. What is the acceptance strength required 60KSI
for Tensile test
63 What is WPS (Welding Procedure specification)
Qualified document, which provide direction for making production welds to Code requirements.
64 What is PQR (Procedure Qualification Record) Records of welding variables recorded during welding Coupon and includes test results
65 What is the content of WPS Essential and Non Essential Variables and if applicable Supplementary essential variables.
66 What is the content of PQR
Essential variables and if applicable Supplementary essential variables, Test results. On option of vessel
manufacturer Non essential variables may be included.
67 What is essential variables
Change in these variables effect Mechanical property. Change these Variables requires requalification.
68 What is Supplementary Essential variables.
Required for Metal which requires notch toughness test (Impact Test). If required, change any
Supplementary essential variables requires requalification.
69 List out some Essential Variables
Change in Coupon Thickness, Change in P No. of Coupon, Change in A No., F No. of Consumables,
decrease in Preheat temperature, Change in PWHT, etc
70 List out some supplementary Essential Variables
Change in group No., Coupon thickness, Increase in interpass temperature, PWHT- Time and
Temperature, increase in Heat input, Change in Polarity/Current
71 SMAW Process with Supp Essential requirement, 25mm thick plate used in
procedure qualification. What is the minimum base metal thickness
qualified.
16mm (Refer QW 403.6)
72 SMAW Process without Supp Essential requirement, 25mm thick plate used
in groove weld procedure qualification and Weld deposited [Link] is
the minimum/maximum base metal thickness qualified and max weld
deposit thickness qualified
Base Metal-Min5mm/Max50mm, Weld deposit-50mm Maximum
73 SMAW Process without Supp Essential requirement, Coupon was heat
treated at 610 deg C for 1 Hour. Will change in soaking time in production
weld requires requalification
No (Change in soaking time requires requalification only when supp essential variable is applicable)
74 SMAW Process without Supp Essential requirement, 25mm thick Pno.1,
Coupon was heat treated at 910 deg C for 1 Hour. What is the maximum
base metal thickness qualified
27.5mm (Refer QW 407.4)
75 SMAW Process with Supp Essential requirement, Heat treated at 610 deg C
for 100 minutes. What is the maximum soaking time permitted in
production.
120 Minutes
76 Coupon thickness 12mm. List of test required for welding qualification
Tensile Test-2Nos, Bend test (Face bend-2Nos, Root Bend-2Nos or Side bend-4Nos as substitute for root
and face bend)
78 What are all the test required to qualify Corrosion resistance welding
procedure
PT, Bend Test, if specified chemical.
79 If welder qualified in pipe 2G & 5G, is the welder qualified for 6G Yes for all position
80 Type of Heat Exchangers U-Tube, Fixed Tube Sheet, Floating Head Tube sheet
81 What is floating head Tube sheet Heat Exchanger
Heat exchanger with one stationary tube sheet attached to the shell and channel, and one floating tube
sheet that can move axially. The heat exchanger contains a bundle of straight tubes connecting both tube
sheets
82 What is shear load testing in Heat Exchanger
Carried out to establish the allowable load in tube to tube sheet joint. Tubes are welded or expanded
identical to production on a Mock-up Block and then tube is pulled/pushed out in Universal Tensile
Testing Machine and strength is recorded. (Refer Non Mandatory Appendix A of ASME Sec VIII Div.1)
83 Why Shear load test not applicable for U-Tube and Floating Head Tube sheet
Tubes in U-Tube & Floating head heat exchangers will not act as stays and will not support or contribute
to the strength of the tube sheets in which they are engaged (Refer Non Mandatory Appendix A of ASME
Sec VIII Div.1)
84 What is the meaning of "common element" in Heat Exchanger
Parts which are subject to both shell side and tube side pressure are called common element, like Tube,
Tube sheet
85 What is Differential pressure in Heat Exchanger
Common elements are designed to the pressure equal to Pressures difference between Shell side and
Tube side pressure.
86 In differential Pressure Heat Exchanger how hydro test pressure calculated
Hydro Test pressure calculated based on differential pressure.
87 Which standard/code applicable for Heat Exchanger Fabrication Tolerance
TEMA (Tubular Exchanger Manufacturer association.)
88 Which standard/code provides Bolt tightening procedure for Heat
exchangers
TEMA (Tubular Exchanger Manufacturer association.)
89 What are all Class of Heat Exchanger as per TEMA Class R, Class B, Class C
90 What is Class C, R & B Heat exchangers
Class R- Exchangers for Petroleum Industries with severe requirements, Class B- Commercial & general
process purpose with moderate requirement , Class C for chemical and process industries
91 What is the minimum Hydrotest Holding time as per TEMA 30 Minutes (Refer TEMA Para RCB 1.31
92 How much Flattening permitted in U Tubes as per TEMA 10% of original Tube OD(Refer TEMA para RCB2.31)
93 How much thickness reduction is permitted in U tubes as per TEMA 17% of original thickness (Refer TEMA para RCB2.31)
94 What is the tolerance on diameter of Heat Exchanger shell Inside design Diameter shall not exceed 3.2mm (Refer TEMA para RCB 3.122)
95 How much over tolerance permitted on Tube Holes in Baffle
0.3mm over tolerance permitted and 0.4mm over tolerance permitted in 4% holes (Refer TEMA Para RCB
4.2)
96 Where and why Impingement Plate provided. Impingement Plates are provided at shell nozzle to avoid erosion of Tube Bundle
97 Tolerance on Tube Hole of Tube sheet Refer TEMA Table RCB 7.41
98 What is the purpose of Pass Partition Plate in Heat Exchanger
To create multipass of Tube side fluid. Pass Portion Plate are fixed in Channels. Even Partition plate may
be used in shell to create multiple pass or split flow.
99 What is the purpose of Tie Rod in Heat Exchanger Tie rod are used in Tube Bundle to Tie the Tube Bundle
100 What is the purpose of Spacer in Heat Exchanger Spacers are used between baffle to maintain baffle space
101 what is the purpose of baffle in Heat Exchanger Baffles-to create transfer flow of shell fluid
102 How Type of Heat Exchangers designated
Designated with three letter. First letter denotes type of Stationary Head, second letter denotes type of
shell, third letter denotes rear head (Example AEL, A-Channel with removable cover, E-one pass shell, L-
Fixed Tube sheet with Stationary Head) Refer TEMA Figure N1.2
103 What is stacked heat exchangers
Two or more heat Exchanger assembled one over other. Shell side and Tube side fluid, after completing
the flow cycles in first heat exchanger flows to other Heat exchanger for further Heat transfer between
these fluids. (Note: Generally fit up of interconnecting nozzles and Support saddles of both the Heat
Exchangers are carried out in stacked position.)
104 What are all methods used for Expansion of Tube in the Tube sheet Mechanical Expansion and Hydraulic expansion (General mechanical expansion is carried out)
105 How tube expanded inside Tube Holes using Mechanical rolling.
In mechanical rolling, a set of hardened rolls in a cage rotate around a tapered mandrel. The rolls travel
up the mandrel causing an increasing radial force exerted at the contact point between the rolls and the
tube. This increasing force moves the tube material outwards until it contacts the ID of the tube sheet
hole and continues until supposedly the tube sheet material is just below its yield point.
106 What is the reason for qualifying the Expansion on a mock up block
To set the required parameter of expander to achieve leak tight joint , tube thinning within specified limit
and if tube act as stay in Heat Exchanger then minimum shear strength as per Appendix A of ASME Sec
VIII Div.1).
107 Percentage of Tube thinning formula
[(Original Thickness- Final thickness)/Original thickness)]x100 this is calculated as {1-[(Dh -IDf)/(OD-
IDi)]}x100
Dh- Tube Hole Diameter in Tube Sheet
Idf -ID of Tube after expansion
OD- OD of Tube before expansion
IDi -ID of Tube before expansion
108 What is strength weld in Tube to Tube sheet weld joints
A full strength tube‐to tubesheet weld is one in which the design strength is equal to or greater than the
axial tube strength
109 What is Partial strength weld in Tube to Tube sheet weld joints
partial strength weld is one in which the design strength is based on the mechanical and thermal axial
tube loads (in either direction) that are determined from the actual design conditions.
110 What is strength weld in Tube to Tube sheet weld joints
A tube‐to‐tube sheet seal weld is one used to supplement an expanded tube joint to ensure leak
tightness.
111 The letters HT The letters HT shall be applied under the Designators when the complete vessel has been postweld heat
treated as provided in UW-10.
112 The letters PHT The letters PHT shall be applied under the Designators when only part of the complete vessel has been
postweld heat treated as provided in UW-10.
113 Pressure relief device When a single pressure relief device is used, the set pressure marked on the device shall not exceed the
maximum allowable working pressure of the vessel.
114 corrosion allowance apply above 3mm, NACE material to be use
The steel shall be made by a process that includes vacuum degassing while molten. Unless otherwise
115 what is Vacuum Treatment? agreed upon with the purchaser, it is the responsibility of the manufacturer
to select suitable process procedures.
In addition to the marking required in Specification A20/A20M, each plate shall be legibly stamped or
116 stenciled,depending upon the ordered thickness, with the letter A for annealed, N for normalized and
tempered, and Q for accelerated cooled and tempered, as applicable
The preheat zone shall be at or above the specified minimum temperature in all directions
117 Preheat Temperature. Ref B 31.3 from the point of welding for a distance of the larger of 75 mm (3 in.) or 1.5 times the greaternominal
thickness.
Interruption of Welding After welding commences, the minimum preheat temperature shall be maintained until any required
PWHT is performed on P-Nos. 3, 4, 5A, 5B, 6, and 15E, except when all of the following conditions are
satisfied:
(a) A minimum of at least 10 mm (3∕8 in.) thickness of weld is deposited or 25% of the welding groove is
118 filled,whichever is less (the weld shall be sufficiently supportedto prevent overstressing the weld if the
weldment is to be moved or otherwise loaded). Caution is advised that the