Industrial Process Terms and Definitions

Questions and Answers

What is the condition termed as 'Layup'?

A system not in operation for an extended time (correct)

A technique for removing contaminants

A process of adding components to a system

A method of testing system integrity

What does 'Pickling' refer to in tubing and piping systems?

Chemical or electrochemical removal of surface oxides

What is Ferritic steel?

Steel with less than 0.10 percent carbon dissolved in iron

What is Mill Scale?

Flaky material that forms on hot rolled steel Signup and view all the answers

What does Turbinizing involve?

Mechanical removal of scale from pipes Signup and view all the answers

What is the most effective method for removing tight scale?

Sand shot or grit Signup and view all the answers

When is pickling an effective cleaning method?

For cleaning large quantities of straight tubes or small size subassemblies Signup and view all the answers

What solution is most commonly used for pickling?

Hydrochloric acid or sulfuric acid Signup and view all the answers

What is passivating?

Forms a protective layer on surfaces Signup and view all the answers

What is Austenitic Stainless Steel?

The most common type of stainless steel Signup and view all the answers

What is a dead leg in piping systems?

An area without flow during cleaning operations Signup and view all the answers

What is turbidimetry used for?

Testing flushing fluids for cleanliness Signup and view all the answers

What does water flushing involve?

Filling and flushing a system with water Signup and view all the answers

What is air cleaning?

A method for cleaning and drying piping systems Signup and view all the answers

What is the primary use of nitrogen in cleaning and purging?

To provide an air-and moisture-free environment Signup and view all the answers

What is steam cleaning used for?

Removing oils, grease, and preservatives Signup and view all the answers

What special procedures are required for oxygen service lines?

Special cleaning and purging due to reactivity of oxygen Signup and view all the answers

What do ASME, ANSI, and ASTM stand for?

Organizations for standards in piping and tubing testing Signup and view all the answers

Why is leak testing needed?

Before service, after repairs, or after unique events Signup and view all the answers

The test pressure is applied before the system and test medium are at the same temperature.

False Signup and view all the answers

What are important parameters for conducting a leak test?

Temperature, pressure, and leakage limits Signup and view all the answers

Leak-tested components may be tested at a pressure exceeding 25% of the design pressure unless specified otherwise.

False Signup and view all the answers

What is an initial service test?

Gradual increase of pressure for a minimum of 10 minutes Signup and view all the answers

What must be dry and filtered in pneumatic leak tests?

Air Signup and view all the answers

What is Snoop?

A popular brand of liquid bubble leak solution Signup and view all the answers

How should the bubbler be installed for a leak test?

Between the compressed air source and the system to be leak checked Signup and view all the answers

What is hydrostatic leak testing?

A method using liquid pressure to test for leaks Signup and view all the answers

Study Notes

Definitions and Terms

Layup: A condition of inactivity in a system requiring protection from corrosion and contaminants.
Pickling: Removal of surface oxides through chemical or electrochemical processes, especially after welding to eliminate mill scale and discoloration.
Ferritic Steel: Contains less than 0.10% carbon, cannot be hardened by heat treatment.
Mill Scale: Flaky material formed on hot rolled steel, composed of various iron oxides.
Turbinizing: Mechanical scale removal from inside pipes using air-driven rotating cleaners.
Sand Shot or Grit: Highly effective technique for removing stubborn scale.

Cleaning Techniques and Methods

Pickling Effectiveness: Ideal for cleaning large straight tubes prior to fabrication or small subassemblies where blasting is impractical. Used when other cleaning methods are ineffective.
Pickling Liquors: Hydrochloric acid or sulfuric acid solutions commonly utilized for pickling operations.
Passivating: Creating a protective surface layer to inhibit corrosion.
Austenitic Stainless Steel: Common stainless steel type, typically does not require aggressive cleaning, except for grease removal.
Dead Leg: An area in the system that does not facilitate flow during cleaning or cannot be drained without special provisions.

Testing and Flushing Methods

Turbidimetry: Method for testing flushing fluids for cleanliness by analyzing suspended particles using light beams.
Water Flushing: Involves filling and flushing the system with specified quality water.
Air Cleaning: Effective cleaning and drying method leaving no residues, suitable for loose particles and minor corrosion.
Nitrogen Cleaning and Purging: Utilizes nitrogen for air and moisture-free purging; its inert nature prevents oxide formation.
Steam Cleaning: Efficient method for removing oils, grease, and preservatives from systems.

Special Considerations

Oxygen Service Lines: Require special cleaning due to oxygen's reactivity with oils; uses caustic or degreasing agents for cleaning.
Industry Standards: ASME, ANSI, and ASTM provide accepted standards for leak testing in piping systems.
Leak Testing Necessities: Conducted before the system is operational, after significant repairs, or following events like fires.

Test Procedures and Parameters

Test Temperature and Pressure: The test medium and system must share similar temperatures before applying pressure.
Leak Testing Parameters: Important factors include temperature, pressure, and leakage limits.
Pressure Limits for Leak Testing: Normally not exceed 25% of design pressure unless authorized otherwise.
Initial Service Test: Involves gradually bringing piping systems to normal operating pressure, maintained for a minimum of 10 minutes.
Pneumatic Leak Testing: Requires dry, filtered air; employs bubble leak testers; common gases used include nitrogen and argon.
Snoop Solution: A popular brand of liquid bubble leak solution used during leak tests.

Installation for Leak Tests

Bubbler Installation: Should be placed between the compressed air source and the system to check for leaks; indicates presence and rate but not the leak's location.

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Description

Test your knowledge on various industrial process terms such as 'Layup', 'Pickling', and 'Mill Scale'. This quiz encompasses key definitions and concepts in tubing and piping systems, as well as materials like Ferritic steel. Explore the terminology and techniques used in industrial operations.