Welding Inspector Interview Question [PDF]

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WELDING INSPECTOR INTERVIEW QUESTION’S 1.Welding Position? As For ASME SEC IX (QW-461.9) Groove PLATE: 1G-Flat 2G-Flat, Horizontal 3G-Flat , Vertical 4G-Flat, Overhead 3G & 4G- Flat, Vertical & Overhead 2G,3G, & 4G- All Position. PIPE :

1G-Flat 2G-Flat, Horizontal 5G-All position 6G-All position pipe shall 45°

Fillet PLATE:

1F- Flat 2F- Flat & Horizontal 3F- Flat, Horizontal & Vertical 4F- Flat, Horizontal & Overhead 3F & 4F- All position

2. If the One Welder Qualified in the P1-Material what are material he is qualified? As per the ASME SEC IX QW-423.1: P1 Through P15F, P34, P41 Through P49 Welding Inspector Questions

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P21 Through P26 P51 Through P53 or P62 and P63. 3.What is the Joint Details? A

B C

A. Included Angle - 37° ± 2° B. Root Face - 1.6 ± 0.8 C. Root Cap - 2.4 ± 0.8 4. How Much Internal Misalignment Allowed? Shall Not Exceed 1.5mm 5. What is (CS) Carbon Steel Material? Pipe

- ASTM A106 Gr.B, API 5L Gr.B & ASTM A53 Gr.B

Elbow - ASTM A234 WPB Flange - ASTM A105 N Bolt

- ASTM A193 B7

Nut

- ASTM A194 2H

6. What is (LTCS) Low Temperature Carbon Steel Material? Pipe

- ASTM A333 Gr.6

Elbow

- ASTM A420 WPL6,3,8 & 9

Flange - ASTM A350 LF2

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Bolt

- ASTM A320 Gr.L7M

Nut

- ASTM A194 Gr.7M

7. What is (SS) Stainless Steel Material? Pipe

- ASTM A312 TP 316L, ASTM A312 TP 304L

Elbow

- ASTM A403-WP316L & ASTM A403-WP304L

Flange

- ASTM A 182-F316L & ASTM A 182-F304L

8. What is Heat Input Formula: (Heat Input) HT = Voltage X Amperage X 60 ( CM/MIN) Travel Speed 9. What is Carbon Steel Minimum Chirpy Impact Absurd Energy? As per SAES-W-011 (para-7.4.13.1) P1.Gr.1 Material - 34/27 J P1.Gr.2 Material - 40/32 J 10. What is Welder Weekly Repair Rate? Shall not exceed 2 % in the one week. Formula:

RR = (LR / LW) X 100

Where, RR(Repair Rate) LR(Welder’s Total length of Repair for the one week) LW(Welder’s Total Length of weld Radiographic for the one week) 11. What is Essential Variable? When A change welding condition, which will affect the mechanical properties of weld metal that is essential variable. Ex. Welding process, Base material, Filler material, pre-heat,(PWHT) post-weld heat treatment, Welding Position,

Welding Inspector Questions

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12. What is the Non-Essential Variable? When a change welding condition, which will Not affect the mechanical properties of weld metal that is Non-essential variable. Ex. Joint Design, Method of Backing, and cleaning.

13. What is the Supplementary essential Variable? When a change welding condition, which will affect the Notch Toughness properties of weld metal that is Supplementary essential variable. Ex. Welding Process, Uphill, Downhill, Preheat, PWHT & Heat input. 14. What is Following API 510

: Pressure Vessel Inspection Coed

ASME B31.1

: Power Piping

ASME B31.3

: Process Piping

ASME SEC II C

: Welding Roads, Electrodes, Filler Metal

ASME SEC V

: Non Destructive Examination

ASME SEC VIII

: Rules for Construction of the Pressure Vessels

ASME SEC IX

: Welding & Brazing Qualification.

15. What is the WPS? WPS(Welding Procedure Specification) it’s written welding document, it’s guild for the welder to make the good production weld and give in the range of the parameter readings. 16. What is the PQR? PQR(Procedure Qualification Record) it’s mother of the WPS, it’s use to make the WPS, give in the Actual parameter reading.

Welding Inspector Questions

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17. What is P-Number? Base metal are assigned the P-Numbers in ASME Sec IX, to reduce the number of welding procedure qualification required. For Ferrous base metals having specified impact test requirements, group number within P-number are assigned. The arrangement based on comparable base metal characteristic such as Composition, Weld ability, and Mechanical properties. A complete list of P-Number assignments provide in QW-422 of ASME Section IX. Steel and Steel Alloys- P-No. P-No.1 Through P-No.15F including P. No. P-5A, P-5B, P5C Aluminum and aluminum-base alloys- P-No. P-No.21 through P-No.25 Copper and copper base alloys- P-No. P-No. 31 through P-No. P-No.35 Nickel and Nickel base alloys P-No. P-No.41 Through P-No.47 Titanium and titanium base alloys P-No. P-No.51 through P-No.53 18. What is F-Number? Electrodes and Welding rods, are assigned the F-Number, To reduce the number of welding procedure and performance qualifications. The F-Number grouping based on essentially on their usability characteristic, Which fundamentally determine the ability of welders to make the satisfactory weld with a given process and filler metal. A complete list of F-numbers for electrodes and welding rods is given in ASME Section IX, Table QW-432.

19. What is A-Number? To reduce the number of welding procedure qualification, steel and steel alloy filler metal are also grouped according to their A-number’s, A-Number based on the chemical composition of the deposited weld metal. 20. What is difference between the 316 & 316L material? Only Carbon contented is different, 316L is low carbon contented. 316 carbon level Maximum - 0.08 % 316L carbon level maximum Welding Inspector Questions

- 0.03 % Page 5

21. What is difference between E7018 & E7018-1? E7018-1, 1- is requirement of chirpy V-Notch impact toughness at low temperature. E7018-1 has better toughness at very Sub-Zero temperature. The E7018 impact value of 47 J at -30°C The E7018-1 impact value of 47 J at -50°C 22. What is difference between GTAW & GMAW? GTAW use the gas of full an full 100% argon gas. GMAW use the gas 50% argon and 50% helium gas. And GMAW use the extremely useful. Because it can weld all types of ferrous and non ferrous material of all thickness. 23. What is Electrode using CS, SS, Alloy steel in process of GTAW and SMAW? CS: GTAW-ER70S-2 SMAW-E7018 & E7018-1 SS: GTAW-ER316L, ER309L SMAW-E316L-16, E309L-16 Alloy: GTAW-ER80S-B6 SMAW-E8015-B6 24.What is difference between 304 and 316 Material? Molybdenum Presence 304- Nil % 316-2 to 3% 25. Why need to start the high frequency in GTAW Process in SS- Material? 1. To avoid defects in the root 2. To get Better deposit chemistry. 26. The low hydrogen electrode why use the repacking only one time? Mn content in electrode will be evaluated and toughness will be decreased. Welding Inspector Questions

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27. What is following of ASME B31.3? 1. 2. 3. 4. 5. 6. 7. 8.

Pressure Design for the piping components Fluid service requirement for piping components Fluid service requirement for piping joints Piping flexibility Piping support Material Fabrication, Assembly, Erection. Inspection examination and Testing

28.What is Procedure Essentials variables? 1) 2) 3) 4) 5) 6)

P-numbers F-numbers Welding Process Qualified Thickness Pre-heat Post heat

29.What is Welder Essential variables? 1) 2) 3) 4) 5)

Welding Process Welding Position Filler metal Welding Technique Polarity

30. If welder qualified in 5G & 6G position how many band test required? 1G and 2G position for 2 Bend test 5G and 6G position Blow the 19mm- Tension test-2, Face band-2, Side bend-2 Above the 19mm-tension test-2, side bend-4 31.If welder Qualified in the Fillet Weld what is NDT test is Required? Macro Test and Fracture Test. 32.What is welding inspector responsibility? To monitor the all welding activities than recorder and compare the acceptance criteria. And request the NDE Test, and Monitor the welder performance in filled. 33. Which defect can you find on surface area? Welding Inspector Questions

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a) b) c) d) e) f)

Arc stick Surface cracks Undercut Surface Porosity Spatter Mechanical damage

34. What is SMAW Essential Variable? 1) 2) 3) 4) 5) 6) 7)

Polarity Arc length Travel speed Angle of electrode Selection of electrode Base Material Position

35.When need the welding machine validation? When the impact test is required at the time due the validation. 36. What is PT test required the surface temperature? Minimum - 10°C Maximum- 52°C 37.What is planar defect? Major(Serious) weld defect such as Cracks and Lock of Fusion. 38.What is NDT method use to find out the Lock of side wall fusion? Only for UT(Ultrasonic Testing) 39.What is the propose of pre-heat?  To reduces the Hydrogen contented to delayed cracking  To reduces the Marten site Formation.  To reduces the shower cooling to avoid cracking. 40. What is use of PIE gauge?  To check the sensitivity of magnetic filed in the MPI-Yoke  To calibration of the MP-Yoke

Welding Inspector Questions

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41. How to calibration the MP-Yoke? AC-YOKE:  

Yoke have to lift the 4.5kg lifting block And check the magnetic filed by use of pie-gauge or indication.



Yoke have to lift the 18.1kg lifting block.

DC-YOKE:

42. One Welder Qualified for 10mm thickness, so what is the minimum and maximum thickness qualified? As for the ASEM SEC IX- Minimum-0 Maximum- thickness X 2T 43. When Fit-up is ready what are you going to check? 1. 2. 3. 4. 5. 6. 7.

Qualified WPS Qualified Welder Welding Machine calibration Bevel are cleaned Root cap Root Face Internal misalignment(HI-LO)

44. If misalignment is more than as per specified, what will you do? Re fit-up and pipe internal tapering by the grinding, The Tapering shall exceed 30°(Degree) 45. How will you check the Voltage & Amperes? By use of the Clamp meter. 46.If the welder is qualified in 0.5” Dia, so how much the maximum dia and minimum dia? Minimum- Size of the weld Maximum-Unlimited As per the ASME SEC IX-QW-452.3 Size of Dia Welding Inspector Questions

Minimum

Maximum Page 9

Less than 1”

Size of the Weld

Un-limited

Above 1” to 2 7/8”

1”

Un-limited

Above 2 7/8”

2 7/8”

Un-limited

47. How many technique in the RT(Radiographic Testing) 1. SWSI-Single Wall Single Image i. Panoramic Shot 2. DWSI-Double Wall Single Image 3. DWDI-Double Wall Double Image 48. What is panoramic shot? Source located in the Inside of pipe, the films fix in the weld join of the topside, So you start the only one time full joint image shall be covering. that is panoramic shot. 49. What is DCEN and DCEP? DCEN: The arranged of direct currant in the ace welding machine, the electrode is the Negative pole, the work piece is the positive pole of welding arc, commonly Known as this is Straight polarity. DCEP: The arranged of direct currant in the ace welding machine, the electrode is the positive pole, the work piece is the Negative pole of welding arc, commonly Known as this is Reverse polarity. 50. What is the thickness required for the PWHT? As per ASME B31.3, Over the 20mm shall be PWHT.

51.What is the soaking time for PWHT in thickness Based? PHWT Soak time minimum- 1 Hour in 25mm 52. What is the inter pass temperature for P8-Material? P8, P3X and P4X material-177°C Minimum P1, P3,P4, & P5-material-316°C Minimum 53.Piping Fitting Specification?

Welding Inspector Questions

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ASTM A234 WPB, ASTM A420 WPL6, ASTM A403 WP316L. 54.Flange Specification for any two? ASTM A105, ASTM A350LF2, ASTM A182 F316L. 55. What are the Document’s in the Hydro test package? 1. 2. 3. 4. 5. 6. 7.

Flow Diagram All valve calibration certificates Manifold calibration certificate All joint welding final inspection report All joint RT-Report Bolt Tatting Inspection report Water analyzer report

56. What is SEC II C? Welding rode and Electrodes specification 57.Type of IQI? Hole Type and wire type. 58.What is Pre-heat temperature of the CS, SS & Alloy Steel? Minimum – Should be 10°C it’s common CS over the 25mm - 79°C SS Maximum - 10°C Alloy Steel Gr.P11-150°C Gr.P22-149°C

59.What is Inter Pass Temperature of the CS, SS & Alloy Steel? CS-Minimum-315°C SS-Minimum-177°C Alloy- Minimum-300°C 60. What is Post Weld Heat treatment Temperature of the CS & Alloy Steel? Welding Inspector Questions

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CS- Above 20mm- 593°C to 649°C Alloy- Above 13mm-704°C to 746°C 61. What is Schedule “Q” ? Quality Requirement’s 62. What is F-Number for GTAW & SMAW in the Material CS, SS & Alloy? GTAM

SMAW

CS F6

F4

SS

F6

F5

Alloy F6

F4

63. What type of the Gasket? Metallic Gasket  Spiral Wound Gasket  Octagonal Ring Gasket  Flat Ring Gasket Non-Metallic Gasket    

Rubber Gasket Asbestos gasket Teflon Gasket Oil paper Gasket

64. Type of Bore Fitting?     

Weld let Sock let Thread let Elbow let Nippo let

65. Type of flanges?    

Weld Neck Flange Slip on Flange Socket Flange Screwed Flange

Welding Inspector Questions

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 Blind Flange 66. Type of Reducer?  Concentric  Exocentric 67. What are following in ARAMCO Standard? SAES-L-105 SAES-L-108 SAES-L-109 SAES-L-110 SAES-L-130 SAES-L-132 SAES-L-150 SAES-L-310 SAES-L-350 SAES-W-010 SAES-W-011 SAES-W-012 SAES-W-013 SAES-W-016 Materials  SAES-W-017              

: : : : : : : : : : : : : :

Piping Material Specification Selection Of Valves Selection of Flanges, Stud bolts, and Gasket Limitation on pipe joints and Components Material for low temperature Service Material Selection of Piping System’s Pressure testing of Plant piping and pipe line Design of Plant Piping Construction of Plant Piping Welding Requirement for pressure vessels Welding Requirement for On-Plot piping Welding Requirement for Pipe line Welding Requirement for Offshore Structures Welding Requirement for Special Corrosion Resistant

: Welding Requirement for API Tank’s

68. Why should use the purging gas when your welding Stainless Steel (SS)? To avoiding Discoloration 69. When will required the Impact test? When you going to do the PQR(Procedure Qualification Record) At the time test coupon should be tested the Impact test. 70.Full Definition of the E7018? E - Electrode 70 - Tension test(7000 Psi) 1 - Position 8 - Chemical composition on the electrode 71. What is Differences QA and QC? Welding Inspector Questions

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Quality Assurance

Quality Control

Definition:

QA is a set of activities for ensuring quality in the processes by which products are developed.

QC is a set of activities for ensuring quality in products. The activities focus on identifying defects in the actual products produced.

Focus on:

QA aims to prevent defects with a focus on the process used to make the product. It is a proactive quality process.

QC aims to identify (and correct)defects in the finished product. Quality control, therefore, is a reactive process.

Welding Inspector Questions

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