NTERVIEW QUESTIONS

ASME SECTION IX : WELDING

1. What is the minimum length of volumetric NDE required
for welder qualification?

Ans: 6 in (150mm) [QW 302.2]

2. Please tell about one etching reagent used for ferrous materials.

Ans: One part of nitric acid and 3 parts of water by volume is one of the etching
agent used for ferrous materials.

3. What is the P number of IS 2062 grade material.

Ans: P number is 1

4. What is a linear indication?

Ans: An indication in which the length of indication is more than 3 times the width.

5. What is a rounded indication?

Ans: An indication in which the length of the indication is 3 times the width or less.

1. What is WPS?

Answer: WPS stands for Welding Procedure Specification. A WPS is a written

document that provides direction to the welder or welding operator for making
production welds in accordance with code requirement.
(Refer: ASME Sec IX; QW:100.1)

2. What is PQR?

Answer: PQR stands for procedure qualification record. The PQR documents what
occurred during welding the test coupon and the results of testing of the coupon.
3. Why a WPS needs qualification?

Answer: The purpose for qualification of a WPS is to determine that the weldment
proposed for construction is capable of providing the required properties for its
intended application.

Welding Procedure Qualification establishes the properties of the weldment not

the skill of the welder or welding operator.

4. Why a performance qualification is done for welder?

Answer: In performance qualification, the basic criteria established for welder

qualification is to determine the welders ability to deposit sound weld metal. The
purpose of the performance qualification test for the welding operator is to
determine the welding operators mechanical ability to operate the welding
equipment.

5. Is there any expiry date for WPS/PQR/WPQ/WOPQ?

Answer: NO.

WPS, PQR, WPQ/WOPQ made in accordance with the requirements of the 1962
edition or any later edition of section IX may be used in any construction built to
the ASME Boiler and Pressure Vessel Code or the ASME B 31 Code for pressure
piping.

1. Is WPS, PQR or WPQ/WOPQ need to be amended for using it according to a

later edition of ASME BPV Section IX?

Answer: No. Except as specified in QW:420 (Last Paragraph)

2. What are the different type of mechanical tests used in procedure

or performance qualification as per ASME Section IX?

Answer: 1. Tension test. 2. Guided bend test. 3. Fillet weld test 4. Notch
toughness test
3. Why the different mechanical tests are conducted for procedure
or performance qualification as oer ASME Section IX?

Answer:
1. Tension test: Used to determine the ultimate strength of groove-weld joints

2. Guided bend test: Used to determine the degree of soundness and ductility of
groove-weld joints.

3. Fillet weld test: Used to determine the size , contour and degree of soundness of
fillet welds.

4. Notch toughness test: Used to determine the notch toughness of the weldment

4. What are the tests done for stud welding procedure and performance
qualification ?

Answer: Deflection bend, hammering, torque or tension tests and macro

examination.

5. What is the first test that to be done on a procedure or performance

qualification test coupon ?

Answer: Visual Testing.

1. Can NDT be used to replace mechanical testing for

the performance qualification of welders?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for

mechanical testing for groove-weld performance qualification as permitted in QW-
304 to prove the ability of welders to make sound welds.

As per QW-304. Welders may be qualified by volumetric NDE when making a

groove weld using SMAW, SAW, GTAW, PAW and GMAW (except
short circuiting mode for radiographic examination) or a combination of these
process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welders making groove welds in P.No.21 through P No.26 and P.No.51 through P
No.53 metals with the GTAW process may also be qualified by volumetric NDE

2. Can NDT be used to replace mechanical testing for

the performance qualification of welding operator?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for

mechanical testing for groove-weld performance qualification as permitted in QW-
305 to prove the ability of welding operators to make sound welds.

As per QW-305. Welding operators may be qualified by volumetric NDE when

making a groove weld using SMAW, SAW, GTAW, PAW, EGW and GMAW (except
short circuiting mode for radiographic examination) or a combination of these
process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welding operators making groove welds in P.No.21 through P No.26 and P.No.51
through P No.53 metals with the GTAW process may also be qualified by volumetric
NDE

3. Is a written radiographic examination procedure is needed for

welders/welding operator qualification using radiographic examination?

Answer: No

As per QW-191.1.1 (a), A written radiographic examination procedure is not

required. Demonstration of density and image quality requirements on production
or technique radiographs shall be considered satisfactory evidence of compliance
with article 2 of sectionV.

4. Is a written ultrasonic examination procedure is needed for welders/welding

operator qualification using ultrasonic examination?
Answer: Yes

As per QW-191.2.1 (b), Ultrasonic examination shall be performed using a written

procedure verified by the manufacturer to be in compliance with paragraph T-150,
Article 1, Section V and the requirements of Article 4, Section V for methods,
procedure and qualification.

5. Is there any base material thickness restriction for ultrasonic examination of

test coupons of welders and welding operators?

Answer: Yes

As per QW-191.2.1 (a), The ultrasonic examination for welder and welding
operators may be conducted on test welds in material 1/2 in. (13 mm) thick or
greater.

1. Can NDT be used to replace mechanical testing for

the performance qualification of welders?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for

mechanical testing for groove-weld performance qualification as permitted in QW-
304 to prove the ability of welders to make sound welds.

As per QW-304. Welders may be qualified by volumetric NDE when making a

groove weld using SMAW, SAW, GTAW, PAW and GMAW (except
short circuiting mode for radiographic examination) or a combination of these
process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welders making groove welds in P.No.21 through P No.26 and P.No.51 through P
No.53 metals with the GTAW process may also be qualified by volumetric NDE

2. Can NDT be used to replace mechanical testing for

the performance qualification of welding operator?
Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for

mechanical testing for groove-weld performance qualification as permitted in QW-
305 to prove the ability of welding operators to make sound welds.

As per QW-305. Welding operators may be qualified by volumetric NDE when

making a groove weld using SMAW, SAW, GTAW, PAW, EGW and GMAW (except
short circuiting mode for radiographic examination) or a combination of these
process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welding operators making groove welds in P.No.21 through P No.26 and P.No.51
through P No.53 metals with the GTAW process may also be qualified by volumetric
NDE

3. Is a written radiographic examination procedure is needed for

welders/welding operator qualification using radiographic examination?

Answer: No

As per QW-191.1.1 (a), A written radiographic examination procedure is not

required. Demonstration of density and image quality requirements on production
or technique radiographs shall be considered satisfactory evidence of compliance
with article 2 of sectionV.

4. Is a written ultrasonic examination procedure is needed for welders/welding

operator qualification using ultrasonic examination?

Answer: Yes

As per QW-191.2.1 (b), Ultrasonic examination shall be performed using a written

procedure verified by the manufacturer to be in compliance with paragraph T-150,
Article 1, Section V and the requirements of Article 4, Section V for methods,
procedure and qualification.
5. Is there any base material thickness restriction for ultrasonic examination of
test coupons of welders and welding operators?

Answer: Yes

As per QW-191.2.1 (a), The ultrasonic examination for welder and welding
operators may be conducted on test welds in material 1/2 in. (13 mm) thick or
greater.

1. Can NDT be used to replace mechanical testing for

the performance qualification of welders?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for

mechanical testing for groove-weld performance qualification as permitted in QW-
304 to prove the ability of welders to make sound welds.

As per QW-304. Welders may be qualified by volumetric NDE when making a

groove weld using SMAW, SAW, GTAW, PAW and GMAW (except
short circuiting mode for radiographic examination) or a combination of these
process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welders making groove welds in P.No.21 through P No.26 and P.No.51 through P
No.53 metals with the GTAW process may also be qualified by volumetric NDE

2. Can NDT be used to replace mechanical testing for

the performance qualification of welding operator?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for

mechanical testing for groove-weld performance qualification as permitted in QW-
305 to prove the ability of welding operators to make sound welds.

As per QW-305. Welding operators may be qualified by volumetric NDE when

making a groove weld using SMAW, SAW, GTAW, PAW, EGW and GMAW (except
short circuiting mode for radiographic examination) or a combination of these
process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welding operators making groove welds in P.No.21 through P No.26 and P.No.51
through P No.53 metals with the GTAW process may also be qualified by volumetric
NDE

3. Is a written radiographic examination procedure is needed for

welders/welding operator qualification using radiographic examination?

Answer: No

As per QW-191.1.1 (a), A written radiographic examination procedure is not

required. Demonstration of density and image quality requirements on production
or technique radiographs shall be considered satisfactory evidence of compliance
with article 2 of sectionV.

4. Is a written ultrasonic examination procedure is needed for welders/welding

operator qualification using ultrasonic examination?

Answer: Yes

As per QW-191.2.1 (b), Ultrasonic examination shall be performed using a written

procedure verified by the manufacturer to be in compliance with paragraph T-150,
Article 1, Section V and the requirements of Article 4, Section V for methods,
procedure and qualification.

5. Is there any base material thickness restriction for ultrasonic examination of

test coupons of welders and welding operators?

Answer: Yes

As per QW-191.2.1 (a), The ultrasonic examination for welder and welding
operators may be conducted on test welds in material 1/2 in. (13 mm) thick or
greater.
1. The purpose of the WPS and PQR is to determined that:

1. the welder is qualified

2. the base metals are strong enough

3. the weldment has the desired properties

4. the skill of the welder

2. The WPS lists:

1. nonessential variables

2. essential variables

3. supplementary essential variables if required

4. all of the above

3. The PQR must list:

1. essential variables and supplementary essential variables when notch toughness is required

2. nonessential variables

3. welder qualification variables

4. all of the above

4. What is the earliest Edition of Section IX recognized by the current edition?

1. 1958

2. 1992

3. 1987

4. 1962
5. New Welding Procedure Specifications must meet the ____________ Edition and addenda of
Section IX.

1. 1962

2. current (latest mandatory)

3. Inspector

4. All of the above

6. Each ______________ shall conduct the tests required by Section IX to quality the WPS’s used
during the construction, alteration, or repair.

1. Welder or welding operator

2. Manufacturer or contractor

3. Inspector

4. All of the above

7. The records of procedure, welder and welding operator qualification must be available to the
________________.

1. Manufacturer or Contractor

2. Welder

3. Authorized Inspector

4. Foreman

8. A welder qualifying with a groove weld in plate in the 4G position is qualified to weld groove
welds in plate and pipe over 24” O.D. in the ______________ positions.

1. Overhead

2. Flat and horizontal

3. Flat and overhead

4. Horizontal

9. A welder qualifying with the plate fillet welds in the 3F and 4F positions is qualified to weld
groove welds in plate in the ________________ positions.

1. Flat only

2. Flat and horizontal

3. Flat and vertical

4. None of the above

10. A welder qualifying by making a groove weld on pipe with an O.D. of 3/4" in the 5G position is
qualified to weld groove welds in:

1. 1/2" O.D. Pipe in the overhead position

2. 6” O.D. Pipe in the vertical position

3. 3/4" O.D. pipe in the horizontal position

4. None of the above

11. In general, qualification on groove welds also qualifies a welder to make:

1. Stud welds

2. Overhead welds

3. Fillet welds

4. All of the above

12. Charpy V-notch tests are performed to determine a weldment’s

1. Tensile strength

2. Ductility
3. Notch toughness

4. All of above

13. A welder making a groove weld using the SAW process on P1 materials may be qualified using
radiography.

1. True

2. False

14. When a tensile specimen breaks in the metal outside of the weld or fusion line, the

strength recorded may be _______________ below the specified tensile and be accepted.

1. 3.5%

2. .5%

3. 5%

4. All of the above

15. Guided-bend specimens shall have no open defects in the weld or heat effected zone exceeding
____________ measured in any direction on the convex surface of the specimen after bending.

1. 1/16”

2. 3/32”

3. 1/8”

4. None of the above

16. When using radiographs to qualify welders, the acceptance standards used are found in:

1. ASME Section V

2. ASME Section IX
3. ASME Section VIII

4. The referencing code

17. A WPS must describe:

1. Essential variables

2. Nonessential variables

3. Supplementary essential variables when required for notch toughness

4. All of the above

18. A PQR must describe:

1. Nonessential variables

2. Essential variables

3. Results of Welder Qualification tests

4. Project description & NDE methods

19. The ____________________ must certify the PQR as accurate.

1. Inspector

2. Manufacturer or contractor

3. Welder

4. All of the above

20. For the SMAW process ___________________ is an essential variable for the WPS.

1. Groove design

2. Post Weld heat treatment (PWHT)

3. Roof spacing

4. Method of cleaning

21. For the SAW process ________________ is an essential variable for the WPS.

1. Supplemental powdered filler metal (if used)

2. Filler metal diameter

3. Preheat maintenance

4. Addition or deletion of peening

22. The basic purpose of testing a welder is to establish the welder’s ______________.

1. Knowledge of welding requirements

2. Ability to deposit sound weld metal

3. mechanical ability to operate equipment

4. General attitude toward welding inspectors

23. The record of a welder’s performance tests is called a ________________.

1. PQR

2. WQR

3. WPS

4. WPQ

24. if a welder qualified with the manual SMAW process on Jan. 1, 1997 and last welded with
manual SMAW on March 15, 1997, would he still be qualified on October 7, 1997?

1. Yes
2. No

25. A welder qualifying with the SMAW process with a double welded groove weld is qualified to
weld.

1. Without backing

2. With all base metals

3. With backing only

4. With P1 backing only

26. Immediate retests of welders qualifications coupons __________________.

1. shall use the same method

2. May use any method

3. Are not allowed

4. Required Inspector approval

27. Welder performance qualification records must describe all the _____________ variables
specified.

1. Essential & nonessential

2. Nonessential

3. Essential

4. Brazing

28. A welder depositing 1/2” of weld metal in three layers in a groove weld with the SMAW process
is qualified to deposit up to __________________ of weld metal.

1. 8”
2. 1”

3. Max to be welded

4. 1/2"

29. “P” numbers are used to designate groups of

1. Electrodes

2. Flux

3. Base metals

4. Joints

30. A welder qualifying with P-No.21 is qualified to weld

1. P-1 – P-11 to P-1 – P-11

2. P-8 – P8

3. P-21 – P-25 to P-21 – P-25

4. P21 to P21 only

31. Section IX groups welding electrodes by

1. AWS class

2. ASME specification

3. SFA

4. “F” number

32. Ferrous weld metal chemical composition may be designated using

1. “P” number
2. Welder I.D.

3. “A” number

4. page number

33. For welder qualification with the SMAW process _________________ is an essential variable.

1. Base metal thickness

2. Peening

3. P-number

4. Electrode diameter

34. Each welder must be assigned a(n)

1. P number

2. Unique identifier

3. Hood & gloves

4. Inspector

35. A welder qualification coupon welded in the 2G position of 5/16” thick plate material must have
how many root and face bends?

1. 2 – 1 each

2. 4 – 2 each

3. 6 – 2 face and 4 root

4. 8 – 4 each

36. A WPS shall have:

1. the welder referenced.

2. the PQR referenced.

3. the NACE referenced.

4. the PDQ referenced.

37. Welding in the 1G position qualifies a welder in what position?

1. horizontal

2. vertical

3. flat

4. overhead

38. Which of the following is an essential variable for qualification of an SMAW welding procedure?

1. “F” number

2. joint design

3. diameter of the electrode

4. pipe diameter

39. A welder may be qualified by RT if:

1. The first 3’ of the first production weld is radiographed.

2. the first production weld passes mechanical tests.

3. If the first production weld passes mechanical tests.

4. If the first production weld is passes by MT examination.

40. A welder may be qualified using RT in these processes except for _______________.

1. GMAW (short-circuiting mode)

2. GMAW (pulsed-arc)

3. GMAW (spray-arch)

4. SMAW

WELDING INSPECTION INTERVIEW QUESTIONS

There is a growing importance of certification in the welding inspection

sector in the oil and gas industry.
This series contains questions that can be used to welding inspection
certification exams such as CSWIP 3.1, AWS-CWI and IWE-IIW.

1. Which of the following quenchants will produce maximum distortion

on cooling heated metals.
a. Water
b. Brine solution
c. Salt Water
d. Oil

2. For overlay weld, essential variables for welder selection is/are

a. Weld metal thickness
b. Base metal thickness
c. Both of the above
d. None of the above

3. What is cooling medium employed in normalizing heat treatment.

a. Oil
b. Brine
c. Air
d. Controlled cooling in furnace

4. What is the purpose of Run-in and Run-our plates.

a. To reduce the chance of weld defects in the joint
b. Keep the start and end point of the bead out of the weld joint
c. To increase the length of weld joint
d. All of the above.

5. Which of the following is not an all position SMAW electrode

a. E7028
b. E7018
c. E6010
d. E6013

6. magnetic device is used for ESSC welding to

a. Nullify natural magnetization effect
b. Nullify electro magnetization effect
c. Reduce dilution
d. Act like flux holding arrangement

7. Hardness is related to
a. Toughness
b. Resistance to fatigue
c. Impact resistance
d. Resistance to abrasive wear/Indentation

8. The location of tensile test specimen should be such that

a. Longitudinal axis should coincide with atleast 1/2 thickness
b. Should have one face on surface.
c. Longitudinal axis should coincide with atleast 1/4 thickness
d. None of the above.

9. For GMAW process, the burn of rate of the wire is directly related to
a. Stick out length
b. Travel speed
c. Arc voltage
d. Wire feed speed

10. Welder is qualified for weld overlay on 16mm thick plate using
SMAW process, he is qualified for base metal thickness
a. more than 25mm to unlimited
b. more than 16mm to unlimited
c. up to 16mm
d. None of the above.

1. Most commonly used mineral for extraction of iron is

a. Cementite
b. Hematite
c. Bouxite
d. Anthracite

2. To achieve high temperature creep resistance, the weld should usually

contain
a. High Mn & Si
b. High Ni & mn
c. High Cr & Mo
d. High Cr & nb

3. Prime purpose of SMAW-DWT and Twin-Head SAW is to

a. Increase welding speed
b. Increase produxtivity
c. Reduce distortion
d. Reduce heat input

4. Weld reinforcement is restricted for weld joint because

a. it consumes more weld metal
b. It acts as stress raiser
c. It acts as stress raiser and it consumes more weld metal
d. None of the above

5. Which of the following can be determined by impact test

a. Percentage shear area
b. Lateral expansion
c. Energy absorbed
d. All of the above
6. In twin-head SAW, the current of lagging wire for first pass shall be
a. not related to current of leading wire
b. lower than current of leading wire
c. higher than current of leading wire
d. should be the same.

7. Selection of the diameter of the electrode to be used depends upon

a. Volume of welding
b. Thickness of base metal
c. Length of welding
d. Position of welding

8. A welder qualification test is to verify

a. The manufacturing process
b. The quality of the material used
c. Non destructive test procedure verification
d. The skill of the welder

9. In AWS A5.1 classification of E6013 SMAW electrode, the type of coating

and current is denoted by the suffix/suffixes
a. 13
b. 1
c. 3
d. 01

10. pipe welding SMAW electrodes under AWS A 5.1:6010 class before
welding to be re-dried at
a. 150deg C for 2 hrs
b. Generally not to be re-dried
c. 110deg C for 30 mins
d. 130deg C for 60mins
 INTERVIEW QUESTIONS

Radiography Testing

1. What is "sensitivity"?

Ans: Sensitivity in a radiograph is a function of 'contrast' and 'definition'.

2. What is "Contrast"?

Ans: Contrast is the comparison between film densities for different areas.

3. What is "Definition"?

Ans: Definition is the demarcation between areas of different densities.

4. What is "Penubra"?

Ans: The fuzzy edges of the image are called Penubra. This is related to
geometrical unsharpness.

5. What is the relation between radiography film grain size and exposure time?

Ans: Large grain size needs less exposure time compared to small grain size films.

1. What is the half-life of Iridium-192 Isotope?

Ans: 73.83 days.

2. What is meant by half value layer?

Ans: The thickness of a material at which the intensity of radiation becomes one
half that of radiation falling at its surface is called half value layer.

3. What is the difference between primary and secondary radiation?

Ans: Radiation that is part of the original beam is called primary radiation. When
this radiation hits the atoms of a material radiation is produced that is called
secondary radiation or scattered radiation.

4. Iridium-192, natural or artificial isotope?

Ans: Artificial isotope.

5. What is the difference between atomic number and mass number?

Ans: Atomic number is the number of protons in an atom whereas mass number is
number of protons and neutrons in an atom.

1. What is IQI?

Ans: IQI stands for image quality indicator. Penetrameter is the another word used
for IQI.

2. What is the difference in placing DIN and ASTM penetrameter in a radiography

film?

Ans: ASTM standard penetrameter is placed on the left side of the radiography film
as the smallest thickness wire is on the left side of the penetrameter.
DIN type penetrameter is placed on the right side of the radiography film as the
thinnest wire is on the right most side of penetrameter.

3. How many wires are there in a ASTM and DIN penetrameter?

Ans: ASTM penetrameter is having 6 wire's where as DIN penetrameter is having 7

wire's.

4. What are the main classification of penetrameter?

Ans: Hole type and wire type are the two types of penetrameter.

5. Which is the material of construction of penetrameter?

Ans: Same material or a material similar to the specimen being radiographed.

 DYE PENETRANT TEST

Dye Penetrant Test (DPT) also known as Penetrant Testing (PT), Dye
Penertant Examination (DPE) and Liquid Penetrant Testing (LPT). This is
a simplest of the several Non Destructive Testing (NDT) methods
available.

• What is Dye Penetrant Test (DPT)?

Dye penetrant testing is based on the ability of a liquid to seep into

cavities that are open to the surface and remain in the cavity when
excess material is removed. The liquid remaining in the cavity is then
drawn out to form an indication that is much more visible than the cavity
itself.
In simpler terms a color dye is applied to a surface. The dye enters to
the discontinuity and remains there. The dye which is on the surface is
removed and a developer (a white powder) is applied on the surface.
The dye in the discontinuity is bleeded in to this white powder and from
this a discontinuity is identified.

HOW TO FITUP A SOCKET WELD JOINT? CLICK HERE

• Where we can apply dye penetrant test?

• Places where dye penetrant test is applied?
• Why liquid penetrant testing cannot be used for casting?

DPT is used to detect surface discontinuities in solid, nonporous

materials. It is used on wrought and metal alloys, weldments, powdered
metals, plastics, ceramics and glass. Porous materials cannot be tested
with DPT. Some plastics and rubber may be adversely affected by
penetrant petroleum base.

DPT can be applied on materials regardless of their orientation or the

shape of the part. Complex geometrical shapes can be inspected in a
single operation. It is portable and of low cost when compared to
other methods.

Casting generates a porous material. So LPT/DPT cannot be done in

casting products.

CAN WE DIFFERENTIATE CS AND LTCS? CLICK HERE

Q
• Can we use DPT on paper?
• Can we use DPT on cloth?
• Can we use DPT on cast Materials?
• Is there any material thickness limitation for DPT?

DPT cannot be used on materials that absorbs the dye. Due to that
reason DPT cannot be applied on paper and cloth.

It can be applied on cast materials, but not in as cast form as

interpretation will be difficult. The removal of excess dye from a as cast
form is practically difficult. This will create false indications of the surface
which will be difficult to interpret.

As we discussed, DPT can detect discontinuities that are open to

surface. So there is no materials thickness limitation for DPT.

WHAT IS HYDROTEST? CLICK HERE

• Surface preparation requirements before application of DPT?

• Cleaning methods prior to DPT application?
• Grinding of root before DPT is permitted or not?

The condition of the surface plays a critical role in the success or failure
of the DPT. The most common surface condition that affects DPT is the
presence of contaminants such as oils, grease, dirt, rust, scale, carbon
deposits or others. These materials prevent the dye from entering to the
discontinuity. Suitable cleaning methods to be adopted to remove
these surface contaminants.

DPT should not be done after the operations that deform the surface.
Operations that deform the surface, such as grinding, cutting, shot
peening, sand blasting and vapor honing can cover discontinuities
by smearing a thin layer of metal over the opening, reducing its size or
sealing it completely. Because DPT cannot detect any discontinuity that
are not open to the surface.

HOW MANY WPS ARE NEEDED ON A

PROJECT? CLICK HERE

• Can a dye penetrant test be used in overhead welding?

The principle of DPT is, capillary action which is not affected by

gravitational force. So DPT can be applied at any angles including
overhead.

HOW MANY WPS ARE NEEDED ON A

PROJECT? CLICK HERE

• Why is the visible penetrant in dye penetrant testing red? Is

there a specific reason behind choosing this color?
For Day light in VIBGYOR (R stand for RED) has highest wavelength in
the spectrum of colors. Due to highest wave length it will travel to
long distance and easily seen from far distance. Same for PT, we can
see small flaws in material from long distance without much stress on
our eye.

Image From Quora

HOW MANY WPS ARE NEEDED ON A

PROJECT? CLICK HERE

• What are the flaws that can be detected by DPT?

DPT can detect flaws that are open to surface. So those flaws which
are open will be detected by the application of DPT. Some of the flaws
that are detected by DPT are,

• center bead crack in weld

• Fatigue crack in materials
• Hot tear in casting
 • Quench crack in heat treatment
• Surface porosities in weld

How to decide the WPS requirements for a project?

on February 16, 2020

Welding Procedure Specification(WPS)

requirements for a project
rel="canonical"

How to decide the WPS requirements for a project?

How many WPS are to be made for a project?

Finalizing the number of welding procedure specification (WPS)

is one of the difficult tasks for any QA/QC or welding engineer.
The non-availability of a WPS will pop up at any time during a
project phase and that is one of the nightmares of any welding
engineer.

How to solve it? It is impossible to solve it by 100% but can be

reduced by following small steps and some logic. Experience can
add a further helping hand in this.

From Documents:

1. Go through the project documentation for understanding

the welding requirements of the project. Note down those
requirements.
2. Search for the special requirements, if any, laid down by
the piping designer.
3. List the materials that are in the project. This can be
obtained from project documents/contract documents.
Note down all the materials that are mentioned in those
documents in a paper or MS Excel.
4. From project documents /contract documents/ piping
line list/ piping schedule, note down the minimum and
maximum thickness to be welded of a material. Write that
thickness against each material in the MS Excel we have
made for materials.
5. Decide which welding process is to be used for each
material. This will vary according to thickness also. Detail
the process against thickness and material in that MS Excel
sheet.
6. From the project specification/contract documents find
the requirements for preheating, post heat and
PWHT. Mention that against each material and thickness
range.

7. Write the welding consumables against each welding

process and material. Special requirements such as NACE
qualified, Ferrite controlled if any also to be listed out.
8. Now we have listed all the requirements for the
WPS/PQR.
9. Search for the availability of pre-qualified WPS, WPS
qualified by reputed clients or the third party if any. Discuss
with the client whether those qualified PQR are acceptable
which are qualified in the witness of the reputed client or
the third party.

10. If PQR is not available go for PQR qualification.

11. Search for material and thickness which minimize your
number of PQR qualification coupons.

From Experience:

1. SS to CS welding will be there in any of the refinery

related projects. So PQR for that should be made available.

2. Alloy steel to SS maybe there particularly at

instrumentation connections.

Following these guidelines will help you to generate the

WPS/PQR for a project.

How can we differentiate LTCS and CS?

How can we identify LTCS from CS?

Can LTCS be detected by PMI?

These are some common questions we face at work site, where Carbon Steel(CS) and
Low Temperature Carbon Steel (LTCS) are used.

The answer is NO, unless there is a clear marking/ traceability.

SA-106 Grade B : Specification For Seamless Carbon Steel Pipe For High-Temperature
Service.

SA-333 Grade 6 : Seamless and Welded Steel Pipe for Low-Temperature Service and
Other Applications with Required Notch Toughness

Please see the below table for the chemical composition of LTCS and CS for their pipe
form. There is no remarkable difference from which PMI methods can
differentiate both. So we cannot differentiate LTCS and CS materials with out
marking/identification.

Click the below link to see one of the methods of handling the
mix-up based on ASME B 31.3

https://www.whatispiping.com/cs-in-place-of-ltcs

The above link will guide you to a website which is not owned by this blogger. Use
the link and it's contents at your risk and cost.

HYDROTEST
PART 1
Those who are in piping construction will be familiar with the activity called
hydrotest. Hydrotest engineers/Supervisors, hydrotest coordinators are some of
the posts available for engineers/supervisors in hydrotest activity.

What is hydrotest?
Fill the pipe with water, pressure it and inspect for pressure change and release
water. Hydrotest is over. Hydrotest uses water as the test medium.

Is it that simple?

Those who are in hydro testing activity will say a big 'NO'. There are many pre-
activities, preparation activities, and post activities for a hydrotest. Moreover, it is
also governed by many code rules and good engineering practices.

Hydrostatic Pressure Test

This is the exact technical terminology for hydrotest activity. This is Pressure change
leak test when we refer ASME BPVC Sec V. The hydrotest is coming under the
category of pressure test. The other one under the heading of pressure test is
'pneumatic test' where the air is used as the test medium.

What are the pre-activities for a hydrotest?

The first activity for doing the hydrotest, is the identification of the pipe system, of
which the hydrotest to be done.
All the pipe systems will be parted to small piping lengths called piping loops. For
each piping loop, a document (file) is generated (Piping loop file is a topic that
needs more detailing and is not discussed here). Each piping loop is checked for
mechanical completion and then for NDE completion by respective engineers. After
clearance from those two activities, the document is handed over to hydrotest
department.

Hydrotest engineer/supervisor will check the document for 'clearance for

hydrotest' approval.
From the loop file (the normal site terminology for a piping loop document) the
pipe along with its hydrotest limits are identified.

In the identified piping loop, the high point location and low point location will be
noted. The basic logic is water will be filled from the low point and vented from the
high point.

Safety precautions and access for all flange joints and valves are to be made as part
of pre-activity to hydrotest.

SOCKET WELD JOINT

on February 10, 2020

SOCKET WELD JOINTS

Socket Welding or Socket Weld Joints are a inevitable part

of a piping project. The concept of socket weld joint
configuration is done as per code, eg:-ASME B31.3
Though the type of welding done is a socket weld joint is
fillet weld, type of weld is also normally mentioned as socket
weld (SW).

The fit-up requirement required for a socket weld joint is

mentioned in ASME B 31.3 as below.

The gap of 1.5mm is to accommodate the thermal expansion

that may occur during welding and with the flow of process
fluid. We can ensure the gap at the time of fitup only. So
inspection during fitup is the important inspection point in
the case of socket weld joint.

The fit-up requirement for socket weld flanges (as per

ASME B31.3) are as below.

The fillet weld size requirement as per ASME B31.3 is as

below.
Figure 328.5.2A shows the acceptable profile of fillet welds.

Please note that the size of fillet weld in a socket weld joint
can be achieved by multi-run welding. Though the normal
tendency of a welder is to complete the fillet size with one
run, it is not to be allowed because of the below two
reasons.

1. The weaving done in a single run fillet weld will be more

than 2.5times (depends on the weaving permitted in WPS)
of the filler/electrode diameter.

2. Due to improper closing point welding leak occurs. Multi-

layer welding will avoid such incidents. It is a good practice
to do multi run welding with starting point at different
points on the weld joint.

1. For a protective oxide layer to form, the ratio of the volume of oxide formed
to that of metal consumed should be

Answer: >1

2. The key properties required for good oxidation resistance of an oxide film are

Ans: Low electrical conductivity and continuous oxide film

3. What are the elements that are added to iron to improve its oxidation
resistance?

Ans: Chromium , Aluminum and Nickel

4. The peak in corrosion rate of martensite occurs when

Ans: Tempered at about 400deg C

5. What is the 18-8 stainless steel?

Ans: Stainless steel that contains 18% Cr and 8% Ni

1. What is Galvanic series?

Answer: To describe the tendency to corrode in a given environment common

metals and alloys are arranged on a qualitative scale called the galvanic series.
Eg: 18-8 stainless steel is passive in a a water and it is on the top on the top of the
table of the galvanic series in sea water environment.

2. What is a sacrificial anode?

Answer: Sacrificial anode is related to corrosion protection. Protection by galvanic

action is provided by connecting the structure to be protected to a sacrificial anode.
The sacrificial anode to be replaced periodically.

3. What is passivation?

Answer: Passivation refers to the formation of a thin, high resistance oxide layer
which reduces the corrosion current by two or three orders of magnitude.
4. What are the common methods that are adopted in piping to avoid corrosion?

Answer: Wrapping and Coating, Painting and Cathodic Protection.

5. For the grid blasting (For the surface preparation for painting)of stainless steel
material which grid material is most preferred?

Answer: Aluminum Oxide

POST WELD HEAT TREATMENT (PWHT)

INTERVIEW QUESTIONS
PART ONE

Post Weld Heat Treatment (PWHT) is one of the most used topics in mechanical
construction industry. PWHT is done as material requirement or as a process
requirement. PWHT is also known as stress relieving, though stress relieving is a
boarder term as compared to PWHT. Pre heat and post heat is also associated with
PWHT.

This series is to list out the questions that are commonly asked in interviews.

The materials that require PWHT from the material point of view and based on the
common usage in refinery are, SA 335 Gr.P11, SA 335 Gr.P22, SA 335 Gr.P5, SA 335
Gr.P9 and SA 335 Gr. P91 pipe form and their related flanges and fittings.

The materials that require PWHT from the process point of view (which is decided
by the process designer) and based on the common usage in refinery are, SA 106
Gr.B pipe form and it's related flanges and fittings.
The output of a PWHT process, is the graph which is generated during the execution
of PWHT.

The X axis of the graph is ?

Answer: Temperature

The Y axis of the graph is ?

Answer: Time

The graph is generated with the help of a recorder. There are 6 point recorders and
12 point recorders.

How many thermocouples can be mapped with a 6 point recorder.

Answer : 6 Thermocouples.

How many thernocouples can be mapped with a 12 poiny recorder

Answer : 12 Thermocouples.
What is the normal speed of the movement of the graph in a recorder?

Answer : 25mm/hour.

What is the principle of working of a recorder?

Answer : Potentiometer

What are the colours that are normally used in a 6 point recorder?
Answer: Red, Blue, Black, Brown, Green, Violet

What is the input of a recorder to plot the graph?

Answer: voltage from thermocouple

The thermocouple brings the temperature as voltage to the recorder.

Which thermocouple is used normally for the detection of temperature?

Answer : 'K' type

What is the MOC of 'K' type thermocouple?

Answer: Chromel-Alumel

How the thermocouples are identified?

Answer: 'K' type is Yellow and Red combination thermocouple.

In 'K' type thermocouple Red represents which polarity?

Answer: Negative Polarity

What is the diameter/thickness of the 'K' type thermocouple?

Answer: 0.81mm (#20AWG)

What is the maximum temperature that can be measured by 'K' type

thermocouple?
Answer: 1260 Deg.C

Can a recorder calibrated for 'E' type thermocouple be used for measuring the
temperature detected by 'K' type thermocouple?
Answer: No

How the thermocouples are connected to the surface where the temperature is to
be measured?
Answer: Capacitor Discharge Method

Is PQR required for the welding of thermocouples to the surface?

Answer : No as per ASME BPVC Sec IX

What is the principle of temperature measurement using the thermocouple?

Answer: Seebeck Effect

How the thermocouples are connected to the recorder?

Answer: Through thermocouple extension wire.