Process Piping Interview Questions

Piping process engineer

A Piping Process Engineer is a narrowly-oriented engineer, who applies theoretical knowledge for piping design, analysis, and optimization, for different industries with focus on oil gas, petrochemical, chemical processing, power generation, manufacturing sectors, etc. Their main objective is to prevent the disastrous transportation of fluids including liquids and gasses within the industries. Here are the key responsibilities and roles of a Piping Process Engineer:Here are the key responsibilities and roles of a Piping Process Engineer:

Piping System Design :Piping Process Engineers carry the responsibility of creating methodologies that will be used in the pipeline where the fluids are trans – ported within a certain facility. Some of the tasks required involve material choices, pipe sizing and classification and development of the piping layout and isometric drawings.

Fluid Flow Analysis: They determine and analyze the types of fluids that are in the piping system in order to make sure that the piping system is running effectively and safely. This includes analyzing matters such as pressure drop, flow rates, and the fluids’ characteristics.

Material Selection: As for Pipe Selection, Piping Process Engineers are responsible for the choice of pipes, fittings and other equipment dealing with the transported fluids based on fluid compatibility, temperature, pressure and corrosion allowance.

 stress analysis : They perform stress analysis with a view of establishing the fitness for use of pipes. This comprises an assessment of stresses, strains and deflections that the system is subjected to during the operational conditions to check its robustness in performing the intended function.

Code and Standard Compliance: The process of piping must be efficient In this regard, the piping process engineers must ensure that they meet the relative code of the industry upon the design and construction of piping systems such as the ASME B31. 3 for process piping.

Safety and Risk Assessment: This position evaluates hazards that may be related to the piping systems and find ways of reducing the hazards. Prominent considerations which include pressure relief, emergency shutdown systems, and hazard analysis, among others, are involved.

Equipment Specification: They define and acquire numerous pipe accessories such as the valves, pumps, and instruments for the system.

Environmental Considerations: Piping Process Engineers also take into account emission, leakage, and spilling issues and come up with solutions that have little to no effect on the environment.

Quality Assurance and Testing: They supervise the test and inspection of piping systems to confirm that conform to the design requirement and safety codes.

Cost Estimation: Piping Process Engineers are responsible for cost estimates for such piping projects going forward in relation to material, labor, equipment and other expenses of the project.

Interdisciplinary Collaboration: They work most closely with other engineers and specialists including mechanical engineers, electrical engineers and instrumentation engineers to guarantee that the piping system fits properly into the other system in the facility.

Project Management: At times some of them may comprise the project management responsibilities for the piping projects including; planning or scheduling and managing the piping projects.

Maintenance and Troubleshooting: They also support the aging piping systems and are involved in the identification of problems that cause a reduction in reliability and performance of the systems.

Piping process engineers are in most cases very instrumental throughout the achievement of protected functioning in installed utilities. This can be accomplished by having fast-reducing flexible pipes with an appropriate background in fluid mechanics, thermodynamics, materials science and engineering principles knowledge. At the same time, they need to be aware of different trends and changes in the industries as well as novelties in piping engineering and design.

Process piping engineer

A process piping engineer can be defined as an individual who has a skill of designing new piping systems, installation process of the piping systems and even maintaining them for industries such as oil and gas, chemicals and manufacturing industries. Materials that process piping engineers deal with range from steel, stainless steel, and at times plastics. They also involve components like those valves, fittings, and pumps as well as their parts in their dealings.

Knowledge of flow of fluids, heat transfer, thermodynamics, and structural design in engineering are specifically required in the design of process piping. Also, I think that to perform the tasks, the personnel must be able to read and comprehend engineering drawings. Process piping engineers are mostly degree holders in engineering, either mechanical engineers or civil engineers.

The duties of a process piping engineer may include:

• Piping design for meeting the need of a particular process
• The choice of the suitable materials and parts of a piping system
• Accomplishing engineering drawing and specifications of piping systems
• Supervising the work in relation to the installation of piping systems
• Conducting inspections and maintenance of piping systems
• Troubleshooting piping problems

Several kinds of facilities involve process piping engineers in their design, construction as well as operation. Their major roles include; overseeing that piping systems are safe, efficient and effective.

Here are some of the key skills that process piping engineers need:

• Excellent technical knowledge of conservation laws relating to fluids, energy, and structures.
• Engineering drawing reading and interpretation Usually, engineering drawings will contain blueprints, diagrams, design specifications, a bill of materials and other documents, and I should be able to read and understand those documents.
• Requirement for design and fault finding on piping systems.
• Forbes’ core competencies include skills in decision-making, customer focus, interpersonal communications, ability to motivate oneself and others, ability to withstand pressure and accept responsibility, project management, and information utilization and technology.
• Another essential working attribute that is deemed as a deal breaker is good interpersonal and communication skills.

It is also important to note that process piping engineers’ jobs can be found in quite a number of fields, some of which are: oil and gas industry, chemical industry, manufacturing industries and the power generation plants. They are usually employed in office settings; however, they may from time to time be required to visit construction sites to assess conditions of pipelines.

Based on the analysis, it can be deduced that the job market for process piping engineers is quite active and is projected to grow much faster than the average job market over the next few years. This is due to the current upgrade and growing need for piping systems in many business fields.

Process piping standards

The process piping that is in industries involves having the standard and code that must be followed since it will involve the safety, reliability and other factors that will be considered to be the industry standards. These guidelines and codes that may be used in the process piping may sometimes be specific to the industry, geographical region or the kind of fluids that are being transferred. Below are some of the most commonly referenced process piping standards:Below are some of the most commonly referenced process piping standards:

ASME B31 Series:

• ASME B31. 3: Process Piping – This specification is about the design, fabrication, examination, installation and preservation of the process piping systems to be used in industries such as chemical, manufacturing, power generation etc. Of course, it is widely recognized and used all over the world.
• ASME B31. 1: Power Piping – This standard applies to the piping system of a power plant and is adopted for use in the power generation field only.
• ASME B31. 4: Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids – This standard is applied with relation to piping systems in pipeline transportation of liquid hydrocarbons and other liquids.
• ASME B31. 8: M excessively Tran and Distribution Piping Sves: It deals with the design, construction and service provision of piping systems for the transmission and distribution of natural gas.
• ASME B31. 9: Building Services Piping – This standard is used for the pipes used in the buildings for heating, cooling and sanitary works etc.

API Standards:

• API 570: Piping Inspection Code – This is a set of codes that gives direction on how to inspect, repair , alter or rerate in-service piping.
• API 574: It deals with a vast area of focus that deals with the inspection of different components of piping.
• API 579-1/ASME FFS-1: Fitness-for-Service- This standard is used when there is any sign of flaw or damage on the piping equipment and such items that are already in service.

ASTM International:

• ASTM specifications apply to a Piping material and some tests associated with it. Some of the examples of pipes include the following; ASTM A106, which is a standard specification for carbon steel pipe for high-temperature and pressures, ASTM A312, which is a standard specification for stainless steel pipe, and finally, ASTM D2513, which is a standard specification for polyethylene gas pipe.

ANSI/ISA Standards:

• ANSI/ISA-5. 1: The Instrumentation Symbols and Identification – This standard is responsible for offering symbols and identification numbers or codes for the instrumentation and control systems for process piping.

NACE International:

• To the extent of known corrosion and corrosion protection in piping systems, NACE standards are normally related to industries like oil and gas.

NFPA Standards:

• This document is in line with the NFPA codes, like the code that specifies requirements for the private fire service mains and their appurtenances, namely code 24.

BSI Standards:

• Among the BSI available standards are the following ones which pertain to piping in industries within the United Kingdom and globally.

EN Standards:

• Various rules governing process piping in Europe are provided in the European norms referred to as EN standards.

GOST Standards:

• GOST standards are used in Russia and also other countries of the former USSR in relation to process piping and other industrial equipment.

Local and Regional Codes: Therefore, depending on the region the building is to be constructed and the exact type of business it will be housing, there may be other codes and regulations at state or local level.

When undertaking design or fabrication of piping systems for given project, engineers, designers, and inspectors as well as operators must be in a position to understand the various standards and codes that should apply to given system of piping and make sure that they are in compliance with the set standards for safety and integrity of the system. Also, it is essential to note that standards and codes are reviewed and changed from time to time, and therefore it is very relevant to gain an update before applying them.

Process piping inspection checklist

Piping inspection as part of the processes is the important factor to ensuring the right designs, fitting, and safety of the piping systems of a plant. An inspection checklist is a useful document in the assessment of piping systems for either the inspector or engineers. Below is a general process piping inspection checklist that can be customized to fit the specific needs of your facility:Below is a general process piping inspection checklist that can be customized to fit the specific needs of your facility:

Note: Note that this is a guideline of the required procedures and questions that needs to be followed and answered throughout the process of cyber investigation. With Regards to these guidelines, As far as industrial obligations and procedures concerning these inspections are concerned, it is advised at all times to adhere strictly to the set codes and standards of your industry including other required procedures of your organizational infrastructure.

1. General Information:

• The specification of the piping system and where it is located.
• Evident by the P&ID number of the piping system in consideration.
• Date of inspection.
• Inspector's name and credentials.

2. Visual Inspection:

• Check to see if there is any seepage, rust or any other form of damage on any of the pipes.
• In pipe labeling, it is crucial that the information placed is correct. This includes the material used in the manufacturing of the pipe, size of the pipe and what is inside the pipe.
• The state of all supports, hangers, anchors shall be checked and it is necessary to ensure that all of them are fixed tightly.

3. Piping Documentation:

• Finalize and check the accuracy of the piping isometric drawings, P&ID, and other information as may be necessary.
• The success of this method is also easy to confirm that the documentation matches the reality when doing the installation.

4. Material Verification:

• Ensure that piping material is the correct type and grade specified and is capable of withstand the service condition.

5. Weld Inspection:

• Subject the weld areas to a check on signs of defects which might include crack, incomplete penetration and or lack of fusion.
• Ensure that all welding has labels and is documented according to the welding instruction.

6. Pressure Testing:

• Ensure that code and standards require pressure tests to be done and ensure that the pressure tests have been done.
• Check the test records and make sure their pressure loss is within an acceptable range.

7. Flange Inspection:

• Inspect flanges for such items as leakage, level of corrosion, gaskets’ condition and state of bolts.
• Make sure that flanges are properly placed with the proper face to face distance together with gaskets.

8. Valve Inspection:

• For the check valves, ensure they are effective, any sign of leakage on the check valves or signs of corrosion on the check valves.
• Check the correctness of the position and labeling of all valves.

9. Insulation and Coating:

• One must also ensure that insulation is well okay, that it has not been tampered with or has reached its worst state.
• Several coating systems can be susceptible to one form of corrosion or the other or are otherwise vulnerable to degradation; therefore, inspect the coating for such a deficiency.

10. Instrumentation and Supports: - Ensure on the conditioning and accuracy of the instrumentation equipment; pressure gauges, temperature indicators. - This should also ensure that pipe supports and Hanger maintenance is proper and the structure of the pipe support and hanger is well done.

11. Safety Features: Check whether pressure relief devices, and emergency shutdown systems are provided and properly working.

12. Compliance: Ensure that it conforms to specific codes/standards of the industry (e. g. , ASME B31. 3, API 570). - Ensure that there is documentation of the permits which have been issued to the facility through the planning, designing as well as the construction stages.

13. Documentation and Reporting: Document all inspections and recording any and all notations of defects or suggestions for service. - After the inspection, develop an inspection report and forward it to the concerned employees only.

14. Repairs and Follow-Up: Regarding problems or delays, it is necessary to record them and try to solve them with priority. - It is also necessary to plan follow-up inspections from time to time to ensure that the repair works have been done to satisfactory standards.

The following is a checklist that will help in identifying some of the major points of concern that one would need to look at during a process piping inspection. Nonetheless, it should be noted that the presented checklist needs to be adjusted to a particular institution with regard to the outlined standards and recommendations of the industry. Also, the inspections should be done by experienced people who have adequate training in matters concerning piping systems and methods of inspection.

Difference between process piping and power piping

Process piping and power piping are two types of piping systems that are used in a variety of industries. However, there are some key differences between the two types of piping systems.

Process piping is used to transport fluids, such as liquids, gasses, and slurries, through a facility. Process piping systems are used in a variety of industries, including oil and gas, chemical, manufacturing, and power generation.

Power piping is used to transport fluids, such as steam, water, and oil, to and from power generation equipment. Power piping systems are typically used in power plants, but they may also be used in other facilities that require high-pressure fluids.

Here is a table that summarizes the key differences between process piping and power piping:

Notwithstanding the above differences, there are also other differences between process piping and power piping. For instance, while process piping systems tend to indicate a larger band of flow rates as compared to power piping systems. Power piping systems are also generally less complex in the manner of control unlike process piping systems.

All in all, it can be concluded that process piping and power piping are two types of the piping systems that are applied in various industries. Process piping systems are pipelines that convey production fluids while power piping systems are pipelines that convey fluids to and from power generation equipment.

Here are some examples of specific applications of process piping and power piping:

• Process piping:
  • Transporting oil and gas through a pipeline
  • Transporting chemicals through a reactor
  • Transporting slurries through a slurry pump
• Power piping:
  • Transporting steam to a turbine
  • Transporting water to a boiler
  • Transporting oil to a heat exchanger

The process piping, as well as the power piping engineers, deals with designing, installing, and maintaining the piping system of the industries. They should have prior knowledge in fluid mechanics; thermodynamics and structural engineering. To qualify for the job the candidates must also be able to read and interpret Engineering drawings.

What is process piping

Piping is the combination of pipes through which the fluids like liquid, gasses, and slurries are conveyed in a plant. Process piping systems are utilized in such sectors as oil and natural gas, chemical, manufacturing as well as power sectors.

It is a system made of pipe, valves, fittings and many other things and widely used in the processing industries. The pipes are utilized as conduits for the fluids while the valves and fittings are employed to regulate the flow of the fluids. The other parts include the ones that lead the fluids and these are pumps and compressors for the movement of fluids.

Piping systems in the processes are established in such a way that they are safe and highly reliable. It is required that such tubing should have the ability to handle pressures and temperatures of the fluids that are being conveyed. Speaking of their design requirement, they need to be resistant to the corrosive effects of the fluids as well.

process piping engineers  are involved with the design, fabrication and erection of the process piping systems. The candidates must be well-educated in the domain of fluid mechanics, thermodynamics, and structures. They must also have to be able to read and comprehend engineering drawings.

Process piping systems are considered as one of the fundamental components in many types of plants and establishments. They are also employed to carry the fluids that are required in manufacturing of various goods and services locally. This is why it is important that piping systems within processes are designed and installed correctly and also well maintained.

Here are some of the key benefits of process piping:Here are some of the key benefits of process piping:

• Efficiency: Piping systems are key elements of process plants that may have a positive impact on the efficiency of the manufacturing processes since they minimize the time as well as the energy needed for the transportation of fluids.
• Safety: A typical process piping system is generally utilized in industries and businesses that involve the processing and transferring of hazardous fluids so as to enhance safety.
• Compliance: Through process piping systems, one is able to avoid Pollution without treatment since it only allows passage of different media without the release of pollutants to the atmosphere or environment.
• Reliability: Process piping delivers specified fluids to the right location and at the right time hence helping in boosting the reliability of production processes.

In sum, process piping is an integral component of numerous kinds of establishments. It is employed in conveying fluid that is required in the manufacturing of products and provision of services. Process piping systems should be well selected, installed and commissioned to provide adequate reliability and protection, and be efficient.

Process piping interview QA

1) What is the minimum distance to be maintained between two welds in a pipe?
The thumb rule is that the minimum distance between adjacent butt welds is 1 D.If not, it is never closer than  1 - 1/2 “ . This is supposedly to prevent the overlap of HAZs. minimum spacing of circumferential weld between centerlines shall not be less than 4 times the pipe wall thickness or 25 mm whichever is greater.

2) What are weldolet and socket? And where are they used?
Welolet  and sockolet are basically self - reinforced fitting. Weldolet is used for butt weld branch connection where standard tee is not available due to size restriction and the piping is of critical/high pressure service. sockolet is used for socket welding branch connection , which require reinforcing pad

3)What do you mean by Jacketed piping ?
Piping which is recognized as providing the most uniform application of heat to the process , as well as maintaining the most uniform processing temperatures where steam tracing is not capable of maintaining the temperature of fluid constant. Usually used for molten sulphur, polymers service.

4)What is the basis of using short  radius & long radius elbow ?
Long radius elbows are used for  small pressure drops whereas short radius elbows are used for high pressure drops. For catalyst flow vary long radius are used

5)Normally where do we use the following ?
A. Eccentric reducers.
B.  Concentric  reducers.
A. Eccentric reducers - pump suction to avoid cavitation, To maintain elevation ( BOP ) in rack.
B. Concentric  reducers - Pump discharge, vertical pipeline etc.

6)How are  pipe fittings classified based on end connections?
No, air pockets  may form if concentric reducer is used at pump suction, which results in cavitation and causes damage to the pump. To avoid this problem, eccentric reducer with Flat Side Up (FSU) is used in pump suction.

7)How are pipe fittings classified based on end connection ?
Pipe fittings are classified based on end connection as
A. socket weld fittings.
B. screwed end fittings
C. beveled end or butt weld fittings
D. spigot socket fittings
E. buttress end fittings

8)From which side of the pipe will you take a branch connection ?
When fluid is gas, air or steam and cryogenic service - topside when fluid is liquid - bottom side

9)What is the difference between pipe and tube ?
Pipe is identified by NB and thickness is defined by schedule whereas tube is identified by OD & its thickness as BWG  ( Birmingham Wire Gauge or 1/100 inch ).

10)From which size onwards NB of pipe is equal to OD of pipe ?
From the size 14 “ and onwards NB = OD of pipe

11)What should be the radius of a long elbow ?
1.5 D ( where  ' D’  is the diameter of the pipe )

12)How can flanges be classified based on pipe Attachment?
Flanges can  be classified based on pipe attachment as-slip-on. The slip on type flanges are attached by welding inside as well as outside. These flanges are of forged construction
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 pipelines where welling cannot be carried out
Lap joint - The lap joint flanges are used with stub ends. The stub ends are welded with pipe & 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 service 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 smaller size without using a reducer, In case of reducing flanges, the thickness of flange be that of the higher diameter.
Integral - Integral flanges are those, which are cast along with the piping component or equipment.

Process piping interview questions are pre-scripted with intents of probing the candidate from the standpoint of view of the design, installation, and maintenance of the piping system. These questions may cover a variety of topics, including:

• Fluid mechanics
• Thermodynamics
• Structural engineering
• Piping materials and components
• Piping codes and standards
• Piping design software
• Piping installation and maintenance procedures
• Troubleshooting and problem-solving

Here are some examples of process piping interview questions:

• Describe the different types of piping materials and their applications.
• What are the different types of piping codes and standards?
• How do you design a piping system to withstand the pressures and temperatures of the fluids that it will be transporting?
• How do you select the appropriate valves and fittings for a piping system?
• What are some common piping problems and how do you troubleshoot them?
• Describe your experience with piping design software.
• What is your experience with piping installation and maintenance procedures?