CSWIP-3.1 HINTS SECTION-1(1HR_1S5MINT OUT OF SIX QUESTIONS YOU HAVE TO ANSWERE FOUR (4/6), 1, DUTIES OF WELDING INSPECTOR (YOU HAVE TO REFER AWS BOOK). 2. ANY ONE TYPE DEFECT A) HYROGEN CRACK-CAUSES & REMIDIES B) LAMMELLER TEAR( - CAUSES & REMIDIES ~ C) SOLIDIFICATION CRACK ~ 3. ANY ONE TYPE WELDING PROCESS | A) SMAW i B) GTAW ty C) SAW \/ D) GMAW YOU HAVE TO REFER AWS BOOK 4. ADVANTAGE AND DIS-ADVANTAGE OF UT & RT 5. EXPLATION MACRO & MICRO REFER AWS BOOK SECTION-II (30MINT MULTI CHOICE THIRTY QUESTION ABOUT WELDING/RT/PT/GENERAL & SPECICATIONa ,_ SECTION 111 MACRO EXAM WITH TWO SAMPLES (DEFECT TO BE MENTION ON THE, ANSWERE SHEET WITH REFERENCE CODE. (1.30HOURS) (CLASS ROOM TRAING ENOUGH) SECTION IV PRACTICAL VISUAL WITH ONE PLATE & ONE PIPE (DEFECT TO BE MENTION WITH SKETCH AND REF CODDE) (CLASS ROOM TRAING ENOUGH) SECTION V HINTS: 1. WELDING REPAIR PROCEDURE (REFER AWS BOOK) 2. YOU R WELDING INSPECTOR WHAT YOU WILL CHECK, DURING WELDING IN FAB SHOP ANS: WELDER ID CARD, VALIDITY, WELDING PARAMETER,OVEN TEMP. 3. HOW MUCH DISTANCE REQUORED TO WELD FROM GROUND TO PIPE (FOR OVER HEAD WELDING) oss UNCHECORRECTED) ETC--- NOTE: 1. SECTION I & SECTIONI: YOU HAVE TO PREPARE BEFORE ATTANDING COURSE AND EXAM. 2. SECTION TI & SECTION IV : AT THE TIME COURSE THEY WILL GIVE TRAINING THAT IS ENOUGH FOR EXAM.Welcome to Rediffimail: http://f2mail rediff. com/bn/folder.cgi?formname=read_msgéfolder=Inbox&file_name: Page 2 of 4 {All fees by bank draft in Pounds Stering, payable on a bank in England in favour of "The W institute’, along with Course Enrolment form/Event form and other relevant enclosures, to b Jenny Edwards, TWI Training and Examinations, UK. To secure a place enrolments are to jeast two weeks before commencement of each programe, Enrolment is stricty on first-cc served basis. Copy of application and foes draft may please be couriered to the undersigned. Kindly eno seats are limited. MR. J.C. SHAAN, JWI CONSULTANT IN INDIA, Clo, WATSCO., Tel: 00 91 33.22 1725 3-8, Chowringhee Lane, Fax: 0091 332 2nd Floor, Caleutta-700 016. E-mail watsco@cal2.vsnl.net.in INDIA. Original Message — From: manickam tt gq Date: Thursday, January 6, 2005 7:10 pm Subject: Re: Re: RE: CV APPROVAL FOR CSWIPS.2- M Ulaganatha > Please send 2008 sch for 3.2 > Regards, > muuleganathan > On Sat, 16 Oct 2004 jc shahani wrote > >Dear Sir, > >Thank you for your mail, > >For 2004 the CSWIP 3.2 Senior Welding Inspection course & exam > was held in Calcutta in the week of 13th September 2004. For 2005, > the dates and venue will be confirmed by the end ofthis year, We > will Keep you informed. > >With best wishes, > 2Yours sincerely, >5\.0. SHAHANI, FIE FllnstWele > STW CONSULTANT IN INDIA >5Cio Welding and Technical Services Co. >>3.B, Cnowringhee Lane, 2nd Floor > >Calcutta - 700016, INDIA > >Tel: 033 2252-1725/2200 , 2282 8425 > >Fax: 03 2248 6871 > >E-mail; watsco@cal2.vsnl.net.in > STWI Website: wore. twi.co.uk >> — Original Message — >> From: manickam tt gg >> To: watsco@cal2.vsni,net.in >> Sent Friday, October 15, 2004 7:13 PM >>. Subject: Re: RE: CV APPROVAL FOR CSWIP32- M Ulaganatha 10... 7/9/2005 3_ Welepme to Rediffimail: Rediffmail 1 GB Welcome mulaganathan, Inbox ‘Write Mail ‘Address Book Folders + Junk Mail | empty My Settings Upgrade Reditfmait Rediffmall on Mobile Send SMS. at 16,000 Recruiters Post ur Resumen Naukrueom - FREE Got MARRIAGE Proposais in ‘your inbox Fy Spice Del «Mum @ s.1089 Page 1 of 4 Help | Feedback Logout Upgrade Reditfmall Check storage space Inbox : Read Mail [Back to Inbox | 5) Printable Formet | Shove full Headers Boh] Reon] eonwart | Dots | Move to Folder. From: welding technical servicesco | Add to Address Book | 7 To: manickam tt gg Subject: Re: Re: RE: CV APPROVAL FOR CSWiP3.2 - M Ulaganatha Date: Mon, 17 Jan 2005 09:41:32 IST te: To ele pcctsc your pvc, images rom hie message heve been blocked iw ins | hts hi? 2005 COURSE SCHEDULE’. CSWIP, NDT & BGAS-PAINTING IN INDIA. “The following are scheduled to be hel in the year 2005 ((ees given below) 44 to 18 March (Mumbai): Course Ref. WISSE/IN 29. CSWMP 3.1 Welding Inspector Course & Exam Package GBP 740. Bridging Exam only GBP 160; 1-day Tutorial GBP 110; 3.1 Re-test GBP 146. 44 t0 18 March (Mumba): Grade 3/2, Course Ref ATCSEIIN 14. BGAS-CSWIP Painting Inspector Course & Exam Package GBP 780 Up-grade Exam only GBP 965; Re-test only GBP 230. 48 to 22 July (Mumba): Grade 4/2, Course Ref. ATCOSEMN 15 BGAS-CSWIP Gr 3/2 Painting Inspector Course & Exam Package GBP 760 Up-grade Exem only GBP 365; Re-test only GBP 230, 25 to 29 July (Mumbai): Grade 1, Course Ref. ATC89ENN 2. BGAS-CSWIP Gr Painting Inspector Course & Exam Package GBP 780. 22.10 26 August (Chennai): Course Ref. WISSENN 30, ‘CSIMIP 3.1 Welding Inspector Course & Exam Package GBP 740, Bridging Exam only GBP 180; 1-day Tutorial GBP 110; 9.1 Re-test GBP 146. 22 t0 26 August (Chennai): Course Ref. NDTSO(M&P)ENN 1 CSIMP Practical Magnetic Particle & Penetrant Inspection Course & Exem Package fee: 10 to 14 October (Chennai): Grade 312, Course Ref. ATCOSEIIN 16. BGAS-CSWIP Painting Inspector Course & Exam Package GBP 780 Up-grade Exam only GBP 365; Re-test only GBP 230. 31 Oct to 4 November (Calcutta): Course Ret. WISSE/IN 31 CSIP 3.1 Welding Inspector Course & Exam Package GBP 740. Bridging Exam only GBP 180; 1-day Tutorial GBP 110; 3.1 Retest GBP 146. 1 Oct to 4 November (Calcutta): Course Ref. NDT 2BEIIN 4 CSWP Level 2 ‘interpretation of Radiographs (Weldsy’ Course & Exam Package GBP 670. 5 to9 December (Calcutta): Course Ref. WISTOEIIN 6, CSWIP 3.2 Senior Welding Inspector Course & Exam Package GBP 816. 3.2 Re-tect GBP 154; 3.1 Re-test GBP 146, hitp://{2mail. rediff. com/bn/folder.cgi?formname=read_msgé&folder=Inboxéefile_name=110... 7/9/2005WIS 5 Section Duties of a Welding Inspector INTRODUCTION At the start of a fabrication contract, the Welding Inspector should make sure he is familiar with th all documents that he will need to refer to, such as: * Application Standard (or Code) * fabrication drawings + procedure for the control of the work to be carried out * Quality PlatvInspection Checklist He should also ensure that: BEFORE WELDING Check Application Standard ‘Drawings Materials Weld Preparations WPS's Welder Qualifications Welding Consumables Welding Process Check Item Fi Weld faces Prebeat (if any) the acceptance criteria for visual examination all necessary inspection equipment isin good order and calibrated - where applicable Before Assembly Action/Document/Reference to check for compliance specific requirements for inspection actions acceptance criteria for visual examination details of joint alignment & tolerances correct materials are being used ‘materials are clearly identified are in suitable condition for use (free from damage & contamination) are in accordance with drawing / WPS are approved are applicable to the joints being inspected are available to welders certificates are valid \(in-date) are applicable to the assigned weld(s) are in accordance with those specified by WPS. are being stored and handled in accordance with the procedure is in accordance with WPS welding equipment is calibrated (or validated) After Assembly Aetion/Document/Reference to check for compliance dimensions are within tolerance required by WPS / Drawing ire to good workmanship standard tack welds & alignment devices free from imperfections and cleaned to good workmanship standard is in accordance with WPS Supplementary Notes: CJM-Rev.2) inWIS 5_- Section 2: Duties of a Welding Inspector DURING WELDING Check Item Sitelfield welding Welding Process Preheat temp. (& Inter-pass temp.) Welding consumables Welding Parameters Root run Gouging /grinding Distortion Inter-run cleaning Welder identification AFTER WELDING Check Item ‘Weld identification Visually inspect Dimensionally survey Drawings NDE Repairs (if any) PWHT (if any) Pressure/Load Test any) Documentation Action/Document/Reference to check for compliance ‘weather conditions comply with Code (will not affect welding) are in accordance with WPS is in accordance with WPS are in accordance with WPS (& are in good condition at point of use) current, volts, travel speed are in accordance with WPS is visually acceptable to standard before filling-out is by an approved method & to good workmanship standard welding is balanced & ‘over-welding' is avoided is to a good workmanship standard Welder is on the register of approved welders for the WPS being used Aetion/Document/Reference to check for compliance Weld marked with welder identification (& for traceability if required) ensure weld has been cleaned and is suitable for all NDE visually inspect and sentence in accordance with Code ensure final dimensions are in accordance with Drawing/Code ensure any modification details are available for ‘as-built’ drawings ensure all NDE operations have been completed and reports available monitor any repairs in accordance with repair procedure visually inspect & ensure final NDE completed monitor in accordance with procedure check chart records for compliance equipment is calibrated monitored to ensure compliance with procedure/Code reports/records completed ensure all records and reports are completed & available collate documents as per Quality Plan / Code / Client requirements 4 Supplementary Notes: CIM-Rev.2)Lamellar tearing: In is a step like crack occurring in the parent plate or HAZ of stecls with poor through thickness dust where the fusion boundary of the weld is parallet with plate surface. It is usually associated with restrained joints on comer. tce or fillet welds joining thick plate. Causes Poor through thickness ductility b, Non-metallic inclusion in the dircetion of rolling, 2 cc. Restrained join . Through thickness stresses ©. High sulphur content £. Presence of hydroyen, Control: a. Modify joint design b. Control restraint ©. Use forged products for critical work 4. Grind the parent metal and fill with ductile weld metal. A buttering layer of high ductility weld metal ‘may be deposited where the vertical momiber is to be welded Assess the through thickness ductility by short tensile test, Inspect the plate for non-metallic inclusions 8 Carry out full chemical analysis to make sure sulphur is less than 0.05%, Solidification crackine: (ferrtic steel) Solidification cracking is a hot cracking mechanism that is caused during solidication of weld in ferrtic steels, containing high sulphur content During welding, sulphur in the plate may be remelted and, will fuse sith iron to-freiron-sulphide (FeS) ‘Thesg jiron-sulphides are low melting point impurities; otieStound the grain boundaries, which are SP reat stress due to the action of contragtional forces. The bonding between the grains may ‘ow be insufficient to maintain cohesion and cracks (vill result running through the length of the weld centerline Lehch will Seek Fe bab painted Solidi kedion HO oe eee a. High sulphur content Q b. High dilution process : ¢. High carbon content in weld metal wwe ahs 40 wets alco 4. High contractional stresses. fyb Contra: Control the sulphur content Use low dilution process. Use consumables with high manganese. Keep Manganese-stlphide: carbon rato as low as possible. Minimise restraints, - Go etipionse tie veld ep fo WAMU Jain Weld decav ~ Solidification cracking if, Solidification cracking is a hot cracking irecivsism that occurs during solidification’ of weld metal in, austenitic stainless steel. Austenitic sia vg agge grain strocture compared to ferric ste! / grains. During welding low melting p: foraSbround thiselarge solidifying austenitic grain ~ structure in the weld centerline, ‘These large b small grain boundaries compared to feritic steels. This lack of grain boundary‘Eatiscs ail of ies to concentrate in small area. Due to high contractional forces ‘hese 2: @ ie great stress and the bonding between the grains may be insufficient to maintain oo? ks occur in the centerline of weld along its length. * pppoeCauses Low molting point impurities High dilution procoss High contractional stress i Inerease the grain boundary by adding deita ferrite Minimise restrain, Ensure plates are very clean Pee cennes Liquation cracking mitt chs oscus in sts, which have high wi pecan When weing fos quali: high fulbhur content sts. itis possible that anes sma os4Dhids (FES) in the HAZ will Lge ing 8 teking point ior-sulpige usual scene 2 the grain boundaries, If this melting ccccy ee boundaries will be pulled apart and. Ligeatcn cracks occurs Causes High sulphur content, i High restraints High contraction stresses, rol: &. Use high quality refined stot . Controle heat input © Minimise restrain, 4. Use pre-heat ‘daring mess telacation cracking. it mainly occurs in HAZ of welds ge arly it low allo sicel during post weld hans Mot at OF Service at elevated temperatures, Mics {ype eg., creep-resisting steels During post weld stress relief and at high operating temperature the residual stresses would be relieved by creep deformation which involve grain boundary sliding and grain deformation, Tf due to Tetallurgical conditions these actions cannot cour, then grain boundaries may open up inte erace Causes 2 Areas of high stress concentration and existing weld defects, : b. The toes of badly shaped filet welds, incomplete root penetration welds © High creep resistance HT Foe grinding, etinination of partial penetration welds, Rejection of poor weld profile }CSWIP EXAMINATION QUESTIONS: _ J: LAMELLAR TEARING IS OBSERVED IN CROSS-SECTION x SUGGEST METHOD BY WHICH YOU WILL OVER COME IT: s/2. WHAT IS THE USE OF NICK BREAK, HOW IS MACRO & 4 MICRO EXAMINATION CARRIED OUT =—* 3. THERE IS 25MM THICK PLATE AND T-FILLET WELD 'TO BE WELDED WITH 2MM REINFORCEMENT. 5M ROOT PENETRATION. DRAW A SKETCH OF DESIGN THROAT, EFFECTIVE THROAT, ACTUAL THROAT ~4: WHAT ARE THE ADVANTAGES AND LIMITATIONS OF THE FOLLOWING NDT ULTRASONIC, RADIOGRAPHY 5» DESCRIBE A SEMI AUTOMATIC PROCESS WITH RELEVANT SKETCHES AND EXPLAIN IN DETAILS. BAHOW WILL YOU REMOVE CLITS / TEMPORARY ATTACHMENTS WHAT NDT METHOD YOU PROPOSE TO CHECK IT \. ¥ STATE THE CAUSE FOR CRACKING ANDY SUGGEST PREVENTIVE METHODS Be WRITE IN YOUR OWN WORDS. THE DUTIES OF WELDING’ INSPECTOR TO THE CHOSEN CODE wa “Leg length of a fillet weld is located in front of the weld symbol Throat thickness by letter a Fillet weld with 7mm-design throat, when both leg length throat thicknesses are given Intermittent fillet welds are dimensioned by giving, number of weld elements : | length weld elements @ distance between weld element General Questions — welding _- Viva test likely to ask 1, what is WPS, PQR, WPQT Welding procedure specifications (WPS)- A WPS is written qualified welding Procedure prepared to provide direction for making production welds to code requirements. ™Procedure qualification records (PQR) — a PQR is a record of welding data recorded duyring,the welding of test coupons. It also contains the test results of the tested spétirmiens- recorded variables fall with in a small range of the actual variables that will be used in production welding. The purpose ef the WPS and PQR determine that the weld- ment proposed for construction is capable of having the required properties for its inténdéd application, , Welding Procedure Qualification Test (WPQT) 's to establish the properties of the weld-ment and not the skill of the personnel Performing the welding. It is pre supposed that the welder performing the welding procedure qualification test is a skilled workman. WPAQT is to determine the ability to deposit sound weld metal by the welder. It reflects the skill level of the welder. The performance-qualified test shall be welded in accordance with qualified WPS. 2. Why WPS PQR's shall be approved? Welding qualifications ere statement by that company that the welding Procedures and personnel have been tested in accordance with the proper codes and specification and found to be acceptable. All information on the POR such as ampere, voltage- travel speed, PWHT. Heat treatment time and temperature as applicable, shall be actual data as recorded using calibrated instruments. Welding procedure qualification is performed to show the compatibility of 1. Base metals 2, Weld or brazes filler metals 3. Process and technique f 3. What ere the essential variables in WPS? -Essential variables are those features of the welding process which if changed beyond certain limits require that a new welding procedures are established, essential variables are change in welding process, pipe material, joint design, position, direction of welding, shielding gas and flow rate, shielding flux, speed of travel. 4. What are the main variations — essential variable from WPS to POR? Thickness range, diameter range, change in direction of welding» 5. Why there is a gap in the socket weld? There is a gap of 1.6mm in the socket weld, to take care of thermal expansion during welding 6. What is the difference between a socket weld & butt weld Bult weld needs edge preparation whereas socket weld needs no special edge preparation7. What is the purpose of weldolets & socket welds? Weldolets where there is a change in cross section i.e. from higher thickness to lower one and where a branch comes out from the existing one. Sockets are used for instrument tapping, sampling points, drain & vents etc 8. Why vents and drain to be installed? Vents to release the air entrapment while doing hydrotest in the systems and the drain to drain out liquids in the line 8. Why low hydrogen electrodes should be dried? Drying to take place (baking) to remove the moisture content 10. Where is cellulose coated electrodes used? Cellulose coated electrodes are used in pipeline for making stringer bead in mainline and for the root pass in tie-ins. They need not bé baked. Deep penetrating property 11.What is the difference between up hand and down hand welding? Which is similar to stove welding? The direction of welding, if it is in the up hill progression it is up hand. The direction of welding down wards is down hill i. the flow and direction in which the welding is carried out. Stove welding is similar to down hill welding. 12. What is a welding boss? What is its purpose? ‘Welding boss is attachment to the line pipe to enable for instrument tapping thermo wells, sampling point and for measuring the temperature of the liquid flowing through the system. 13. Why should bevel ends (cut) be MT done? To check for lamination and surface cracks 14.why a metal should be of sufficient thickness? To avoid mett-through } ‘15.which is the best MT technique for austentic SS? MT can not be done on austentic SS IT. (MT) applies only for ferrous materials. LPT should be carried out 16. What is the normal PWHT for P8 materials? P8 materials not be PWHT. 23 n “17. How an are is produced in TIG welding? By high frequency generator (-ve polarity) 18.what are the welding parameters in welding? How it is measured? Current, volts, travel speed, current & volts by tong tester travel speed by run out length 19.1s an arc strike needs further NDT? Why to do so? Arc strike is a crack initiation site. Needs to be NDT by UT/PT etc., tendency to cracking may occur. It is a localized HAZ, which contains martensite. 20.What is the minimum distance between parallel welds? 20mm or (3) times the wall thickness of the joint whichever is greater. 21.What are the minimum pre-heat temperature for welding? 20° C to be preheated 22.what are dropping characteristic? In which process it is used? Constant power source, it is used in SMAW. To maintain the arc length it is used. 23.what are the main reason for undercut & acceptance criteria? Undercut is due to incorrect; poor manipulation of the electrode. Welding speed is excessive, excessive current. 1/32".8 mm not acceptable 1/64.4mm-2" IN 12" 24.What are off set? To how much it is restricted & why? 7 Misalignment. 1/16" 1.59 mm allowed. Offset can lead to misedges-lack of fusion, 25.What are the circumferential off set between longitudinal welds? 400mm 26.what are reinforcement? Is it acceptable, if it is below the parent metal by 1mm? Weld metal in excess of the quantity required to fill a joint, at the face or the root Not acceptable. it should be above the parent metal by 1.59mm, 27.why preheating is to be done? 24To remove moisture, To avoid cracking, to have uniform cooling 28.what is an arc & spark? Where it is used? By using high current arc is produced, Used in the welding. By using high voltage spark is produced. Used in holiday testing. 1.State the basic principle of radio graphic testing? What are it s advantage and disadvantage? Basic set up (I) source of energy (ii) object to be inspected (iii) recording media \ (film). itis the differential absorption of energy. Factors influencesthe difference {difference in atomic number 2.difference in density of material 3.difference in thickness Discontinuity should be parallel to the central ray of radiation and perpendicular to the surface of object | Advantages of radiographic testing (RT) 1.best suitable for voluminar type discontinuity e.g. PO, siag | 2.permanent record 3.defect characteristic is easy Disadvantages of RT } “1.Radiation hazard 2.difficulty to detect planar discontinuity Impossible to detect amination 3.two sides of accessibility 4.depth of defect is not possible to find out by RT 5.operating cost is high- film consumption and setting time 2what is ultrasonic? What is the principle, what are its advantages & disadvantages? Sound energy having frequency >20 kHz or 20 KCPS is called ultrasonic. It is above the human hearing perception. principle of piezo electric effect is used in UT. Difference in acoustic impedance, which will affect the reflection and transmissions of ultrasound through a interface Advantages and applications of UTuseful for planar discontinuities e.g. crack, lamination penetrating ability very high upto 6 meters high sensitivity (very small defects detectable) defect characteristics (type planar, voluminar ) orientation, depth, shape instantaneous indication , interpretation one side accessibility is enough digital signal processing is possible NOOBONS Disadvantages of UT 4,high skilled operator is required 2.extensive technical knowledge is required 3.couplant is required 4 permanent record 3.state the basic setup for magnetic particle testing and what principle it works. List the advantage & limitations? Basic set up 1 pre cleaning if necessary 2 magnetization 3. Application ion particles and gently blow off excess particles. 4.Interpretation relevant Indication non-relevant indication 5. Evaluation decision making as per codes & standards.6, demagnetization if necessary 7. Post cleaning Basic principle: Detection of leakage field or flux leakage Advantage of MT: ao 1.detect surface & sub surface up to 6mm. 2.direct indication of defect location Limitation of MT: cannot detect internal discontinuity Only applicable for ferromagnetic material iron, steel, nickel and cobalt austentic steel cannot be inspected b MT ona 4, What are the types of cracks and what causes for cracking to occur in a weld metal? 1 solidification cracking. Causes excessive deep or wide bead. high current and or welding speed, less root gap, carbon (sulfur) or Phosphorous pick up from carbon steel. 262.Hydrogen induced cracking Causes: hardened HAZ heat affected zone of the parent metal. Coupled with presence of hydrogen diffused from metal. Susceptibility increases with increasing thickness of section especially in steels with high carbon equivalent: increased heat input necessary. Preheating sometimes necessary. Control of moisture in consumables and cleanliness of weld preparation is.essential. 3.Hydrogen induced weld metal cracking Causes weld metal more highly alloyed than parent steel, Usually in thick section with in-sufficient consumable drying or preheat may be transverse at 90° or 45° to its surface or longitudinal. Control as for HAZ cracking 4,Lameliar tearing Causes poor ductility in through thickness, direction because of non-metallic inclusions, Only found in rolled plate. Occurs mainly where weld metal is deposited on plate surface such as |) corner and cruciform joints. Avoid by specifying plate with sufficient through-thickness (short transverse) ductility. 5.Reheat cracking Occurs in creep resisting and some thick section structural low alloy steels during post weld heat treatment. Causes-poor creep ductility in HAZ coupled with thermal stress- accentuated by severe notches such as pre-existing cracks or tears at weld toes or unfused root of partial penetration weld. Heat treatment may need to include low temperature soaking — grinding or peening of weld toes after welding can be beneficial Can be avoided by two layer welding techniques and use of non-susceptible weld metal. 6. What is meant by arc blow? How can it be avoided or minimized? An electric current flowing through the electrode sets up magnetic field in a series of continuous circles in a plane perpendicular to the axis of the rod. Similarly magnetic lines are also formed around the work piece and ground cables-when the fields around the work piece or around the electrode are unbalanced, the arc bends away from the greater concentration of the magnetic fields, This deflection of the arc from its intended path is called arc blow. Arc blow is encountered particularly when using direct current, because the: magnetic field is in @ constant direction. Back word blow is encountered when welding towards the ground connection, toward the end of the joint or ino a corner. This kind of arc blow can lead to incomplete fusion and excessive weld spatter corrective methods for uses when severe arc blow occurs are as follows.Change to alternating current Reduce welding current and keep arc length at the minimum Weld towards a heavy tack weld or toward an existing weld On iong welds use a back-step sequence Place the ground connection (a) as far as possible (b) at the start of a weld and then weld toward a heavy tack weld or (c) at the end of the weld Wrap the ground cable around the work piece so that the current flows in a direction that will establish a magnetic field that will neutrelize the magnetic fields causing arc blow ' MAwNS ° et is lamellar tearing? Suggest preventive measures to overcome it? Lamellar tearing ~ it is the pulling apart of base metal under stress acting in the thickness direction generated by thermal contraction strain in a welded joint. It is primarily associated with T-type or corner joints that are highly restraint. The tearing originates in or just outside the heat affects zone. It is trigged by de cohesion of elongated silicate or sulfide inclusions. 1. Resistance to lamellar tearing is increased by aluminum killing of steels (fully killed) and de-sulphurisation by rare earth additions or liquid metal treatments at additional cost _ 2. The fabrication procedures can be altered to reduce the possibility of lamellar tearing e.g. Welding sequence, avoiding over size welds or over matching strength electrodes, moisture contro! of low hydrogen electrodes, intermediate stress relief and controlled peening. 3. An effective technique is to butter the surface of the members, butter either in a pre-grooved area or on top, before attaching the leg of the T-joint / 8. What is the weld decay? Suggests methods for prevention of it? Weld decay: sensitization of carbide precipitation. It occurs in HAZ due to the Precipitation of chromium carbides resulting in the reduction of chromium in grain at temperature 800°F to 1600 ° F (mostly at 1250°T) Chromium will combine with carbon to form chromium carbide (weld decay also called knife line attack) ocours in un-stabilized stainless steel e.g. 18-8 type with in 600-850" (range HAZ at that temperature change) Carbon absorbed by chromium and chromium carbide is precipitated at grain boundaries as the metal cools down. This causes local reduction in chromium content has affect at lowering the resistance of corrosion attack result in rusting of steel 28 16Prevention of weld decay: 1. Add stabilizer to base metal and filler (Titanium Ti or Niobium, Columbium) to 300 series alloy in 8-10 times the carbon content. These alloys combine with carbon and reduce the carbon available for carbide formation. 2. Decarburize-reduce the carbon content in the base metal and filler metal reduce the carbon content in molten steel to 0.03% which will produce extra low carbon steels 306 L% C is less then 0.03 % steel grades contain -.08% 3. Heat the stainless steel to 1950 ° F to 2000 ° F, quench it 9. What is destructive test and for what purpose it is carried out? Mention briefly the various destructive tests and purpose w.r.to welds? Destructive tests are applied to samples representative of the welded joint under review. Often made specially for test purposes. In a destructive test the test piece or specimen is destroyed in most cases by fracturing. After destructive testing the specimen remains no longer useful for further use. Destructive test is used for welding procedure approval, welder approval, quality approval ete. Destructive tests as applied to welds are The tensile test The bend test The impact test The nick-break test The hardness test and The etch test ~"paoc9 Tensile test, A steadily increasing load is applied to the specimen, until it fails in tension. The aim of the test is to ensure that the welded joint is as strong as is required. In carbon Manganese steels the failure usually occurs in the parent material and there can be no measurement of the yield stress of the weld. Allweld metal test: To measure the yield or proof stress of the weld metal on all-weld metal specimen is extracted from a specially made weld which does not however simulate a typical welded joint. This test is used as a quality control of test for welding electrodes but cannot be directly applied to predict the behavior a real joint as the weld preparation and welding conditions de not reproduce those normally used in fabrication ‘Through thickness test: Susceptibility of @ stee! to lamellar tearing is assessed by a tensile test on @ specimen taken in the through thickness direction of steel plate. To enable the complete thickness to the tested bars are welded to the surface of the plate to form extensions, which can be gripped in a tensile test specimen. The specimen is then cut out of the plate and tested, The reduction in 29area of the specimen at failure is taken as a measure of susceptibility to lamellar tearing, Reduction of area’ 2% high risk of lamellar tearing Reduction of area: 20% low risk of lamellar tearing. Bend tests Bend test assists in determining the soundness of the weld metal the weld junction and the heat affected zone. There are three types of tests specimens which are used for full welds in plate depending on the thickness of the metal Free bend test determines the ductility of weld metal Specimens are cut from welded test pieces and bent round a former. These bend tests show if the ductility of the welded joints is satisfactory and also open up weld defects to give an indication of the weld quantity. Bend tests will indicate only those defects, which are near or at the surface of the specimen and are therefore of limited values ‘Tube welds: For bend testing butt welds in tubes, a tongue of metal containing part of the joint is isolated by two cuts. The weld in the tongue is dressed flush and the tongue is bend over a former. - Fillet welds: For fillet welds a cut is made in the weld face to allow the weld to be tested by bending in the direction causing the root to open. This shows if full root fusion obtained but has no other significance. Impact test: Charpy Impact test Impact testing becomes essential in order to study the behavior of welded objects under dynamic loading, An impact test determines the behavior of welds when subjected to high rates of loading, usually in bending, ‘An impact test gives an indication of the relative toughness of the material Toughness is defined as the resistance of a meal to fracture after plastic deformation has begun. The purpose of impact testing is to determine the amount of impact a specimen will absorb after fracturing. In an impact test 2 specimen machined or surface ground and notched is struck and broken by a single blow in a specially designed testing machine. The quantity is measured is the energy absorbed in breaking the specimen by a single blow. Nick Break Test Involves breaking the weld joint to examine the fractured surfaces for internal defects such as gas pockets, slag, porosity, % ygHardness test: The hardness test gives an idea of the resistance to weer of the weld metal. Hardness values can give information about the metallurgical changes caused by welding. In the case of medium and high carbon steels and cast iron the heat affected zone or weld junction may become hard and brittle because of the formation of martensite. Hardness values in a welded joint are usually sensitive to such condition of welding as i) The process used ii) The heat input iil) Preheat or inter pass temperature iv) Electrode composition and v) Plate thickness Hardness value indicates whether the correct welding technique and pre and post heat treatments have been carried out, The hardness of weld is particularly important if the welds must be machined. Various commonly used test methods for finding hardness are a) the brinell test 6) the rock well test c) Vickers hardness test 500 times BHW value gives you approx. tensile strength of the material , The Etch Test: An etch test involves inspecting the welded test specimen after Polishing and etching the same with a chemical re-agent (e.g. a dilute acid) There are two types of etch tests namely 1. macro-Etch Examination 2, Micro-€tch Examination » Macro-Eich Examination: After preparing the specimen by, polishing and ‘ _. etching. itis examined either by the naked eye or by low power magnification up to X15. Macro-examination gives a broad picture of the specimen by studying relatively large sectioned areas 2 1.cracks ji) slag inclusions iii) blow holes iv) shrinkage porosity v) penetration of the weld vi) boundary between the weld metal and the base metal etc. Se examinations: After preparing the specimen by polishing end etching, it is examined under a microscope at magnification from X20 to X2000 Micro-etch examination involves areas much smaller than those considered in macro-etch examination and brings out information that can never be revealed by macro-examination Micro examination determines in a welded specimen |) cracks and inclusions of microscopic size ii) grain boundaries and solidification structures of weld metal iii) distribution of micro-constituents in the weld metal iv) the quality of heat treatment etc., Preparation of test specimen:1. The specimen shall be the full thickness of the material at the welded joint and the weld reinforcement and penetration bead shall be left intact. 2, The specimen shall contain a length of the joint of at least 10mm and shall extend on each side of the weld for a distance that includes the heat-affected zone and some base metal portion ry Specimen after being cut from the plate is filed or ground to obtain the filed surface on the specimen 4. Intermediate and fine grinding is carried out using emery papers Progressively fine grade is of grades 200 grit, 320 grit, 400 grit and 600 grit from coarse to fine 5. Rough and fine polishing of the specimen is carried out on a rotating Polishing wheel. Fine polishing removes the scratches and very thin distorted layer remaining on the specimen from the rough polishing stage 6 Etching. The specimen is then etched in order to make visible the grain boundaries, heat affected zone, the boundary between the weld metal and parent metal etc,, etching imparts un-like appearances to the metal Constituents and thus makes metal structure apparent under the microscope Etching is done either by a. Immersing the polished surface (of the specimen) in the etching reagent or by ». Rubbing the potished surface gently with a cotton swab wetted with the etching agent Hydrochloric acid: the reagent contains equal parts by volume of concentrated HCI and water specimen is immersed in this agent at or near the boiling point Ammonium phosphate: Mix one part of ammonium per sulphate nine paris by weight — rubbed, vigorously on the surface of the weld with cotton saturated with this reagent Nitric acid: _ One part of concentrated nitric acid is added to three parts of weter by volume. The reagent may be applied to the surface of the weld either with glass-stitring rod at room temperature or the weld be immersed in boiling feagent. Provided the room is well ventilated. This regent is used on polished Surfaces only to show the weld metal zone as well as the refined zone. Nital contains 2CC HNO3 con + $8 CC absolute methy! of alcohol. «=» Leak or tightness test: Leak testing is the determination of the rate at which a liquid or gas will penetrate from inside a tight component or assembly with the outside as a result of pressure differential between the two regions. To test welded pressure vessel, tanks and pipeline to determine if leaks are presentLAKE INTO No / VU The Duties of q welding inspector My Duties as welding Inspector are moh ed Be lding pa eae 1) All applicable documents are checked a 2) Application standard is up to date with latest edition, revision or amendment Permit are available and valid ats dy 7) Calibration certificates, Material Certificates (mill Sheets) and consumer certificates are available 8) Quality plan is authorised and endorsed with signatures, date and company stamp 9) Parent metal identification ig verified against documentation and markings checked and verified '2)Plant and equipment are ina safe condition and are adequate for the job, the approved drawings {5) Pre-weld cleanliness is maintained 16) Pre-heating for any tack Welding isin accordance with specitied Procedure. During Welding . fades Ve 1) Welding process such as tack welding and root runs most be monitored and inspected 2) Welding should be completed without undue interruption and within a specific period 3) Hot pass must be timed. 4). Essential variables such as Current, voltage, travel speed and number of runs must be monitored, 3) Inter pass cleaning, ‘emperature, and run sequence must be inspected. ©) Welding is carried out in compliance with the welding procedure sheet and application standard. Miter Welding 1) Dimensional accuracy must be checked 2) Visual inspection is carried ascertain acceptability of appearance of welds 3) Post weld heat treatment (ifany) should monitored and recorded 4) NDT report is assessed 5) Delayed inspection is carried out 72 hours later to check for Hydrogen (12) 8) Weld defects and other influences alecting the acceptability of a weld are Teasidered in accordance to the written Specification (standard) 7) Urepairs are required then approved procedure marked. marked,cei) INSPECTION REPORT JOB CODE -0000 Report Registration No.: IR- R- 2153-101-02 P.0.No. P-2153-1p1-8 INSPECTION DATE : JULY 122005 SHEET 4 6. Inspection performed & results 6A ITP step Description Result — i ‘GHEGK OF MARKINGS, VISUAL AND DIMENSIONAL INSPECTION SATISFACTORY C2 PROTECTION CHECK: GALVANIZED € PENDING REPECIION RELENSE CERTIPATE 6.2 INSPECTION DETAILS INSPECTION VISIT AT AKP, JUBAL WAS CARRIED OUT ON JULY 13,2005; PER NFI REF # L-TT-GY-02440 DATED 30.06.05, MET MR. ABDULLA LABBAD, AKR\QVQC MANAGER AND MR.BASHAN, QC ENGINEER AND THEY WERE ‘SURPRISED OF MY VISIT BECAUSE THEY ARE NOT AWARE OF THIS NOTIFICATION. ‘THE FOLLOWING ACTIVITIES Wi COMMENTS: 1) QNQC DOCUMENTS i.e. MATERIALS TEST CERTIFI FINAL VISUAL AND DIMENSIONAL REPORTS, NDT. PERFORMED DURING THIS VISIT: VISITED THE AK&P WORKSHOR WITH QC ENGINEER IT WAS OBSERVED THAT FIT UP, WELDING, NDT AND FINAL CLEANING OF WELDED STRUCTURES FOR APPROXIMATELY 120 TONS OF MATERIALS ARE ON PROGRESS|AT THE WORKSHOP. ‘SPOT DIMENSIONAL CHECKING QN FIT UP MATERIALS FOUND ACCEPTABLE IN ACCORDANCE WITH THE SHOP DRAWING. THE SURFACE PREPARATION ON MATERIALS PRIOR TO TACK WELDING OF COMPONENTS IS SATISFACTORY. VISUALLY CHECK ED THE WELDED|MATERIALS AND FOUND THAT SIZE OF FILLET WELDS AND THE WELD PROFILE CONFORM TO AWS| ‘SHARP EDGES AND SPATTERS WEF ATTENDED. VERIFIED 20 RADIOGRAPHIC TEST: )RTS FOR THE SPLICE JOINTS. RESULT OF TEST IS ACCEPTABLE. NDT IS BEING PERFORMED BY A LEVEL 2 QUALIFIED RT TECHNICIANS FROM ‘AMSYCO NOT COMPANY VERIFIED DOCUMENT # V-2153-101-A 0 REFERENCE REQUIREMENT ON NFL. THEY ONLY HAVE REV. AOO 'AK&. P DO NOT HAVE A COPY OF REV. CO} ‘AK &P INFORMED ME THAT THEY ARE WORKING ON THEIR OOCUMENT # V~ 2183-101-A.202 REV.A00 ALREADY ON CODE 8, VISITED AL AJAB METAL GALVANIZING F/ OBSERVED THAT APPROXIMATELY 170 TONS OF MATERIALS HAVE BEEN GALVANIZED, ‘VISUALLY CHEKED THE GALVANIZED MAT ‘SATISFACTORYAND NO DAMAGE HAVE BEI NOTED ON STRUCTURES. ALS AND FOUND THAT THE CLEANING IS RANDOMLY CHECKED THE GALAVANIZED COATING THICKNESS ON WALKWAYS, BRACINGS AND BEAMS FOUND ACCEPTABLE PER ASTM A124 AS THE COATING IS RANGING FROM 120 TO 230 MICRONS, WHICH IS ABOVE THE SPECIFIED VERIFIED THE GALVANIZING CERTIFICATES RED COATING THICKNESS. \TES, FINAL INSPECTION WELDING REPORTS, PORTS AND GALVANIZING CERTIFICATES HAS. NOT BEEN SIGNED BY GEA.BTT INDICATING THAT THEY HAVE REVIEWED THE DOCUMENTS AND MEETS THE ITP DOC. #¥2153-101-A014 ITEM K AND SPECS # S-000-1520-001 REQUIREMENTS, 2) THE MATERIALS REQUESTED FOR FINAL VISUAL INSPECTION FOR DELIVERY HAS NO PACKING LIST. 1.1 REQUIREMENT. SOME MINOR COMMENTS NOTED SUCH AS POINTED OUT TO SUPPLIER AND WERE IMMEDIATELY ceritimmeuvmmarcenoemnwe ID FOUND MEETING THE ASTM A123 REQUIREMENTS. 3) IT WAS NOTED THAT SPLICE JOINTSON PRIMARY MEMBER STRUCTURES HAD NOT BEEN REFLECTED IN THE SHOP DRAWING. THE TRACEABILITY OF THE NQ, OF ITEMS WITH SPLICE JOINTS ARE UNACCOUNTED ON SOME ITEMS HAVING MORE THAN 4) BOLTS NUTS AND WASHERS ARE NOT YET AVAILABLE 5) CLARIFICATION ON DOCUMENT # R. 2153-101,REV. CO0."SCOPE OF INSPECTION FOR STEEL STRUCTURES" PARA. #65, TRIAL ASSEMBLY TESTS, THI SAID DOCUMENT REFERENCED IN THE P.O. INSPECTION RELEASE CERTIFICATE FOR THE GALVANIZE PENDING SUBJECT TO COMPLETION ON COMMENTS ABOVE. 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RIGHTWARD THIN SHEET & PIPE BUTT WELDS Senn - Seen Typ. 90° INCLUDED ANGLE NO ROOT FACE SEO. of 60° INCLUDED ANGLE FLAME TYPES NEUTRAL WELDING STEELS/AI & BRAZING STEELS I l CARBURISING OXIDISING 1 FOR HARDFACING (e.g. STELLITE) | WELDING BRASS & BRONZE WELDING STEELS | PROCESS VARIABLES T NOZZLE TO GAS VELOCITY WORK DISTANCE, | QUANTITY OF QUANTITY OF HEAT HEAT T | NOZZLE SIZE TECHNIQUE L | QUANTITY OF QUANTITY OF HEAT HEAT TRAVEL SPEED FUSION & PENETRATION TYPICAL DEFECTS ae rrr rence een] LACK OF FUSION & PENETRATION OVERHEATED WELD OVERLAP” OXIDISED WELDOXY FUEL CUTTING 5 OXYGEN FUEL —— ACETYLENE PROPANE, OTHERS T HIGHEST GREATER TEMPERATURE, QUANTITY OF HEAT EQUIPMENT (SIMILAR TO OXYACETYLENE, WELDING) MANUAL MECHANISED OPERATION OPERATION HIGH s¥iLL PROFILE TRACTOR LEVEL | | COMPLEX SHAPES STRAIGHT POSSIBLE UNE L l MATERIALS MAINLY STEELS (POWDER ADDITIONS USED | ON SS & Al) THICKNESS 3mm TYP __ UPTO ———s 450mm TYP 1 | HIGH DISTORTION QUALITY DEPENDANT ON LEVELS OXY PRESSURE & PRE-HEAT CUTTING PARAMETERS f T T 1 TIP TO ‘PREHEAT GAS CUTTING NOZZLE TRAVEL GAS WORK © -VeLOcITY pressure ‘size SPEED PRESSURES | | ee | TYPICAL DEFECTS HARDENED OXIDISED GOUGING & FLUTING DISTORTION EDGE SURFACE, (FINISH) SAFETY (CUTTING & WELDING) I T T | T 1 EXPLOSIVE FLASHBACK BLOWBACK Cu OXY & NITROUS. ACETYLIDE on. OXIDEActivated 2% thoriated: _used where are stability required with low amperage also used with de-ve for all materials except light alloys. General: My duties are as a welding inspector to check that all welding and associated activities are being carried out at the job site in accordance with the requirement of the approved welding procedure specification and through my qualities of honesty, integrity and knowledge. [ also apply my knowledge in observing, measuring, and recording; before, during and after welding, Prior to welding Before assembly: Icheck; Applicable codes, standards and project specification. Alll applicable documents such as QIP, procedures, inspection formats and any special safety requirements Approved WPS with supporting WPAR as per code Welder qualification and identification as per WPS Material; composition, condition, ratting and storage handling as procedure. MTC’s and drawings Consumables; composition, type, size and baking requirement as per WPS Surface preparation method and finish as WPS and to good workmanship Welding machine validity as Line-up clamp type and condition as WPS After assembly: check: Cleanliness of surface to good workmanship Preheat as procedure Purging dump to avoid oxidation as WPS. Weather condition as suitable to site/field During welding. I check: Consumable and control as WPS and to good workmanship Welding process as WPS Line-up clamp; remove after completion of root pass as WPS Laps timing between root and hot pass as WPS Welding parameters such as voltage, amperage and polarity, welding technique, weld-direction and run sequence. Inter-pass cleaning to good workmanship Inter-pass temperature minimum and maximum as WPS Speed of travel as WPS After welding I check; Compliance to WPS. Weld and welder ID marked as drawing Any modification or as-built add to drawing Visual inspection as code or spec.* No spatter is sticks smoke, © No visible are (no need eye protection) Disadvantages: O Very costly equipment Limited position of welding Need accurate fit-up Poor portability No good for thin material Manual! Metal Arc Welding Drooping characteristics (constant current) Type of operation: Manual Mode of operation: Are is created between the tip of electrode and work piece. Arc is formed by momentarily touching the tip of electrode on the parent plate and then lift the electrode to give a gap 3 ~ 6mm between the tip of electrode and the plate. Arc melts parent metal and electrode: the molten metal so formed is transferred as small globules across the arc gap. Welder controls arc length and electrodes feed rate by the hand movement. The slag must be removing afier each deposited layer. Normally a small degree of penetration, plat edge preparation required. Power source: Generator, transformer and rectifier. Current: Normally de +ve but also use de -ve or ac. De +ve best penetration De-ve deposit is high Defect: Porosity, slag inclusion, under cut, excessive penetration and spatters. Equipment: * Power source . Welding cables * Electrode holders © Earth retum + Welding shielding helmet Consumable: BS EN 499, AWS AS.1, ISO 2560, BS 2926, BS 2493 JkBasic: E7018, E7015, £7016 Rutile: £6013, E38 2R Cellutasie: E7010, E8010 Advantages: . Low cost equipment . Easy to operate at site * Easy shift to site * Easy and more deposit thickness * Wide range of material * Welding all position Disadvantages: + Low production due cleaning required after every layer . Dirty and smoke production * Not sufficient to weld all material successfully. Welding process defect: 1 - Weld decay Weld decay? Weld decay is corrosion between grains. Causes? ‘The reduction of the chromium from grains is main cause of the weld decay. When material is over heated 600° C~800° C, chromium comes out from the grains, joins with carbon and becomes chromium carbide on the grain boundaries. It happens in the heat- affected zone. Chromium is retard corrosion, Corrosion occurs between the grains as, chromium is reduced. Avoidance? We can avoid weld decay * By using the low carbon content material such as 316L & 3041 instead of 304 & 316, * By using the stabilized stainless steel such as 321 & 347. * By adding the titanium and niobium, Titanium and niobium join the carbon and become titanium and niobium carbide. Titanium and niobium give stabilization to chromium. * By the keeping of appropriate heat input, By the keeping of appropriate inter pass temperature. 152 ification cracking Solidification cracking? Solidification cracking is hot cracking, hot shortness, and centerline cracking in the weld metal Causes? © Sulphur, stre cracking * Sulphur comes from parent metal, joins with the iron and becomes iron sulphied. Iron sulphied has low solidify temperature than steel. Iron sulphied becomes a thin film in liquid form between the solidify grains on the center of the weld. Iron sulphied possess a very little tensile strength. Any stress makes a solidification crack at this moment. ind joint design are the main causes of the solidification Avoidance? We can avoid solidification cracking . By the using low sulphur content material . By changing of joint design. . By good cleaning of joint, * By the adding of manganese to join the Sulphur to become manganese sulphied. Manganese sulphied has a same temperature to solidify with steel. Manganese reduces Sulphur content and discrete the iron sulphied. Therefore, less chance to crack. 3 - Lamellar tearing Lamellar tearing? Lamellar tearing has characteristics step like crack. Occurrence? It occurs in the thick section in the T, Y, K, and corner joints, wrought plate, in the HAZ, of steels, where fusion boundary of the weld and only in the rolled direction of parent material, Causes? Poor through thickness ductility, stress and high Sulphur contents are main causes of lamellar tearing. Although, others non-metallic inclusions may also play a part. The presence of the hydrogen increases steel’s susceptibility to lamellar tearing quite significantly. Avoidance? Lamellar tearing can be avoided: © By reducing the size of the weld, try to use fillet weld instead of butt weld. * By changing the joint design, where stress moving in the roll direction. © By using the low Sulphur content steel. 4* By buttering layer * By using z quality plate that has been stra tested Assessed? Assess by short tensile test according to BS 5135 4- Hydrogen cra ie Hydrogen cracking? Hydrogen cracking is known as cold cracking, hydrogen induced cracking (HICC) and delayed crack. Cause? Hydrogen cracking can be occurred when: . Hydrogen is exceeds 1 5ml/100gms of the weld metal. © Stress exceeds 4 yield stress © Temperature is less than 350° C * Hardness exceeds 400VPN (Vickers pyramid hardness) . Oil/greasy surface © Moisturized flux Avoidance? Hydrogen cracking can be avoided by: . Appropriate baking of flux covered electrode. * Appropriate pre-heating * Adequate inter pass temperature © Appropriate heat in put. + Post-heating to defuse hydrogen and reduce the residuals stresses, * Using the hydrogen controlled electrode Consumables Welding consumables are the electrodes, wires, fluxes and gases. Each consumable is critical in respect to specification/supplier, condition and treatment (if any), Many codes are covered the various consumables. Covered electrodes: BS EN 499, AWS AS.1, ISO 2560, BS 2493, BS 2926 Gas shield wires: BS 2901 Part 1-5 Gases:BS 4365, BS 4105 Fluxes & wires (SAW) BS 4165 (CS), BS 5465 (A/SS), AWS A5.17 (CS) Function of shielding gases (TIG/MIG/MAG): Argon: Helium: Nitrogen: It provides a suitable, ionize able atmosphere for the electric are. It protects the weld pool from the atmospheric contamination. provides a smooth are at low are voltage with de-ve also gives cleaning action with ac for light alloys. , In addition of hydrogen, provides a high are voltage and gives deeper penetration also increase speed on stainless steel. Jess than argon therefore high flow rate (2~2.5 times) required to achieve same effectiveness with argon. Produces high arc voltage and heat suitable for thick section. More cost expensive than argon, inert gas in the room but becomes active with oxygen therefore unsuitable for majority of material but gives good result on the copper. More cost effectiveness than argon or helium. Function of fluxes: o Provides a gas shield to protect the weld pool and arc from atmospheric oxygen and nitrogen. assists in manipulation during the welding. Provides a slag, which gives additional shielding to the weld pool and i Improves the physical properties of the arc (are initiation and stability) Introduces weld metal alloys such as iron powder, de-oxidant ete. Improves metallurgical properties to lowering oxygen and nitrogen levels a Increasing deposition factors and over all efficieney ‘Types of fluxes (MMA): Rutile, cellulose and basic fluxes are the common types of covering s for MMA electrodes; Rutile: Cellulose: others include acid and oxidizing coverings. Constituents; titanium dioxide, clay and sodium silicate, Medium weight of titanium dioxide plus fluorspar. i Used for general purpose such as ms fabrication, low pressure pipe work, supports, structure and bracket ete. Gives fluid fast freezing slag, suitable to easy use in all positions but not for vertical down. Should be kept dry but never baked, Constituent’s cellulose (wood pulp), titanium dioxide, sodium silicate, 48High cellulose content produces a large volume of gas around the arc * Shield gas consist on Hp, Co, CO; & Hho. ‘+ Most important gas is hydrogen, which increases the are voltage and corresponding in power, which cause for deep penetration, © Rapid, rate of burn. * Produces fast freezing weld pool and thin slag, suitable for vertical down and overhead work. * Main use on stovepipe welding of high strength large diameter pipelines and storage tanks. * Good quality of penetration bead. Rough appearance and uneven ripples of completed weld. Spatter content higher than other electrode. Hydroscopic flux designed to hold between 4-7% moisture. Must be kept dry but never baked. * High limestone and fluorspar content to produce weld metal with low hydrogen content. * Limestone has good stabilizing and produces carbon dioxide gas shield © May be bake up to 500C approximately or depending on the manufacturer. Ability to weld low alloy, high & medium tensile strength with high sulphur content without any cracking, also reduce the possibility of the hydrogen induced cracking in the weld metal and heat-affected zone, but dependant upon the properly dried. * BS 639 certifies for MMA as hydrogen controlled. Must be less than 1Sml/100gms of the weld metal but can be reduced less than 5 ml/100gms of the weld metal with proper control. © Need higher degree of skill and must be used vertical up technique. * Productive and expensive. * Constituents; limestone (calcium carbonate) gas former, Co2 secondary ionizer, fluorspar slag former, sodium/potassium silicate main ionizer. Filler wire & Fluxes (SAW): * Solid wire is used, @ 1.6 mm to 6 mm according to BS 4165. * Fused and agglomerated according to BS 4165. Fused flux (granular): © Manufactured at high temperature, glassy appearance like crystal * Good chemical mix achieved. + Donot attract moisture, © Good handling, storage, used and weld ability * Bach removal of impurities and fine particle during recycling Agglomerated flux: © Dry mixed and then bonded with either potassium or sodium silicatemanufactured at high temperature. @ Absorb moisture and limited reeycling, ‘© Weld appearance not good. dvantages and disadvantages Radiography Testing Advantages: * Permanent record * Good for thin material. © Wide range of material. * No skill required for gamma rays. * No surface cleaning required. * No power required for gamma ray Disadvantages: * Dangerous for health. * Lamination and lack of sidewall fusion cannot detect, . Expensive film, © Affected all other activities, * Power source required for X-rays. * Not good for thick material. © High skill required for X-rays. Ultrasonic Testing Advantages: © Give accurate location and depth of defect. * No health hazard. + Noneed power supply. * — Notaffected other activities. © Good for thick material. © Lamination and lack of sidewall fusion can detect. © Portable, Disadvantages: No permanent record. High skill required © Surface defect cannot detect. © Smooth surface required. * Not good for thin material © Large grain size material defect cannot detect. 2dDye Penetrant Testing Advantages: * Can check all materials. * No need power source * — Loweost. Direct indicate to defect location. * No high skill required, Disadvantages: © For surface defect. * More dwell time as compare to MT genetic Particle Inspection Advantages: * Surface and sub-surface defect can check. + Lowcost, © Less time and more output, * Direct indicate to defect location. Disadvantage: * Cannot use for non-ferrous. * May be danger for operator. . Power required. Difference between microscopic and macroscopic Micro: opic «For grain structure analysis * Cross-section view at high magnification e.g. 100x or 1000x Some defects could also be detected and assessed, * The degree of preparation is much higher than macroscopic examination, for ferrite steel; P1200 grade finished followed by lum polish using a diamond paste then an etch using 1-5% nital This test is primarily used by the metallurgists Macroscopic * Por welder/procedure qualification * To view the cross-section view magnification is required 5x ~ 10x * To detect the weld defect and also to measure the actual defects already detects.Carried out on full thickness specimen included reinforcement Width of cross-section should include the heat-affected zone plus some parent material Same test piece is sometimes used for hardness testing after macro examination Specimen transversely cut from the weld Each test specimen is then ground, polished and etched to the degree required by the specification, e.g. for ferrite steels P400 grade finish with an acid etch using 10-15% nital (nitric acid + alcohol) Test specimen examined visually ‘The intent is to disclose any cracks, lack of fusion, porosity, slag ete. Steel properties Chemical properties of steel 2. Aluminum; i. De-oxidizer, grain refiner for improved toughness Carbon; i, Hardening agent ii, Increases Strength. iii, Reduces weld ability as increase carbon Chromium; i, Creep resistance and resist oxidation. ii, Corrosion resistance iii, Hardening element iv. Increase the strength of steel Cobalt; i, Knownas red hardness ii, Used where high strength, high hardness at high temperatures are desired Manganese; i, De-oxidant, grain refiner, increase toughness at low temperature ii, Increase strength by increasing harden ability Molybdenum; Creep resistance ii, Increase hardness also improve corrosion resistance qualities Nickel; i, Grain refiner ii, Increase harden ability iii, Improves toughness and ductility even with strength and. hardness iv. Improve toughness at low temperatures 22y. __ Increase tensile strength about 6000psi for each additional 1% of nickel 8. Phosphors; i <0.015% ii, Usually found in all steels iii, Hardened steel iv, Cause to embrittelment y. Improves machine ability of high-carbon steel vi. Improve strength and corrosion resistance of low carbon steel 9. Silicon; i. De-oxidizer (0.2 - 0.3%) ii, Promotes fluidity of molten steel iii, Also contributes to the strength of LA steel 10. Vanadium; i. Grain refiner ii, Promotes control of grain size, grain refine iii, Increase harden ability 11. Sulphur; i, Undesirable impurity (less than 0.04%) ii, Cause brittleness and reduce weld ability iii, Improve machine ability 12. Niobium i, Grain refiner ii, Increase harden ability i Also known as columbium, VIechanical properties of metal: Strength The ability of material to withstand an applied load Tensile strength shear strength, torsional strength impact strength and fatigue strength Tensile: the ability of metal to resist failure Yield: that strength level at which the material’s response to loading changes from “elastic” to “plastic” If the hardness increased, the tensile strength increases also and vice versa If temperature increases, the strength decreases Ductility The ability of material to deform, or stretch under load without failing Ductility increases as temperature increase High ductility is referred to as “ductile” and low ductility is referred to as “prittle” Hardness 23The ability of material to resist indentation or penetration Hardness increases as strength increases, or vice versa If hardness is known possible to estimate tensile strength Toughness The ability of material to absorb energy ‘Toughness decreases as the temperature is reduced Toughness decreases as the hardness is increased Fatigue strength ‘That strength necessary to resist failure under repeated load applications. ay1.1 - Scope This standard covers gas and are welding of welds in carbon and low alloy steel piping used n the compression, pumping, and transmission of crude petroleum, petroleum products, fuel gases, carbon dioxide, and nitrogen and where applicable, covers welding on distribution system. It applies both new construction and in-service welding The welding may be done by SMAW, SAW, GTAW, GMAW, FCAW, PAW, Oxyacetylene or flash butt welding process or by a combination of these processes using a manual, semi-automatic, or automatic welding technique or a combination of these techniques. This standard also covers the procedures for RT, MT, PT, and UT as well as the acceptance standards 5 - Qualification of Welding Procedure 5.3.2 - specific information 1. Welding process 2, Base metal 3. Diameter and wall thickness 4. Joint design 5 er of beads 6. Electrical characteristics 7. Plame characteristics 8. Welding position 9. Welding direction 10. Time between passes 11. Type and removal of line-up clamp 12. Cleaning and grinding tools 13. Pre-heat and post heat treatment 14, Shielding gas and flow rate 15. Shielding flux 16. Speed of travel 5.4 - Essential variables Welding process Base metal a, <42000psi (290mpa) b. > 42000psi ~ < 65000psi ©. 2 65000psi (448mpa) Joint design (V to U) Welding position (rolled to fix or vice versa) Wall thickness a. <4.8mm b. 48~19.1 mm > 19.1 mm 6. Filler metala. Change from one group to another group (Table-1) b. AWS classification for base material which SMYS grater than or equal to 63000psi 7. Electrical characteristics a. De +ve to de -ve b. Detoac 8. 9. Time between passes (time between the completion of root bead and start of hot pass) 10, Welding direction; Vertical-up to Vertical-down or vice versa 11, Shielding gas and flow rate 12. Speed of travel 13. Pre-heat (if decrease) 14, Shielding fux 15. Post weld heat treatment 5.6 - Destructive testing 5.6.2 - Tensile strength test Length 9” (230mm), width 1” (25mm) 5.6.3 - Nick-break test Length 9" (230mm), width 1” (25mm). Shall be notched with hacksaw on side at the center of the weld. Each notch shall be not more than 1.6mm deep. The exposed area of fracture shall be at least 19mm wide. 5.6.4 - Root and face bend test Length 9” (230mm), width 1” (25mm). Reinforcement and root bead shall be removed and flush with the surface of the specimen, Surfaces should be smooth and any scratches that exist shall be light and transverse to the weld, 5.6.5 - Side bend test Length 9” (230mm), width 1/2” (12.7mm). Specimen shall be machined from each side. Table 2 - Type and number of specimen Diameter No of specimen detail of test (<12.7mm) <4 4 2NB+2R >4~12 8 2t+2NB+2R+2F >12 16 4t+4NB+4R44F ( 12.7mm) <4 4 2NB+2R>4~12 8 2t+2NB+48 >12 16 4t+4NB+8S 6 - qualification of Welder 6.2 - Single qualification: A welder who has successfully completed butt weld at any position e.g. PA, PG, PF, H- L045, J-L045.His qualification range shall be determined according to following essential variables, 1. Welding process 2. Welding direction 3. Filler metal a, Change from group 1 or 2 to group 3 or group 3 to group | or 2 4. Diameter a <2” b, 2"~ 12" ce. > 12” 5. Wall thickness a. <4.8mm b. 4.8~19.1mm ©. >19.1mm 6. Welding position 7. Joint design 6.3 - Multiple qualifications: A welder has to perform two tests for multiple qualifications 1. A welder who has successfully completed butt weld at any position e.g. PA, PG, PF, H-L045, and J-L045. 2. A welder who has successfully completed welds a full size branch, which lay out cut and preparation by welder. Note: test coupon piece diameter should not less than 6” and thickness 6.4mm. Scope: 1, If welder is qualified on diameter > 12” He is qualified on all type of joints, all thickness, all fittings, all Position, all joint design and all diameters. 2. If welder is qualified on diameter > 6” <1 He is qualified on all type of joints, all thickness, all fittings, all position, all joint design and on all diameters less than or equal to the diameter used by the welder in the qualification tests. Essential variables: a. Welding process b. Welding direction ©. Filler metal i. Change from group 1 or 2 to group 3 or group 3 to group 1 or 2‘Table 3 - Type and number of specimen Diameter No of specimen detail of test (S 12.7mm) 4 2NB+2R 6 2t+2NB+2R 12 4t+4NB+2R+2F (12.7mm) <4 4 2NB+2R >4-12 6 2t+2NB+28 >12 12 4t+4NB+48 Non-essential variables Number of passes Line-up clamp type Cleaning & grinding tools Pre-heat (if increase) Diameter (for procedure) Joint design (if minor changes) AWS classification for < 65000psi SMYS of base material as 9 - Acceptance standards Discontinuities shall be considered a defect when any of the following conditions will be exist: 1. Inadequate penetration (IP) i. Individual indication > 1” (25mm). ii Aggregate indication > 1” (25mm) in any continuous 12” weld length iii Aggregate indication > 8% of the weld length in 12” in length Inadequate penetration due to hi-lo (IPD) i, Individual indication > 2” (50mm) ii Aggregate indication > 3” (75mm) Inadequate cross penetration (ICP) i. Individual indication > 2” ii, Aggregate length > 2” in any continuous 12” weld length 4. Incomplete fusion (IF) i. Individual indication > 1” (25mm) ii. Aggregate indication > 1” (25mm) in any continuous 12” weld length th *iii, Aggregate indication > 8% of the weld length in 12" in length 5. Incomplete fusion due to hi-lo (IFD) i. Individual indication > 2” (50mm) ii Ageregate indication > 2” (50mm) in any continuous 12" weld length iii, Aggregate indication > 8% of the weld length 6. Internal cavity (IC) i, Any length of internal concavity is acceptable density of thinnest adjacent parent metal should not exceed. 7. Burn through (BT) i, Maximum dimension > 6mm and the density of the BT > thinnest adjacent parent metal. ii Maximum dimension > thinner wall thickness and the density of the BT > thinnest adjacent patent metal. ili ‘The sum of the maximum dimension of the separate BTs > 13mm in any continuous in any 12” weld length or the total weld length, whichever is smaller. 8. Slag inclusion (IST & EST) a. 22” pipe diameter i. Length of ESI > 50mm (wagon tracks shall be considered a single unless the with of either of them > 0.8mm) ii, Ageregate length of ESI > 50mm in any continuous 12" weld length iti The width of ESI> 1.6mm iv. The aggregate length of ISI> 13mm in any continuous 12” weld length v. ‘The width of ISI> 3mm. vi. More than four IST indication with the maximum with of 3mm are present in any continuous 12” weld length vii, The aggregate length of IST & ESI > 8% of the weld length b, <2" pipe diameter i, Length of ESI > 3times of thinner wall thickness ii Width of ESI > 1.6mm Aggregate length of ISI > 2times of thinner wall thickness and width > half of thinner wall thickness iv. The aggregate length of ISI & ESI > 8% of the weld length Porosity a. Porosity (P) i. Individual pore > 3mm ii, Individual pore > 25% of thinner wall thickness it According to figure 19 & 20 b. Cluster porosity (CP) Diameter of cluster > 13mm ii, Aggregate length > 13mm in any continuous 12” weld 29length i. Individual pore with in a cluster > 2mm. c. Hollow bead porosity (HB) i. Individual length > 13mm. ii Aggregate length > SOmm in any continuous 12” weld length iii Aggregate length of all indications > 8% of the weld length 10. Cracks (C) a. The crack of any size or location in the weld, in not a shallow crater crack or star crack. 11. Under cutting (EU & TU) a. Depth > 0.8mm or 12.7% of thinner wall thickness is not acceptable b. Depth > 0.4 or 6%-12.7% of thinner wall thickness i. Aggregate length of EU and IU combination > 50mm in 12” weld length ii Aggregate length of EU and IU combination > one-sixth of weld length ©. Depth of < 0.4mm or 6% of thinner wall thickne: of length 12. Accumulation of imperfections (AI) Excluding IPD and under cutting, any accumulation of imperfection shall be considered a defect, if: a. The aggregate length > 50mm in any continuous 12” weld length b. The aggregate length > 8% of the weld length , acceptable regardless 10 - Repair and removal of defects 10.1 - Authorization for repair Cracks may be repaired provided the length of crack is less than 8% of the weld length and a qualified repair welding procedure is used, A qualified repair welding procedure is required to be used whenever a repair is made to a weld using a process different from that used to make the original weld or when repairs are made in a previously repaired area. 10.2 - Repair procedure The procedure shall be established and qualified to demonstrate that a weld with suitable mechanical properties and soundness can be produced. This shall be determined by destructive testing, The repair procedure, as a minimum, shall include the following: Method of exploration of defect Method of defect removal The repair groove shall be examined to confirm complete removal of defect Requirement of pre-heat and interpass temperature Welding processes and other specific information Requirmetns for inter pass destructive testing 3b10.3 - Acceptance criteria Repaired areas shall be inspected by the same means previously used 10.4 - Supervision The repair shall be made under the supervision on technician experienced in repair welding techniques 10.5 - Welder A qualified worker shall make the weld 7.2 - Alignment The off set should not exceed 3mm 7.3 - Line-up clamp Ifthe weld will be unduly stressed, the root bead shall be completed before clamp tension is released, With external clamps shall have an aggregate length of at least of 50% of the pipe circumference before the clamp is removed 7.6 - clearance Working clearance around the pipe at the weld should not be less than 16"(400mm) 78.2 - Crown surface shall not fall below the outside surface of the pipe It should not be raised above the parent metal, more than 1.6 mm (1/16”) Two beads shall not be started at the same location The completed weld face should 3mm wider than the original groove widthTHE WELDING INSTITUTE asz asa 2 CERTIFICATION SCHEM: cswip 34 ass : ass: FOR WELDING AND INSPECTION PERSONNEL St : Terminology (B.S. 489) 1. Sketch a sin butt joint anc! @ single bevel butt jot. G2. Sketch a tee joint and indicate for fillet welds 2) Legiengin b) Throaththickness —¢) Root). Tee 03. Complete the neceseary features of the sketch: : ————————_ theee (3) types of fillet welds shape. ss weld metal"? ae. Describe Q5, Whatis” o Responsibilities end Duties of 2 Welding Inspector (BS 5285 : 1876) ‘Oi. Give three (3) main responsibilities of e welding inspector. Q2. Give tnree (3) atirbutes which all welding inspectors must possess. 5. What documents or records should be referred (3 by the welding inspector ? Qs. What are the duties of the welding inspectors ? 5. Should the most up-to-date cade or specifcations be used ? odes and Standards (BS 2693, 4518, 6400, 5500, 5950 & 6295; ASME VII; AWS O14; API14 Gi. List the typical tems to be found in a Cods of Practice. 2 Explain tas meaning of the terms: 2) Shall b.) Should 3. What is meant by the term" concession”? Qz, Does a Code of Practice contain all relevant information ? QS. State the three (3) parties generally mentioned in Codes or Standards + Weld Procedure and Welder Approval 1. State six (6) essentia! variables. ming of "extent of approval "and give five (5) exam 03. Explain the cifference between @ welding procedure specification, 9 procs ‘and e welder approval certificates. Q4, Why are procedures and welders approves 7 5, State tae two (2) reasons for re-epproval of: @) Aw 2 qualification re} procedure) Awe! Mechanical Testin 3 of Weldments (B.S.708 ; 1983) ree ritorn a tensile test te folloving items were progressively recorded: 2) Losd &) Extensica 2) Cross-tec ional aree._ Ifthe origina! length is also kaovin, state whet cen be assessed, a.) Areduced vansverse tensile test b) A radius reduced transverse lest 03, Whatis the purpose of the Charpy test ? 4, Whatis tne purpose of: 2.) Face bend b) Rootbendtest QS, Whatis the purpose of the “nick in @ nick bend test ? az. Welding Specification Symbols (BSEN 22553; AWS 2.4) Ot. Sketch f describe the weld show az. =a 03. Speciiy the wel 08 = do Q3. Describe the following x Review of Steels and M Ot. Nar sought G2. Give exameies of composition of the following 2) Arimming ste! b.) Alow carbon stee! Attcol tion of 2 sta Ge. What is the purpose of the increase Mn content of @ cerbon~nanganes= which should be noted when inspecting virou;TI ass: casio: ast: asi2 + asta: costs: ass caste jon terminates with an (H), what i usu: 4, When an elecirode sper the specified results 7 Q5, What is the meaning Four Factors in Welding Qi, State the four (4) factars which must be satisfied for good welds, G2. What are the mechanical tests which ere usualy used to ensu mechanical properties ? 03, Name three (3) methods of protecting the G4, Describe the metal cizsning requirements req 5, Name two (2) methods of protecting the arc from contemina’ metal from contain .d when making high Manual Metal Arc (MMA) Qt. State the three (3) main welding parameters of the process. . G2. Explain two (2) types of electrical supply and an advantage of each tyes. 3, What type of power source charactaristics is cohsidered essential far MMA for the 2.) Constant curent —_b.) Constant voltage 04. Give six (6) functions of an electrode coating QS. What is the usual composition of tne core wire of an MMA e! Tungsten Inert Gas (TIG) 1. State the welding variables for TIG. 2, What is the type of current used for steels and what is the elacirods polarity ? G3. Whatis the purpose of high frequency... 2)forDO? ——_b.) for AC? G4, Name the two (2) inert g2ses mainly used in TIG and give en advantage for each ¢ 5. Give an advantage end a disadvantage of the process. Review of Defects G1, Name two (2) cra: 02. Give Iplanar defects found within the weld mete! of excess penetration. 03. Sketch ; 2.) Incomplete filled grooy b.) Lack of side wall fusion 2 2, Give three (3) main causes of undercut. QS. Give three (3) possible causes of lack of side well fusion. MIG, MAG and CO; welding (Metal Inert Gas Welding) Qi, Give seven (7) main weking parameters and variables of ine prozt 2. Wat polarity is normally used fer welding applications 7 Q3, State the modes of transfer. 2. State three (3) tems of importance when inspecting @ wire to 5, Which defect cen be quite common when using the short-circulting mode of trea 'a.) Lack of penetration b,) Undercut c) Lackoffusion 4.) Porosit Submerged Arc Welding (SAV) Qi. What are the G2. State three (3) t 3. State three (3) ite 4. State to (2) types of fux used in S. Q5. Give an advanta: in SAW? control weld metal composition in SAVY. ms of 8 flux which require inspection. oi and give brief details of racoa: ach of the faltov! 2) DCVe+ —-b) DOVe ) AC Calibration of Welding Equipment Qi. You have been as output of 2 end voltage readings. dard would you wark for MIG / MAG an don ampere vieved and we ings be tah the most eccurate reedi 7. What causes residus 02. Name the thi a 3. What kinds of distortion result from Qs. State two (2) s of controll 5. How can cesicuat sire: for MIG weldingene TWI Qst7 : Weldability Gi. List the four (4) generel fectors which must be assessed to dete 02. List three (3) types of cracks found in weld_ments and their causes. G3. In which type (composition) of steelis weld decey experienced 7 Q4, How ean the level of hardness in the HAZ be controlled ? G5. Describe the full hest treatment requirement required for ensu level of preni ing that basic el QS18 : Heat Treament of Weldments (2) heat teeaments which may be appli G2, State the maximum temperatures used when heat treating welsr Q3, What temperature is used for tempering weldmenis 7 (Q4. Whatis the objective of Normalizing ? QS. Which heat treement is used when maximum toughness Is required ? S18 : Non-Destructive Testing Qt, Name four (4) NOT methods. ” 2, State te two (2) types of rays used in radiography and a limitation of each, 03, What process uses mechanical vibrations ta detect defects ? Q4, Name @ limitation of MPi 5. What is the maia limitation of using the " dye" 10d of inspection ? as20: Repair Welding Qt. State six (6) points of importance of repair welding, Q2. Sketch a plan end side view of a typical repair excavation, Q3. State to (2) NOT methods that may be epalied to a repair. G4. Atwhat stage would each NDT method generally be used ? QS. State three (3) documents which the inspector should rafer to when cerrying out repa! Q82t : Oxy Fuel Gas Welding, Cutting and Gouging 1. What is the principal limitation of oxylacetylene welding ? o (3) flame types and their respective applications. () typical defects found with oxylacetylene welding G4. Give four (4) typical defects found when cutting using the oxy/fuel proces: 05. Give four (4) points of safety which require inspection when cutting, 9822: Are Cutting end Gouging State three (3) ¢afely precautions that must State taree (3) safety ..... when airfare cutting Wy mus! mechanical dressing follow arc air gouging operations 7 ‘What type of current is essential for arc cutting ? State two (2) methods of plasma arc cutting observed when oxyfere cutting Q823 ; Other Welding Systems 1. Hew is contamination of the weld prev 2. Explain the electro slag process " Mode of Opera 3. State two (2) precesses that use the "key-holing 4, Why would PWHT be applied af QS, State bo (2) solid state processes, Miscellaneous Informations Qi. Give three (3} types of welding v five (5) lypes of fusion weldin: of pre-hesting ? of pre-heating ?THE WELDING INSTITUTE i CERTIFICATION SCHEME FOR WELDING AND INSPECTION PERSONNEL, CSWIP 3.4 AS1 to QS1 Terminology (BS. 489} Oe ons rn Se OS AS. Neces 2) b) Root ¢)_ Linear misalignrtent 6. AS. the quanlity required to fill ajoint. Often re but does not necessarily mean it strengthen ¢ joint AS2t0QS2 : Responsibilities and Duties of a Weiding Inspector (BS 289: 1976) ‘Al. (9) Main responsibiities of Wd liance to standard or code, b,) Ensure viorkmanship including safety ding erievia by ‘policing’ work and docum: AZ, (3) Attdbutes @ W.l, must pos: 2) Honesty end integrity b) ui cc) Physically ft and good eyesight A3, Documents or records @ WI, should referred to: a) Welding codes and appliceble b) WPSIPOR, end WOTR (Welders Qualification Test Recor ©) Constuction and shop drawings d) Certificates of materials end consumables. f) Approved cerificates and calibration certificates 9.) PWHT & inspection records AS, Duties of WL 2) bl <) reivelding operators ar (prior to production welding). 2t all test OT end NOT, i 48, No ASS to QS3 :Twi AS4 to OS4 Al 22. 3, AA. ASS to QS5 : Al A2, Weld Procedure and Welder Approval (6) Essentizl variables 2.) Welding processes / Method of application e.) Welding position 1) Travel sped b). Joint design f) Base material spec's i Filler meal c)) Diameter and wall thickness ¢.) Welding direction k.) Shielding flux !}) Shielding gas & flow rat fh) Elect! énacacteristies precede is the range over which certain variables may alter without requiring 2 nev tof Approval e.g 2) Welding process : Tig (root) - MMA/ SMAW fill end cap) b) Joint type ‘Any butt joint in pipe or plate / fillet welds in pipe or pl c)) Metal thickness 6.35 mm and greater d.) Outside diamete : 25.0 mmand greater €.) Welding position : Any position except vertical down Difference between the ff 2) WPS = An approved and accepted document, (is @ vaitten welding procedure prepared to provide éirection to weldersh It scribe in detail ail the vi employed in the proced in making @ production weld to code require essential and non-essential, to the welding proces: Arracord of the procedure o test. (is a record of welding data used to weld test coupons in accordance contain the test results of tested specimens, Used to support WPS). c) WAC © Qualification of welder to a particuler procedure (A document certifying that a welder is qualified to weld to a specific range of appro. Isconsist of the welders information, date of test, code used, the wield lest detail & of approval including test result (DT, NOT, Visual), and signed by test supervisos, by) POR ers are approved to ascertain their capability ing the code requirement prior to jab assignment. [Or, 2) To prove the procedure necessary req's. with reference to physical, mechanical strength, etc. required and; b) To pr iders ere competent to work in a particular job.) (2) Reasons for r2-approvel of the following 2) Aweld procedure : (1) When there is a specific reason to q procedure to produce sound wetcs. (2) When a weld procedure requires revision on essential variables b) AWelder © (1) When he has not used the specific process for a period of 3mo. or more. Wr ‘employed to some other welding process, the period may be extended to 6 m™ (2) When there is a specific reason to question his ability to make welds that meet specification. iene tion the ability of the Mechanical Testing of Weldments (8.S.709 ; 1983) "Assessment from a tensile test ( 2) Tense strength in Nimin?, UTS, elongation! b) Duettty c) Location and type of flaws present on the fracture surface 2) Location of frecture, whether in parent metal, HAZ oF jount of en ied te termine the place at a speci sure the ductily of th sundress oTwi | [ASS to. QSE : Welding Specification Symbole (BSEN 22553; AWS 2.4) | “AL, Sketch and description ofthe weld symbct seat andes tne aro sie, © dep. | i PA > Surface of the is to be ground flush, A2, Sketch and description of the weld symbet { > A double beval but joint welded on both sides, > Convex fillet weld surface at the arrow side. g « > Ground flush other side of surface. a3. okt Mo 7 (es 409) VY AST to QS7 : Steels and Material Defects ‘Al. (2)Wrought plate defects: Laps b) Laminations ¢) Sear AZ. Composition of th 2) Arimming steel = 0.09950, OS0%Mn + residuals | 5.) Alowearbon stes! = 0.2055C, 0.20 %Mn + residuats c) Atco! High catbon stez!) = 0.80% C, 0.90% Mn + esi fa. campostono! 88.(¢9) rotons SS £2. uae one + reste | b) FeriticS.S, = 121027 %Cr, 008%C + residuals ©) Austenitic SS, (non-magnetic) = 181027%Cr, 008%C, Btoz [Ad Increased in content ofa C-n sletis to increase tousligess, nev AS. Featuresidefects to be noted when inspecting wrought plate nd egadiion, \ ASE to QS8 ; British Standard Classification of MMA Electrodes ( BS 63: ‘Al. Meaning of electrode fa: = st 33 B16 2 1) (electrode) (tensile strength) (toughness) (covers) (etfy.) (post. cap.) ygowtipony | 2. Compulsary pat = £, $1, 33. 8 3, Meaning of the B= basic RR = ruiile (heavy coated), © = oxidizing , ther ty Ad When an electrode specification te electrodes (for low Hs potential), in ox to give the specified results, Svengh, T= Toughness, © = Cover ASS to. QS8 : Four Factors in Welding c "Al. (4) Factors to be satistied for good welds | 2) Fusion = through high intensity heat source to melt metal b) Process gad other contamination from the jeintf i 4) Protection fro nd sur | G) Welded joints must have good end a ure compl foot end side) A2. 1) Victor Har 1 from contamination electrodes (SMA). rielded vires (TIGIMI lar pallets (SAV) 6 rf STAWIGMAN). cc) Using grerAa, AS, Al 42. Ae. AS. rs 22. Ae. Metal cleaning requirement’s when making bi ‘2 Clean rigidly the surface of joint to & 1b). Before welding purge with Nivogen / Helium / Argon 2) Mechanical preparation, use hand globes end clean the weld tods. (2) Methods of protecting the arc from contamination, 2.) By shielding gas b.) By flush purgi [ASO to QS10 ; Manual Metal Arc (MMA) vain (3) welding parameters of the process =) Amperes b) Vatese / «) (2) Types of electrical supply and an advantage of each type Hee «Only needs an open circu voltage of 60 te un alle more current to be drawn, but limited to ‘operation away from mei supe) (6) Functions of an electrode coating 2). To shietd the are by providing @ dense, impenet metal, (This is necessary t0 formation of oxides and nitrides in the weld poo.) } To provide scavengers end gaaxidizers to refine # } To produce a molten slag coating over matten slab are stream, To provide the ionization né ravignite each time Ie goes out, an electrically conduct Potassium compounds in the electrode covering pravice oinia of second, thus, re-igntion of the arc is meintzined.) fe) To insulate the weld to reduce the cooling rate and, helps sh 1) tn tubular core, the iron powider's purpose isto increese the & thus the deposition rate, rable eny jad for AC welding, (With AC. the afc goes out 120K & ath must be the wield contour. jon of the core wire of an MMA electrode is simiar to tne comp aly, 2 Fimming st Usual: material Asti toasit : Tungsten inert Gas (716) ‘Welding variables for THB 2) Welding consumables!) Parent mat €) Gas flow rate e) Shielding ges ¢) Speed of travel hy Filler dd trode polarity used for st ‘Type of eurtent end purpose of bigh Frequency (HF) ey for be is toe the arc: epid E} FerAG isto steblize the arc. Conste © used in TIG ead its advent 2.) Aigon {common bb.) Helium - Argon (at 78/25 1 Adventages of the process 2) Smooth weld profile b) Few typical defects & cl ) Disedvantz: b) Se of travel is safer and allows tthe pick-up of oxygen & nitrogen and the chi 's Curing thelr transfer through tne aintained in the ere Jase0us particles up to a tr xy of vse of the arc he: a of the parentTwi AS12 to Q512 : Review of Defects Al. (2) Crack/plenar defects found 2.) Transverse crack, solidification er b.) Longitudinal erack thin the v crater crack A2,_ (2) Main causes of excess pene! 2) Travel speed too slovr b.) Root gap too wide or ine AS. Sketch of the tf: 2) Incomplete leg goove. ————C_A\Y) (XD f 5) Utskof senator ati wedtee 0 A4, (3) Main causes of undercut a a) Excessive welding current ¢) Unbalanced welding conditions b.) Improper or poor welding technique“ reparation zi AS, (3) Possible causes of lack of side wall fusion : 2.) Adhering oxides 2t th d surface of parentmate! —b.) Narr c.) Speed of travel too fast, 4d) Low current at interpass run, w included eng! AS{3toQS13 : MIG, MAG and CO; welding (Mata! Inert Gas Welding) At. Main welding parameters and variables of the process a) Tiltangle bi) Gas flow ra €.) Wire feed rate .) Wire materi ©.) Heat input Q) Eleodewire@ Shielding gas type 1.) Elac'l. chara: @D 22. Posty nowmaly vsedis OOP. For fx cord ite, se DCE A3. Modes of transfer 2) Spraytrensier b) Globular transfer.) Dip tran: irculting transfer ‘As, (3) Important items to consider when inspecting a wire for MIG vreldi a) Wire size 8 ©.) Condition AS. Common defect on shott-ctcuiting mode oft is lack of fusion (and excessive spatt AS14 to QS14: Submerged Arc Welding (SAW) y A, Welding parameters in SAW 8) Wiefesdrate —b.) ) Travel s 2.) Blu f 42. (3) Items which control weld metal composition in SAW 7 2) Voltage b) Wire speed >>Amp, ©.) Flux type Fi 43. (3) Fluxitems which requl 2) Condition ©) Material composition / Tyse A&, (2) Types of flux used In SAW and iis reco: a) Fused type ; Darkin color and glassy in appearan: produced by melting the ingredients at high followed by crusti granulate the flux. t provide good homogeneity not hygro! to add alloying elements and deoxidizers. 4 sd type : Lightin color end spherical in eane: wler form. (4 gi Inthe form of pellets. [This Is produc (potassium siicate &/or sodium silic xidizers can be easily added. This flux h tered lke low hydrogen el type : Consist of mixture: This provides a lar so identified 8 fellows = Contain oxides of metets whi and thus, must be NOTETwi AS. Advantage and zpplication for each of the F 2) DCVe +{OCRP) ; Obtain deepest penetration wi} bead shape end resistance to porosity i because of high deposition rates. b) Dove - (CSP) : Goodin suracing and cladding because of penetration is shallow + Flust se Sirotion ratios less, therefore, alloying tom fxis reduces : Penetration is shalows oer deposition rate is elaively high when using electrodes jn the form of stip for ig purposes ; Ofer used when welding sees of limites weldatiliy g) AC 1 When ere low is @ problem AC gives batter result than DCR? or CSP tandem are systems (OC electrode as leading electrode and an AC et Used when welding Austenitic s.s. stips S15 to QS15 : Calibration of Welding Equipment ‘At. Tolerance of the following when calibrating the output of a welding power sour 2.) Voltage tolerance = 25% b) Amperage toleranc: 9 23% g measuring device end the standard is NA ‘nis tolerance is echiaved by using celibr (NAMAS means a ) readings in the circu! 3. When checking the welding parameters for ‘could be taken when itis close as possible to the arc but not on the Ad, Yes | Speed can be physically measured. (The wire feed speed is cons! Tee sap increasing the vire feed speed increases the welding curvent so that tne Geposition ret ‘as the welding current increases. |AS, ‘The British Standard for are welding equipment is BSEN - 7570. "In-Service C: of Equios (Code of Practice for Validation of Are Welding Equipment) AS16 to QS16 ; Residual Stress and Distortion ‘Al. The residual stress in welds are caused by unequal expansion cou! inhibiting contraction in weld during solidifying followed by subsea} led with restraint, (Also, du cooling.) |A2,_{@) Directions in which cesidual stresses form in 2 weld 2.) Longitudinal residual stress (2long the weld} 1b) Trensverss residual stress (across the weld). cc} Shontransverse residual stress (Ihrough tne vw AG. Kinds of distortion from each direction of residual stress 2) LS. : Contraction in the weld metal and HAZ slong the b) TRS. : Angular and peeking, Contraction in the weld Ripple away from the weld cc) SITRS.: Ripple and angular. Bov Peaking due to V angle. jue to ore (2) Methods of controlling aistortion. 2) Pre-seting — b.) Welding seque > AS. Residual stresses can be reduced through Fr AS17 to QS17 : Weldability At. (4) Genecal factors which must be assessed 2) Carbon Equivalent Value ( C.E. 'b.) Combined thickness in the joint type. GR) s and their cau: ation cracking Poor ductity iekfess Censi 3experienced is_Ch ‘The level of hardness in the HAZ can be controlled by quenching (Control the inte Contrel the hest treatment by PWHT ; Control the heat input ). Full heat treatment required to ensure that basic electrodes are low in hydrogen, the right setting of temperature and time (350~450 °C), electrode quiver during welding (Heated quiver in small batches @ 70°C), c) Supply welders with electrodes twice a shift to minimize the possibility of mois Gd.) Return unused electrodes to the heated cabinet for overnight starag: the electrodes in the oven AS18 to QS18 : Heat Treament of Weldments Al 42. a3. 6. AS. Al A. Aa, AS. Al 43. 3. (4) Heat treatments which may be applied to steel weldments 2) Annealing b.) Normalizing ¢) Quenching ,..d) Temper Maximum tempereture used when heat treating weldments is £20° C Temperature for tempering weldments is §50 to 700°C. The objective of normalizing isto relieve internal stress, improve mech. pr When maximum toughness is required the heat treamentis Normalizing AS18 to. QS19 : Non-Destructive Testing (4) NOT Methods a) Rediogrephic Test b.) Magnetic Particle Test (2) Types of rays in rediography and a limitation of each a.) Gemma rey (shorter wavelength) : Isotope can'tbe sw b) X-ray : Cracks parallel to film may not show up. Process that u: Limitations of MPI not be use on non-ferrous material ial procedure on sub-surface flaws. Main limitation of OPT is that the datected defects are on the surface oniy A$20 to. QS20 : Repair Welding (6) Points of importance of repair welding 2.) Authorization b) Location c) WP.S. / Welder Qualification 1) Inspect before, during and after the €.) Repair to be inspected / NOT. f) Record methads af removal / repair. Plen end side view of & typical repelr excavation (2) NOT methods that may be applied to a repeir 2) Rediogreshic test b) Ge 2 of e2ch NOT methed On completion of repair (but jit onl). -ept those with coer 2 RT cannot es mechanical vibrations to detect defects is Ukrasonie Test. tection ere critically dependent on alignment across the magnaticfiels rous & non-ferrous) for ¢TI [AS. (3) Documents te be referred by Inspector when carrying oul reFSi® © ‘2) Welding repair procedure. |) Applic 5) Welderlwelding operator qualification record. ¢.) Author ‘ c) Defect report form, n standards jon docum ‘AS21 to QS21 : Oxy Fuel Gas Welding, Cutting and Gouging 'AL._ The principal limitation of oxy-acetylene welding is the mat A2. (3) Flame types and their applications 'a.) Neutralizing flame : For brazing ste 5 bp) Oxidizing flame c) Carburizing fleme (Reducing fieme} For hard-surfacine |A3. (3) Typical defects found vith exy-acetylane welding ¢ : 3) Foo concave tuttweld profile b) Oxidzedwelsface ¢) Ove heate: ‘A&. (4) Typical defects found when cutting using the oxyffuel process 2) Sealing b) Undercut ¢) Oxide herd toremeve 4) Excessh dand rounded edges.) Heavy beading AS. (4) Points of eafaty which require inspection when cutting © ro Sse thatthe pes of material tobe cutis above the alouné (concceteleath) 1a avs exa/08 5) Ensue thet tne ftings ofthe eas end oxvgen tanks are toh: end np leakens ) a) A822 to QS22 : Are Culfing and Gouging [At (3) Safety precautions that must be observed when oxy-2re evita 2). Weer Personal Protective Equipment (PPE), i.e, wear face si ‘avoid UV radiation ; wear adequate protective clothing including w prevent burns cause by hot debris blowin out of cut ) Remove flammable material. Avoid arcing on ar nee’ to oxygen eyhinders $) Use a grounding / earthing strep on the oxygen cylinder. Be avare of possile ‘enrichment in enclosed spaces since many materials wili burn viol Ghorks are dane in an oxygen-enriched atmosphere. ‘Ad, (@) Safety precautions when air-arc outing 2) Inflamable materials should be removed from the work sea b) Protective booths or screens should be setup. €)) Workers should have the proper protective clot to work out-of-position, including eet plugs, especially if they 2 [AS Mechanical dressing must foiow erc ir gouging operation fo remove any carbon Pics-uP (Carbon increases hardness and leads to cracking) AS. (2) Methods of plasma ere cutting 2) Transferred arc (arcis bet 1b) Nonstrensferred are (arc is bat need earth connection). til for arc cutting is D.C. trode end work). electrode end nozzle; Has pilct A823 to QS23 : Other Welding Systems At. Contamination of the weld is prev friction welding by pressure end rotation a Oe tang freon beeen abuzing faces thet results to Rot last zone. Som. of the join wen eny oxides formed et the joint @ ‘excess metal oxide! flesh which me & 22, The electeo slag pr between their eco are added and then produced by thi are retained using ws Electrode is F ed by the atc. The molten fix extinguishes the electricaly resist “clamped agzinst shoes‘ are moved up 25 the o: mal positioned int lecticce wire and the guib) Electron beam welding Ad. PWHT should be after electro slaz welding becat it should be normalized. ing proc: AS. (2) Solid state processes 4) Friction welding ding Miscellaneous Informations : Al. (3) Types of welding with pressure 2.) Resistance welding (Spot, Seam and Projection) b)) Friction welding ) Diffusion bonding A2. (5) Types of fusion welding 2) Automatic m 4) Plasma ere welding c) Las wire guide; cons b) Electron beam weldin 0 slzg (consumabl A3. (2) Types of pre-heat 2) Genaral pre. Local pre-hest Only a sectcn around the weld is elec ce heater. Ad, (3) Purposes of preheating 2) To provide a slower rate of cool preventing excessive hardening b) To provide 2 slower rate of cool present to diffuse away from th ) To reduce shrinkage stresses in highly restrained joints. Generally, the higher the carben content of the steel, the lov ‘greeter the necessity for pre-resting and using lov weld and adjecent bese metal - esp NOTE : AS. Movement of the arc by magnetic forces in MIMA welding is termed Ae blow AS. ‘The coaling which is associated with stove welding is Cellulosic @ shielding gas for TIGis Art He , Ar+Naand Ar He 8, The shielding gas for MIG is Arcon (or Hetium). 3. A common gas mixture used in MIG welding Ni elloys to combine ¢o0d level of 2¢¢ stably would be 100 % Araon (because itis an inen gas), AO, The process that joins metal plastically is Friction weldina bhigh nest input ans torch or through the ertical temp. range (about 1809 °F to 1330 °F}, ad i n with good SAW utilizes Deep penetration characteristics on DCEP (shallow penetration when DCEN) The type of SAW flux thatis more resistant to moisture absorption is Fuss The main usage of arc cutting / gouging eracesses is in the removel of Al7, The eletrode classification thats relevant to AWS A5.1 = 61 is E6013, ANB A.basic electrode would normaly nave Suserior mehanical progeriies end Reauite b: A18. A large grain structure in steels is said to produce Low 420. The likelihood of britle fractur ing before use At ‘contaminate: £22, Hz cracking in A23, BS EN Std, 288 would reier to Welding Esscedure Acoroval (2 A24. Porosity ie caused by Entreoped cas in the solidiving weld 228. The process =i TW |A30. The correct term for e "cap height" is Excess weld metal Jat, the important point of high temperature steels is that They can withstand crseo falure vecheat cracking orcblems and They may suffer loss of tovehness |A82, An nustenite stainless steel may suffer Weld decay , Sensiization and Solidification cracking 435, Cov are uselul to determine Weldabillv esoscts , Cracks sensitiv asoacts end Tysieal mec! R34, Ina bend test, the face of the specimen is in tension end the root isin compression: the Iype 0 carried-out would be ¢ Face bend tes |AQ5. Atensile test will essess sttess and strain (A38, UT is of advantage in detecting Lack of si NDT methods, 3s oreater then 2: .syall fusion over Lack of sidewall fusion 237, The use of Cobelt 2s an isotope would generally be used on Plate thick Iridium (192) on thin materials. 42wis 5 M4 Rav. 03/03 =a) WELDING INSPECTION TRAINING ONLY MULTI COICE PAPER 1 ‘Name: > Date: | /¢ ‘Answer ail questions. (ONLY ONE ANSWER PER QUESTION) 4. When “hydrogen control” is specified for a manual metal arc welding project the electrode would normally be: (a) Cellulosic —— (b) __ Iron oxide a (c) Acid a Se) Basic seu 2. You would with certainty recognise a hydrogen controlled flux covered electrode from its : (a) Colour (b) Length _ (c) Trade Name fey AWS/BS€39 Code Letter — BSEN Hd] 3. When manual metal arc welding is being carried out on an open construction site, which group of welders are the most likely to require continuous monitoring? (2) Concrete shuttering welding teams Ab) Pipe welding team (c) Plater welders Plant mair(a) _ Itis too expensive _ (b) The wire would be too thick ~/(c) The weld metal composition may be wrong (4) The wire is too short _ 5. When open site working, serious porosity in metal arc welds is brought to your attention. What would you investigate ? (a) Electrode type _ {b) Power plant type - /(c) Electrode storage (4) Day temperature 8. The steel composition in a structural contract is changed from 0.15% carbon, 0.6% manganese, to 0.2% carbon, 1.2% manganese. Might this influence the incidence of : (a) Porosity ~/(b) Cracking in the weld area (ce) Undercut for filet welds (d) Lack of root fusion defects 7. One of the following alloys is non-magnetic. Which ? (2) 4.0% Chromium molybdenum (b) 12.0% Chromium -J (©) Austenitic Stainless Steel (d) 9.0% Nickel Stee! Page 2 of 8_WIS 5 M1 Rev. 03/03 8 When TIG welding Austenitic stainless steel pipe, Argon gas backing is called for. This is to ~~ (a) Prevent oxidation _ (b) Prevent underbead cracking _ (c) Prevent porosity _ (4) Control the penetration bead shape a 9. Pre-heating a Carbon steel manual metal arc welding is carried out to minimise the risk of : (a) Scattered porosity _ (b) Worm hale porosity _ \/(c) Parent metal cracking _ (4) Lack of penetration _ EN 2259% 10. In UK practice, B&499-Resk2 specifies that the minimum drawing dimension quoted for a fillet weld is the : ~“(a) Leg length (b) Actual throat thickness (c) Weld width (d) Depth of penetration 11. For open site manual metal welding the following equipment is available. Which would you choose for safe working? (a) Single operator transformer (b) Multi operator transformers (c) AC/DC composite power unit /(8) Diesel engine driven motor generatorA described as flux being usad for a SAW application t flaky. What type of flux would you expect this to bs (a) Basic (b) Acid (©) Fused (4) Alkaline 13. During CO2 welding, the arc length is most likely to be affected by: (a) The wire diameter (b) The current return connections (c) The gas flow rate (4) The torch to work angle 14. Preheating for arc welding applies to: (2) Assembly welding only <7) Assembly and tack welding (c) Joints over 25mm thick only (4) Cruciform welds only sharp 15. You see a welder using an Oxy-acetylene flame with a long feathered inner cone. What would be the effect of this on a carbon steel (a) The weld could be hard and brittle (b) The weld metal could be too soft (c) There will be no effect on the weld (4) The weld will have undercut Page 4of8 \8WIS 5 Mt Rev. 03/03 16. Awelder qualification test is to verify: ~~ (a) The skill of the welder _ (b) The quality of the materials ae (c) The non-destructive test procedures _ (4) The manufacturing methods a 17. A fabricating procedure calls for fillet welds to be "blended in” by grinding. This is to: (2) Remove Hydrogen cracking foes 71) Improve fatigue life _ (c) Remove undercut ee (4) Improve yield strength _ 18. Bend test specimens have been taken from a 25mm thick,carbon steel butt weld. Which would show lack of inter-run fusion: (a) — Side bend a (b) Root bend _ (c) Face bend —— (@) Guided bend ae 19. Lamellar tearing has occurred in a steel fabrication. Before welding could it have been detected by: (a) X-ray examination (b) Dye penetrant _ (c) Ultrasonic inspection ene ~ (d) It would not have been found by any inspection methoddmium pia’ Would you! (a) Permit it to proceed ee (b) Permit it to proceed with fume extraction _ Z(c) Stop the operation at once oes | (4) Advise the welder to drink milk and proceed _ 21. Whats the leg length of a fillet weld? (a) The distance from the weld face to the penetration _ (b) The distance between the two toes _ (c) The distance from the original root to the toe _ Y (a) The distance from penetration to the weld toe fens 22. The term duty cycle normally refers to: (a) The shift pattem of inspection staff _ (b) A monthly occurrence involving outage time _ Yc) Output capability of a welding plant_ é : So (@) Component life expectancy . eae 23. The throat dimension, measurable from the surface, of a mitre fillet weld having equal 20mm leg lengths will be: (a) (b) v () (4) Page 6 of 8 25mm —_— 17mm 14mm It cannot be determined form the information provided 20What is a typical carbon equivalent in carbon-manganese steel used for pipes or fabrication purposes? 4%. 0.54%, 0.33%. 0.12%. aes Why is pre-heat sometimes carried out on steels? a. To remove moisture from the weld preparation. b. To retard the cooling rate of the weld. c. Toaid fusion between weld metal and parent material, / d. Allof the above. 13. 14, al ~b. 2. 3. 4. 15. Whai criteria are necessary to produce HICC? a. Hydrogen, moisture, martensite and heat. b. Hydrogen, poor weld profiles, temperature above 2000C and slow cooling. c. A grain structure susceptible to cracking, stress, hydrogen and a temperature below 2000C. d. Weld defects, perlite, hydrogen and a temperature above the melting point for the material being welded. How many temperature indicating crayons would be required to ensure a pre-heat temperature was lying within a specified range? As many as possible A carbon equivalent of 0.5%: “a, Ishigh for C-Mn stee! and may require a pr-heat over 100°C. b. Is generally insignificant for C-Man steels and is certainly not to be taken into consideration for pre-heat temperatures. c. Is high for C-Mn steels and may require a pre-heat temperature over 300°C. d. Is calculated from the heat-input formula,16. Ina martensitic grain structure what would you expect to ine: a. Ductility. Vb. Hardness. ©. Toughness 4. Allof the above 17. Which of the following is not a type of crack? a. Fissure, ~ b. Lamellar tgar. Yc. Fish ove 23 d. Hot tear. F 18. What do you understand by the term minimum interpass temperature? 2. Minimum post weld heat treatment temperature. b. Minimum stress relief temperature, ©. The lowest temperature to be used during pre-heat, 4. The lowest temperature allowed during welding and between weld passes, 19. Which of the following welding processes may be described es a low hydrogen process in comparison to MMA welding? a. TIG/TAG. b. MIG/MAG. &. MIG/MAG (hollow wire/flux core). V& Bothaandd. ¢. AH of the above 20. Pre-heat prior to welding: out on steels. carried out if post-heat treatment is to follow welding. Is always catried out using gas flames. Yd. None of the above. os #3 ai g! zWis 5 M4 WELDING INSPECTION TRAINING ONLY MULTI CHOICE PAPER 4 20 questions total Name: Answer all questions. 1 Which of the following would be a typical MAG, individual pass, heat input (2) 1.2jmm (be) 65 kimm (©) 6.5 kimm __ () 1.2 kim, __ 2. The term “Skip” refers to what in welding/fabrication terms ? (a) Aproduction scheduling term (b) A secure location for quarantined goods (c) An Australian marsupial (4) Arun sequence 3. Aprtod may be used for which NDT process (a) Eddy current (b) Radiography ia (c) Ultrasonic testing. (4) Magnetic particle inspection 4. Which of the following is a typical electrode classified as E7016 according to AWS 5.1 (a) Iron powder electrodes (b) Rutile electrode (c) Cellulosic electrode (4) Basic electrodea During TIG welding the arc vottage is controlled by The welder The voltage control on the power source The power source giving out a constant voltage , The electrode polarity 29o9 5. Which one of the following statements is correct: (2) SMAW may use either AC or DC (©) GTAW may use either AC or DC (c) SAW may use both AC and DC (d) Allof the above 7. Suckback is a commonly slang term used to describe: (a) Lack of penetration (b) Root concavity (C)— Underfil (d) Incomplete root penetration & Atypical temperature specifically for hydrogen removal for a carbon — manganese weldment is: (a) 150°C (b) 600°C (c) 350°C (d) 900°C 8. Atypical angle of bevel used for MAG welding 12mm carbon steel could be: (a) 120° (b) 35° (c) 70° (d) 90° 10. In arc welding processes, excess weld metal Profile is mostly affected by: (2). Arc length (b). Open circuit voltage (). Amperage ~ (d). Root gap Page 2 0f4 to BreWIS 5 Ma 13. 14. “Autogenous welding” basically means: (@) Fully automated process (b) Fusion welding (c) Fully mechanised process (@) Welding without filer wire According to ISO 2553 which of the following symbols represents a permanent backing strip:- @ [ me | a wo [ ™ db.” () | PB (d) None of the above aoe Which of the following radioactive terms do we not normally associate with NDT (a) Gamma (©) Cobalt 60 (2) Thorium (2) Iridium 192 Which submerged arc flux may be described as “powdery” or “ball like"? (a) Basic (b) Fused (c) Agglomerated (d) Acida 47. 18, 19, 20. Page 4 of 4 During visual inspection of a fil fh aven leg lengths of 15mm anda throat measuray f 9mm. Ss ble. The weid profile is: (a) Concave (b) Convex () Mitre (4) Not able to be determined Which of these statements relating to carbon steels is false : (2) High heat input results in high hardness 0 (0) High heat input may result in large grains (c) Loss of toughness may result from weaving (d) Toughness may be restored by normalising Which of the following parameters presents the welding inspector with the greatest difficulty to monitor during fully manual welding operations? (a) Current (0) Travel speed (0) Arclength (4) __Interpass temperature You are the only welding inspector overseeing 4 welding stations, producing Gieumferential single V butt welds on a pipeline, For which of the foliowing Stages would you consider your closest scrutiny to be required? (2) Completion of capping run (b) Cleaning of completed weld (©) Radiography (4) Root pass deposition Which of the following processes would be Potentially most capable of Producing weldments that are low in Hp (a) MMA using basic type electrodes (b) SAW using correctly treated flux (c) Electron Beam (d) Mic Which of the following tests would you normally not expect to be performed during a welder approval test? (a) Bend (b) Nick break (c) Macro ~ (4) TensileWis 5 M3 Rev. 03/03 WELDING INSPECTION TRAINING ONLY MULTI CHOICE PAPER 3 Answer all questions. 1. The BS EN code for welder approvals is: (a) BSEN4872 __ (2) BSEN499 aoe (c) BS EN 287 _ (4) None of the above 2. A Code of Practice for Visual Inspection should cover the following: (a) Before, during and after welding activities (b) Before welding activities only (0c) After welding activities only (d) None of the above 3. Incomplete root penetration in a butt joint could be caused by: (a) Excessive root face width (b) Excessive root gap size (c) Low current setting VY (d) BothAac(@) Linear misalignment (5) Incorrect tilt angle (c) Differing root face widths of (dq) Allof the above 5. Which of the following tests would you normally expect a test house to use for the assessment of HAZ hardness, for procedure approval in the UK: (2) Rockwell () cToD (°c) Brinetl ¥ (a) Vickers 8. You notice a very “ved” ripple shape. This may indicate: (a) Poor consumable choice (0) The use of a fully automated welding process (Cc) Excessive travel speed Yd) Bothbande 7. “Toe Blending’ is important as it may affect: (8) Toughness 2/(b) Fatigue life (c) Penetration (4) Allofthe above Page 2 of 8 9WIS 5 M3 8. _ Slag inclusions may occur with: (a) Manual Metal arc {b) Metal Inert gas (©) Submerged are welding 2 (d) BothA&C 9. —_Undercut may be caused by: @) (b) () od) Excessive amps Excessive volts poor weaving technique in vertical position with MMA All of the above Rev. 03/03 10. Which of the following materials would be considered to represent the greatest problem from a weldability aspect when using SMAW: (a) 2(b) (o) (d) 11, The abbreviation PQR is otherwise known as: (a) a“(b) (c) (d) Carbon Manganese with CE of 0.28 Free machining stee! Carbon Manganese with CE of 0.45 Low carbon steel Provisional Qualification Record WPAR, Personnel Qualification Record wato/(d) 13. Weld samples prepared for micro Change the properties of the weld Influence the visual acceptability Require re-approval of a weld procedure All of the above which of the following levels: (a) (6) (o) of (d) 14. When visually inspecting a fillet weld, it would normally be “sized” by: (a) (b) (c) v (d) 1200 grit 500 grit 3000 grit 3 micron The leg lengths The actual throat thickness ‘The design throat thickness BothA&c 15. Which of the following relate to the term “planar defect” (a) Page 4 of 8 A lamination A serious defect likely to lead to failure of the product Slag inclusion Both a and b examination would typically require a finish toWIS 5 M3 16. 17. 18. 19. Rev. 03/03 Penetrant inspection and magnetic particle inspection are mainly used to: (a) Aid visual inspection (b) Because the application standard says so (©) To confirm ‘visual uncertancies” (a) Allofthe above Defects outside of the limits specified in a standard should always be: (a) Repaired 2/(b) Reported to “a senior person” (c) _ Radiographed (4) Allof the above When MIG welding aluminium alloy in the overhead position which current type would normally be expected to be used: (a) AC (b) DC negative (ce) Drooping 3/(d) DC positive Manual metal arc electrodes can be grouped into three main types. These are: sf (@) Basic, cellulosic and rutile (b) Neutral, cellulosic and rutile (c) Basic, cellulosic and neutral (4) Fused, agglomerated and basicWhi ‘allowing detectable by Radiography: (2) 2mm ceepiamm tong centretine cracking in weld root (6) 200 mm tong Lamination _ (6) 10 mm deep lack of sidewall fusion on a single U butt _ (4) Gas poor 1.5mm g ae 21. Cracks in welds may be due to: Solidification problems ee (b) Hydrogen problems a (C) Excessive stresses a x (d) — Allofthe above _ 22. Welding a single V butt with laminations Showing on the sidewall may give rise to: (@) Lamellar tearing ¥() Solidification cracking eos (C) Martensite ae (6) Undercut a 23. With reference to a root penetration bead, you could certainly assess: (a) Root fusion and penetration _ (b) Toe blend (9) Overlap _ e/ (a) Allofthe above a 02. Page 6 of 8wis 5 M3 Rev. 03/03 24. A welded product has failed in service. This has been confirmed as being caused by material overload due to a design fault. What would you expect the appearance of the fracture surface to be? $/(a) Rough and torn oT (b) Flat and crystalline (©) Flatand very smooth == a (@) Showing beach marks / 25. “Stray arcing’ may be regarded as a serious defect. This is because: (a) __ It may reduce the thickness dimension of a component (b) It may cause liquation cracks ee (c) It may cause hard zones eee (d)__ Allof the above __ 26. Overfap in welds is : (a) Anon planar defect (6) Where the 2 plates to be joined are overlapping >“(c)__ Lack of fusion defect found in the root or cap region (4) Another name for linear misalignment 27. Flame cut edges would normally be required to be ground back to a distance specified in a procedure because: (a) _ Ifthe HAZis left on the prep it may result in weld decay In service (b) The HAZ would have become sensitised (©) There's a strong potential for hardening in this region (4) To reduce weight loading on the completed structureion require (@) Once, after etching Ab) During preparation and after etching (©) Using a microscope (4) By penetrant inspection 29. Which of the following may be classed as a “more serious defect”: {a) Slag inclusions (b) Fusion defects (interun) M0) Fusion defects (surfacej (d) Porosity 30. A code of practice is: (@) A standard for workmanship only ob) Asset of rules for manufacturing a specific product (c) Levels of acceptability of a weldment (d) None of the above Page 8 of 8Wis 5 M2 Revosio3 WELDING INSPECTION TRAINING ONLY MULTI CHOICE PAPER 2 Name: 2: Answer all questions. 1. Movement of the arc by magnetic forces in MMA welding is termed: (a) Arc deviation eee (b) Arc misalignment _ “() Arc blow 5 (d) Arceye _ 2. Ametallurgical problem most associated with submerged arc welding is: (a) Hydrogen cracking in the HAZ s“(b) Solidification cracking in the weld metal fcaeenee (c) Hydrogen cracking in the weld metal (d) Lamellar tearing in the weld metal 3. Oxy pressure and nozzle size would influence what in flame cutting: (@) The temperature required for cut initiation (b) The ability to cut stainless steels ¢“(c) The depth of cut obtainable (d) None of the above 35@) Ao) © (a) 5. Which of the following processes is Not a fusion welding process: vl) (b) (c) (a) ‘The cutting of single bevel preparations The removal of deposited welds The cutting of single U-type preparations The cutting/gouging of non-ferrous materials only Friction welding Resistance welding Plasma welding Allof the above 6. Which electrode classification would be relevant to AWS A5.1-81 “ay £6013 (b) £5133 (c) E 433NR (d) £22553 7. Which of the following MMA electrode coatings is associated with welding: (2) Rutile xv (b) Cellulosic (©) Fused (¢) — Pipetex Page 2 of 8 36wis 5M 2 Revo3/03 8. A common gas/mixture used in MIG welding nickel alloys to combine good levels of penetration with good arc stability would be: (a) 100% CO2 2b) 100% argon = (©) 80% argon 20% CO2 (4) 98% argon 2% oxygen a 9. The type of SAW flux is more resistant to moisture absorption is: (a) Fused ee (0) Agglomerated ee (c) Basic — (4) All of about the same resistance _ 10. The flame temperature of oxygen/acetylene gas mixture is given as: Ka) 3200°C (6) 2300°C (ec) 5000° (4) None of the above 11. Alarge grain structure in steels is said to produce: (a) Low ductility values _ Ab) Low fracture toughness values eats (c) High fracture toughness values (4) High tensile strength(@) _ Alarge grain formation (0) A reduction of in-service temperature to sub zero levels (c) _ Ferritic rather than austenitic steels f the va) (b) (co) (d) following upon contraction of the weld. Id Solidification cracking Hydrogen cracking Intergranular corrosion = Stress corrosion cracking 21. Awelding procedure that has yet to undergo testing is referred to as: @) (b) (6) Sd) WPS _ WPRT _ WPSut ee None of the above _ 22. SMAW welding equipment is said fo have an output characteristic that is: (a) ~ (b) (c) () Flat ——— Constant current ane Constant voltage —_ Either b ore eae 23. Which of the following materials is most likely to require the highest levels of Cleaning immediately prior to welding: @ () “o) (a) Page 6 of 8 Low carbon stee! _ Carbon manganese steel Austenitic stainless steel a All about the same“. wissM2 Rev03/03 24. What is the maximum allowable Hi/LO for 8mm material if the code states the following- “Linear misalignment is permissible if the maximum dimension does not exceed 10% of t up to a maximum of 2mm” (a) 2mm _ (b) 8.8mm ees Ac) 0.8mm — (4) | could not sentence this defect as an incorrect term has been used 26. When visually inspecting the root of a pipe weld, in a single V butt, with the cap ground flush. You have identified root concavity, which has a depth of 0.5 mm. The application standard you are using contains the following statement: “Root concavity shall be acceptable provided the density of the radiographic image does not exceed that of the parent material” Which of the following is correct: {a) You must have the pipe radiographed (b) Sentencing may only be performed by a qualified radiographic interpreter a/(c) It should be rejected (d) You should accept, as there is no radiograph to view 28. Which of the following statements is correct regarding gas welding low carbon steel: (2) __Itwill give a low heat input (©) Acetylene or propane are normally used as fuel gasses (c) A low skill level is required to produce sound welds 2/ (a) Itmay be used for autogenous weldingyot using giv netration allowance: h < {mm +0.6b up to a maximum of mm (Where “h” is the penetration height and “b" is the Penetration width) Which of the following root heights is acceptable? SF (a) -h=0.5mm b=5.0mm (b) h=46mm — b=6.0mm () h=38mm —b=4.0mm (4) None of the above 28. — Which of the following statements is correct: (@) Copper inclusions are usually grouped with slag and other Solid inclusions for sentencing purposes (>) Undercut lengths at both weld toes in the same longitudinal Location are added together for sentencing purposes (©) Ameasurement for maximum penetration height is always specified in Application standards ¢ (2) None of the above 8S EN 22553 29. According to-RSMEEKFa weld on the “other side" is shown by a symbol: (a) Onthe dotted line (©) Below the reference line (©) Onthe solid fine (4) Above the reference line $0. What defect would appear as “bright white specks” on a radiograph? (a) Gas pores (b) Slag inclusions (ce) Tungsten inclusions (4) Undercut Page 8 of 8EXTERNAL DEFECTS Defecis Noted Code or Specification Reference Defect Type PipePlate | Accumulative | Maximum | Section! | Accep¥Reject 5 Section Total | Allowance | Table N° 2 aes 4 5 Excess Weld Metal (Height) 3. | 3 | 8 AcceeT * | Bxe8ss Weld Metal (Appearance) rox Aeoeiue| So00TH ge eerecT _| Incomplete filling «| 65 GeBone)| Nowe Ss RETECT Tnadequate Weld Width (7/76) _ wa = -_| Slag Inclusions [« 27 Fuca ceugrs| 50 9 REFECT [Undereut ; an eae ZL G ACCEPT. Surface Porosity 5 Woe, = = ACERT Cracks/Crack-like Defects 4 L Nowe Z _AESECT Lack of Fusion ” Go 6 | 3 4ETECT ‘Are Strikes NONE = ACCEPT Mechanical Damage ” Tawa |r sta7eo | accerT®| Taps/Laminations — i (Nowe = = Acer Misalignment : ” Os i ACCEPT. [Congiudinal Seams p=) Wale = £6= = t | i Vear Mewok ROOT DEFECTS Misalignment Ane | O-5 O-8 (S| AecerT Excessive Root Penetration 5 7, 2 “13 RETECT. Lack of Root Penetration fi wows | = Accen7 Tack of Root Fusion 39 go | 4 herecr_| Root Concavity | Wen = = AccerT Root Undereut 7 Mine =a AecErT Cracks/Crack-like Defects — ane Wowe. = ACCEPT Slag Inclusions . Ent Hose ceria) 9 he Ste T [Porosity 7 «| nome | Acca Laps/Lamiaations 5 ONE = AcceeT 6¢ WELD INSPECTION REPORT/SENTENCE SHEET Sheet 3 of 3 PRINT FULL NAME A. STUDENT Key L ECIMEN NUMBER GC Ale DIMEDE IONS fot tm This “ Bige /plate has been examined to the requirements of (code/specification) Tent [atts 01-200 fer) and is Apggppgatrejected accordingly. sue Lh fathede Dat AEA “Delete which is not applicable Use the other side for any comments= (OFX topwoyase yy) 0c0 I OUOVN ONINIVEL6c WELD INSPECTION REPORT/SENTENCE SHEET. Sheet 3 of 3 PRINT FULL NAME A. STUDENT key L SPECIMEN NUMBER OC Ala Dteasoib tort tnt tame EXTERNAL DEFECTS Defecis Noted Code ar Specification Reference f Defect Type Pipe/Plate | “Accumulative | Maximum | Section’ | AccepyReject . Section Total Allowance | Table N° e 1 2 3 4 5 Excess Weld Metal (Height) Ane 3 3 eB Accer7 _ | Excbss Weld Metal (Appearance) «oe Horne! Socotra | & eerecT Incomplete filling ” 65 Ce3one)| Nowe S eTECT Thadequate Weld Width (azzz) | A/p = = = ea Slag Inclusions a 207 Foss Cengin| SO 9 RETECT f Undereut ” 150 x / f 6 Accery t Surface Porosity “ wows | = = ACCEPT : Cracks/Crackelike Defects fi 7 none | 7 Recee7 Lack of Fusion ” GO “8 | 3 éjecr | ‘Are Sirikes| = wone | = ACCEPT fr Mechanical Damage ” Lagan \Me7 Sta7ea | Accer7® ‘ Tapa/Laminations rae | Care = Acceer i Misalignment = Os O-8 iS Acceer Longitudinal Seams (pipe) WA eS = = — i Lo ' % veny Miwok ROOT DEFECTS [Misalignment Ane Og (S| AccerT 7 Excessive Root Penetration 2 “3 eezécr _| i Tack of Root Penetration Fi = = Acceer_ > [Lack of Root Fusion : oo (0 | kesecr_| Root Concavity D mee AccerT Root Undercut . | — Es ACCErT ¢ Cracks/Crack-like Defeats . Nowe = = AccerT Slag Inclusions oe Pat cenval! 56 q RETEET Porosity “ none |= - Acceer n [ Laps/Laminations |_- NONE = = AccepT This * Ege /plate has been examined to the requirements of (code/specification) and is Aspepzaatirejected accordingly. Signature, Ch Sfuteat: . Date on M2 AM, JE, “Delete which is not applicable Use the other side for any commentsPlate Inspection: Acceptance Standard & Ref. TWI-N/WIS-PI-sentence Rev2 a IMPERFECTION REMARKS | LIMITS FOR DESIGNATION IMPERFECTION Ee (see Key below) _| 1_| Cracks [all types of cracks not permitted 2, | Porosity/Gas pores/elongated Gas cavities [wormholes}/pipes cluster: max. dimension of area | single pore; max. dimension 3mm max. mm max. 3_| Lack of sidewall fusion sum of total length in weld face Smmmax. | 4 | Overlap sum of total length in weld face (mm max. 3 | incompletely filled groove - not permitted 6 | Undercut (face & root) smooth transition is required D=Imm max. 7_| Are strikes/stray flash E not permitted: 8 | Excess weld metal * “Smooth transition is required and all runs_| D = 3mm max. shall blend smoothly ‘inclusions (slag and silica) sum of total length for weld face (or root) [10 | Lack of root fusion sum of total length in weld root 11 | Lack of root penetration ‘sum of total length in weld root 12 | Root concavity/shrinkage groove 13 | Excessive penetration * ‘D=2mm max. 14 | Mechanical damage Gependent on extent & severity seek advice (make your own | “judgement) | 15 | Linear Misalignment high/low D=10% t max. * when linear misalignment is present, excess weld metal and excessive penetration should be measured from the lower plate (as shown below) ‘ Gicess weld metal height ‘ x t excess penetration bead height KEY L length of designated imperfection D depth or height of designated imperfection t _=plate thickness Document Ref: CIM: Word-Proformas-WIS-PI-Sentence-2001-2 Gs6c VISUAL INSPECTION PLATE REPORT Name (Block capitals), A stiment Signature Zee Welding process_ A ion used_XKX PA_Chown/andd) Length & thickness of plate 29°F 5 @man ALE Dimevsievs ww mm Feon Ews A Date__X%_ x XX. WELD FACE varpaacer ber of Fine Rives Ge SHH TOOT ES ste yp 200 Oe a 295 —sherome oed oeecur - ae, aw adele aw a 2 | osarien deep Taba Fee curse at 2aeap + bacn ce Sime 7 —4S| Wa. Fosse Unb ecor X Riso Suge? rien GEVELAL Commun ri Excess Wem Meme In. oat a, e> 1 I~ Bonn, OF NUMBRCUS TaAAvEnse > pry 14 mm Canc IW rH Aaed Wer PRornc Uvevev Toe Bimd Snagozs —>| MISALIGNMEVT 0.5m PN TEAMTTaN? SCRE Arm SPATIEL Down ROH TORPlate Inspection: Acceptance Standard Ref. TWI-N/WIS-PI-sentence TWI Rev2 (# IMPERFECTI REMARKS | LIMITS FOR DESIGNATION IMPERFECTION (see Key below) 1 | Cracks all types of cracks not permitted 2 | Porosity/Gas pores/elongated | cluster, max. dimension of area L= 13mm max. Gas cavities [wormholes]/pipes _| single pore: max. dimension Imm max. [3 [Lack of sidewall fusion ‘sum of total length in weld face 15mm max. 4 | Overlap sum of total length in weld face L=30mmmax. | 5_| Incompletely filled groove not permitted 6 | Undercut (face & root) smooth transition is required D= Imm max. 7_| Are strikes/stray flash not permitted 8 | Excess weld metal * smooth transition is required and all runs | D = 3mm max. shall blend smoothly | 9 [Inclusions (slag and silica) ‘sum of total length for weld face (or root) | L = 50mm max. 10 | Lack of root fusion sum of total length in weld root L=30mm max. 11 | Lack of root penetration sum of total length in weld root L= 15mm max. 12 | Root concavity/shrinkage groove _ D=2mm max. 13 | Excessive penetration * - : ___ | D=2mm max. 14 | Mechanical damage dependent on extent & severity seek advice (make your own | _ judgement) (15 [Linear Misalignment high/low _ D= 10% t max. * when linear misalignment is present, excess weld metal and excessive penetration should be measured from the lower plate (as shown below) length of designated imperfection jepth or height of designated imperfection late thickness ‘excess weld metal height Document Ref: CIM: Word-Proformas-WIS-PI-Sentence-2001-2 3© 66 WELD INSPECTION REPORT/SENTENCE SHEET Sheet 3 of 3 PRINT FULL NAME A. STudENT hey. t SPECIMEN NUMBER GC Ake DIMEN IONS (at tom EXTERNAL DEFECTS Defecis Noted ‘Code or Specification Reference [Defect Type Pipe/Plate | Accumulative | Maximum | Section’ | Accept/Reject Section Total Allowance | Table N° 1 2 3 4 | 5 Excess Weld Metal (Height) | 4-c 3 3 ge AccEeT Excess Weld Metal (Appearance) [ws 2 Meorne| Sooora | here Incomplete filling w OS Cx3eue) Nowe S EJECT. Tradequate Weld Width (77) _| AJA = = = = Slag Inclusions [Ear fusca) SO 9 eerecr Undercut ~ au [50 x7 Z 6 ACCEPT * Surface Porosity f wowe | — = ACCEPT Cracks/Crackclike Defects 2 7 wowe | 7 RETECT Lack of Fusion ~ | 60 & 3 ETECT. Are Strikes * None =- | - AccEPT Mechanical Damage z 7 aeea__ [MP StaTED | — necerr™ Laps/Laminations i =f = Accery. Misalignment “ O-6 “Ss ACCEPT Tongitudinal Seams (pipe) W/A = = = VERY Mick ROOT DEFECTS Misalignment A-C O-8 77 AccerT Excessive Root Penetration 5 2 73 RETECT | Lack of Root Penetration «| a a (Acceet Lack of Root Fusion * GO 60 _RETECT Root Coneavity - Sle To Root Undercut a — | — | Aecerr Cracks/Crack-like Defects . = | — ACCEPT Slag Inclusions —__ (ee So | 9 ereeT_| Porosity TT ae |e AccerT _| ([Taps/Laminations = = Acer This * Bfge /plate has been examined to the requirements of (code/specification) Ex LMS —0 ~200/ far) and is Segpppiatlrejected accordingly. Signature. OS tulek,, Date... 2X2. Xs. 4X. \ 7) not applicable Use the other side for any comments “Delete whicl & 5VISUAL INSPECTION PIPE REPORT Name [Block capitals] Signature, Pipe Ident? £7 Welding Process_ “774 Joint type Svece -VE. Code/Specification used__ Your 2. ‘Welding position__“C_ (2G) Outside @ & Thickness 2/9x 7 Date Wor. 02 WELD FACE In rénniTenl SPATIER ont weed § a Ske > g g Pl | es: A § 7 a Inreemiprea? MvencuT ~ 60TH S/dés\ ‘ no Se Aaa 75 7. A 5 | FN ne Veny SHascons Uwoencur LIGHT GRIND maktS ON GOTH C/DEL Loe OF weed Excess weed mera: 3 har, Ext£ss Weed r1érae : SD hoax, Foe beend: Shor Toa RLEnD SM0ery Wien WidTel 12 CO ALLS WIOTH , CEI Lintak KS Aerenmtin7T * OS wmrax LignT Cade on hort) o10é¢ oF ALL Ie rbarisren7 Unigene g? 7 hace. 0 Fuconnetté faa Of INTERMITTENT UNDERCUT 4 SH D Sey tiaie dsch | Ey so | <0" 72 bs <€ 2 sseeceseesseseseetitieeE _ 23 fac ane ANTE RUTTEN F UNDERCUT. Maw. O-$ 7| Stewe Stake Excess bbed erm : bt mex. Exckis weed wenn: 3 ; Tos beénwd © Shro07H Foe BLEND £ Seevezy KELO WIDTH L126 Lites wreirt - 12% bp 6WELD INSPECTION REPORT/SENTENCE SHEET PRINT FULL NAME SPECIMEN NUMBER A. STUDENT oc Abe DIMENSIONS Lal tom ae Sheet 3 of 3 Key L EXTERNAL DEFECTS Defects Noted Code or Specification Reference Defect Type ‘Accumulative | Maximum | Section! ] AccepUReject Section Total Allowance | Table N® 1 2 | 3 4 3 Excess Weld Metal (Height) A-c 3 3 gz ACCEPT Excess Weld Metal (Appearanei “ oot Fhofiré| SAooTH & ReTecT Incomplete filling ” 6S ledeng)| Nowe Ss Be secT Inadequate Weld Width (772) | Ja 5 = = = Slag Inclusions « INT Fuss taney! 50 qa RETECT Undercut ” 150 x / i @ Accery Surface Porosity fa NOME mae = Accer7 Cracks/Crack-like Defects « / None / RETECT Lack of Fusion 5 GO 1S 2 KésecT | Are Strikes “ NONE = a BCCEPT ‘Mechanical Damage 7 (een |NeF Stared = AccenT® Laps/Laminations Ai Nowe -_ | — Acer Misalignment ” OS OF a AccérT Longitudinal Seams (pipe) N/A — = = = M Veny womoe ROOT DEFECTS [ Misalignment A-C_ |. 0-5 O-8 1S AccepT Excessive Root Penetration L- 6 2 (3 | Kezecr Lack of Root Penetration ” Nene: = aa AccerT \ Lack of Root Fusion B 37 | go 0 Kerecr Root Coneavity ~ : Nowe - ji - ACERT ‘Root Undercut 5 Mie = = ACCECT Cracke/Grackclike Defects ‘ Mone = = Accerr Slag Inclusions on [RE Aeeesnl 50 FF KETECT. Porosity “ AONE = = AccErT Laps/Laminations . None = = AcceeT This * Bge /plate has been examined to the requirements of (code/specification) 7 7 q! and is Aspeptgei/rejected accordingly. some (LS fatbuct “Delete which is not applicable Use the other side for any comments Date.... 5 G a Laas ~ 01-2001 fev |£ VISUAL INSPECTION PLATE REPORT Is) A- CHANGER Signature a ee Test piece ident__2/ Code/Specification used ZA (MES “AL Welding process “4A (111) Joint type Sings Mee burr Welding position “C (feer2-- yen.) Length & thickness of plate 300x//mm Date 0/+/2-0. £ g ti a g WELD FACE “4 Mine sy a ¥| 3: a ¥ San gf 5 5 fs ge gs ¥e ‘ ay gs CATE Tinos, bo 3 Zebgnurtens searten on = 2 ba, 6. i70|>_ | /¥0 FACE 80TH Tees 295) 3 ° 8 4o——a] fel q | 95 5 Wea y Rate 15014 al a ze 4 Pee Sine ar weed Toe Lack of Sidenmee SHRP TOE BAEXD— Pass/bLé OVERLAP Fusiin € Incempusieey PORE 2:0 DIA. Arectd Stas ve FEUELAL COMMENTS eee ExCESS HELI METAL: 35 max. 53 | DAMAGE R 2-S Der Toe BLEND? SpispactoRy (éxceor HEEL SHown ) “INR MUMIGAMENT > 2. | Xr ANG ULNk OISTOR TION NOTE 7 a= (TX op¥ayrUBETA) 0 ¢€0 I OUDVW ONINIVELName (Block capitals) 2- CHANGER. Code/Specification used ZA | FHL [bits CE VISUAL INSPECTION PLATE REPORT Signature, a Koamens Welding process “4A _(//1 Test piece ident__2 1 Joint type Since Vee burr Welding position “C (4og/2-~veRr) Length & thickness of plate 200. // em Date 07+ 72-02 ° g 1% A 3 WELD FACE C4 te af a : ¥ 3 ge gy ge © gy ge v In rhesurren7? Ss x Ran 3 endences | tax, Io 3 ntéemittta? SPATTER On = 285 b2 85. iyo|® | Mo] M442 FACE B07 Foes 295) 5 : | wees | 95 Als ' Wes ° Dior (210 1a af a 70 1 mal #—— T Sime ar Weed Toe CACK OF Sidtwrce PORE 2-0 aA. StHRP TOE BLEKD— fossicé OVERLAP Furun ¥ Incempcieey Fiecko Gos ve FENEAL COMMENTS Méewanrent, MxCESS HELE METAL? 3° max, $3) Onmave ‘aSiny Toe BLEND > SaiisimcroRy Céxcenr HELL Sonn) LINEAR Mi : NS VAR MICRISMMMENT ; 2 : ANGULAR BSTeh fon NOTEWelding Inspection General Theory Paper QWI-2 This column is for official use only Results Marker 1: Marker 2 1, Which of the following is not an inert gas at welding te: a. Argon, b. Neon, #© Carbon dioxide, dQ. Helium, 2. Which are welding process uses a non-consumable electrode? a. MAG. wb. TIG. ©. Sub-are d. Electro-slag. 3. Which of the following is not a fusion welding process? a. Electro-slag welding b. Oxy-gas welding oc. Forge welding, d. Tungsten inert gas welding. 4. Which of the following current types would be used for the welding of aluminium with the TIG welding process? o%a Ac. b. D.c positive electrode. c. De. negative electrode 4. Both aand b. heWhich of the following stateme: is trus? 2. Electrode de. positive produces a deep narrow weld pool. 5. The word rutile means calcium carbonate, &. Porosity is always repa wd. Deo. electrode positive is used for the MAG welding of steel, 6. Which of the following welding processes is likely to produce the lowest hydrogen content in the weld zone? a. Sub-arc, b. MAG. c. MMA. 5 the heat affected zone? a. It ls the melted portion of the parent material, V >. Itis the area immediately adjacent to the weld metal, which has undergone a microstructural change. c. Itis the weld area plus the parent. material, wi change. It is the area in the weld region with the lowest tensile strength. ‘hich has undergone microstructural 8. Which of the following statements is true regerding hydrogen cracking? a. Itisa type of hot crack. 5. Itis most commonly found in ductile grain structures, c. Itonly occurs in the HAZ. V4. Itis the most common type of crack encountered in steel weidments 9. The heat input during a fusion welding process: & Does not affect the grain structure of steel, unless itis very high. b. Must be as high as possible to avoid lack of fusion. Vc. Affects the width and metallurgy of the HAZ, d. Alofthe above, 10. The HAZ associated with a fusion weld: a. Can not be avoided, b. Usually has the highest tensile strength. ave. Botha and b. 4d. None of the above" What is a typical carbon equivale fabrication purposes? n carbon-manganese steel used for pipes or a. 4%, b. 0.54%, ve. 0.33%, d. 0.12%. ‘Why is pre-heat sometimes carried out on steels? a. To remove moisture from the weld preparation. b. To retard the cooling rate of the weld. c. Toaid fusion between weld meta! and parent material. V4. All of the above. 3, eo. 14, 15, al vb. 2. ©. 3. a. ‘What four criteria are necessary to produce HICC? a, Hydrogen, moisture, martensite and heat. b. Hydrogen, poor weld profiles, temperature above 2000C and slow cooling. A grain structure susceptible to cracking, stress, hydrogen and a temperature below 2000C. d. Weld defects, perlite, hydrogen and a temperature above the melting point for the material being welded. How many temperature indicating crayons would be required to ensure a pre-heat temperature was lying within a specified range? As many as possible A carbon equivalent of 0.5%: v4. Is high for C-Ma steel and may require a pr-heat over 100°C. b ._ Is generally insignificant for C-Mn steels and is certainly not to be taken into consideration for pre-heat temperatures. ¢. Ishigh for C-Mn steels and may require a pre-heat temperature over 300°C d. Is calculated from the heat-input formula.Ina martensitic grain structure w ould you expect to i a. Duetility. >. Hardness. ©. Toughness Allof the above 17, Which of the following is not a type of crack? Fissure, — >. Lameliar tear. Vc. Fisheye. d. Hot tear. 18. ‘What do you understand by the term minimum interpess temperature? 2. Minimum post weld heat treatment temperature. 5. Minimum stress relief temperature, The lowest temperature to be used duting pre-heat. V4. The lowest temperature allowed during welding and between weld pas: 19. Which of the following welding processes may be described as a low hydrogen process in comparison to MMA welding? a. TIG/TAG. b. MIGMMAG. ©. MIG/MAG (hollow wire/flux core), Yd, Botha and b. ©. Allof the above 20. Pre-heat prior to welding: a. Must always be carried out on steels. ». Need not be carried out if post-heat treatment isto follow welding, g. Is always carried out using gas flames. 4. None of the above.1 4. Welding Inspection General Theory Paper QWI-1 This column is for official use onl Results, Marker 1 Marker Which of the following best describes the duty of a welding inspector? a. To carry out inspection and NDT in order to find all weld defects present Vb. To attempt to ensure that all welding and any associated actions are carried out 'n the agreed c. To carry out welding inspection and radiographic interpretation in accordance with the agreed procedures for the work being carried out d. To ensure that all welds, which undergo inspection or defect free. Which of the following butt weld preparations is usually the most susceptible to luck of sidewall fusion during the manual metal are process? a. A double U butt weld. A single V butt weld. A double V butt weld. Itis not possible to induce lack of sidewall fusion during MMA welding. aes ‘What is the leg length of a fillet weld? a. The distance from the toe to the face. b. The distance from the root to the face centre. oc. The distance from toe to root. d. The distance from the toc to toe. What is the throat thickness of a mitre fillet weld with equal leg lenghts? ‘The distance from the toe to the face. ‘The distance from the root to the face centre. ‘The distance from the root to the toe. ‘The distance from toe to toc. ore oris the ratio between the leg length leg lengths? dd the throat thickness on @ mite weld w . Depends on the fillet welds dimensions and the fit up conditions. 6. Lap‘oint contain: Wa. Fillet welds b. Comer joints c. Butt welds 4. Sh gle bevel butt welds 7. Complete the sentence to make a true statement, When welding high integrity structures, the toes of the cap on a butt weld: a, Mus’ always be ground to reduce stress raisers. 5. Must always overlap onto the extemal surface of the pipe or plate by at least 1.5 mm. ©. Must always be checked by NDT. Ae wd. None of the above can be selected — the specification requirements of unknown, 8. A duty not normally undertaken by a welding inspector is to: a. Check the condition of the consumables. b. Check the bevel angle for damage. we. Measure residual stresses. d. Measure pre-heat temperatures. 9. What action should a welding inspector take if arc strikes are found adjacent to a weld on high tensile strength material (specification does not reference are strikes)? a. Have the cotal weld and parent material cut out 6b. Have the are strikes checked with either MPI or DPI ©. Accept the weld area. 4. Have the welder re-qualified. 10. Is it permissible to allow a single vee but weld to cool down between passes? a. It depends upon the welder. eb, It depends upon the specification/procedure. ¢. It depends upon the welding inspector. 4. No. ail welds shall be completed before being allowed to coo! to ambient temperature. aIL. Why is the are shielded when using an are welding process? a, To eliminate hydrogen from the region of the are. b. To retard the cooling rate of the weld. Wc. To exclude the atmosphere from the region of the arc. d. All of the above. 12. Which of the following will vary the most when varying the arc length using the MMA. welding process? e/a. Voltage b. Amperage. Polarity c d. None of the above. ofa root bead What is the possible result if the amperage is too low during the w. using an are welding process with a consumable electrode? a. Incomplete root penetration. b. Lack of root fusion, c. The freezing of the consumable electrode to the work piece. w/d. Allof the above. 14, Why have a high o.c.v. with MMA welding? wa. To initiate the arc. To ensure good penetration. To avoid lack of fusion All of the above aes 15, What is another term for suckback? aa. Concave root. b. Root piping. ©. Incomplete filled groove d._A slag line between root run and hot pass 16. Under most conditions which of the following welding positions will deposit the most weld metal a PG, b. HLO4S. c. PR. wi. PA,17. What is lamellar tearing? a. A product defect aused through steel manufacturing. cb. A type of crack, which occurs in the parent material due to welding stresses actin short transverse direction of the parent material. &. A type of hot crack associated with poor through thickness ductility. 4. A type of crack found in welds, which are subjected to cyclic stresses gina 18. What is a crater pipe? -rm for to coneave root m for a bum throwgh. c. A type of gas pore found in the weld crater. od. A shrinkage defect which may be found in a weld crater 29. Which of the following is true for none planar defects found in welds? a. They are always acceptable. b. Their existence will result in the removal of the entire weld if they brake the surface, vc. They are not usually as significant as planar defects. 4G. They can only be detected using radiography as the inspection medium. 20. Cold lapping is another term for: 2. Lack of fusion at the toc of a weld reinforcement, Undercut at the toe of a weld. Lack of root penetration. Entrapped gas caused through contaminated joint preparations Res oDWelding Inspection - Steels Dayi (Rev. 12) #8Quc bf Multi-Choice Questions Please do not_mark this paper 4 Which one ofthe following destructive tess is used to measure the toughness of weld metal HAZ and parent material ? A mero B nick break C hardness D Charpy impact ‘Whic destructive test would best reveal lack of side-wall fusion and inter-tun fusion ina 25mun thick butt weld > A nick break B side bend © Charpy impact D macro ina transverse tensile test, brittleness would be indicated if A there is a reductioa in cross-section at the position of fracture B the fracture surface is lat and featureless ic} fracture occurred in the weld metal D Fracture occurred in the parent metal 4. The principle purpose of a welder qualification testis A to test the skill of the welder B to assess the weldability of the materials G to decide which NDT methods to use D to Bive the welder practice before doing pr luction welding 5. A fabrication procedure calls for the toes of all welds to be “blended in” by grinding, ‘The most likely reason for doing this is to A make the weld suitable for liquid (dye) penetrant inspection B improve the fatigue life c reduce residual stresses D improve the general appearance of the welds § hen a welded steel component is subjected to eycic loading it may fail due to fatigue, What precautions can be taken to reduce the risk of fatigue failure ? ‘ensure the weld is free from buried porosity. ensure there are no sharp changes in section Use a steel with very high toughness only use fillet welds and partial penetration welds com> SWelding Inspection - Steels Day 1 (Rev. 12) Multi-Choice Questions Undereut may need to be assessed according to depth Jeagth profile or blend all ofthe sbove yaw ‘When the root bead of a single-vee-butt joint is visually inspected you would look for lack of root fasion root concavity burn-dhrough all of the above vamp 9. The sirength of fillet weld is determined by A leg lengthy B weld profile C weld width D throat chickness 20, The European Code for visual inspection of fusion welds BS EN 288 BS EN 499 BS EN 287 BS EN 970- vow 11. Visual inspection of high integrity fabrication should cover inspection activities before, during and after welding before welding only after welding only during welding and after welding only vows 12, Incomplete root penetration in a single-vee-butt joint may be caused by an excessive root face an excessive root gap the current setting being too low both A and C came 13, Incomplete root fusion in 2 single-vee butt weld may be caused by A linear misalignment B the root gap being too small C differing root face: D —allofthe aboveWelding Inspection - Steels Day 1 (Rev. 12) Multi-Choice Questions 14, When visually inspecting a the face of a finished weld you should assess A excess weld metal beight B toe blend © — inter-run blend D —allofthe above 15. The surface ofa fatigue fracture will Abe rough and tom B have chevron markings C be smooth D have shear lips Ls. A bur-through may oceur if A the curent is too low B the root face is too large C the roo gap is too large D all ofthe above 17. A Code of Practice is a standard for workmanship quality only ‘set of rules for manufacturing a specific product a specification for the finished product all of the above vow 18, Porosity is caused by A. entrapped slag in the solidifying weld B entrapped gas in the solidifying weld entrapped metallic inclusions in the solidifying weld D —allof the above 19. A planar defect may be A lack of root penetration B —aalag inclusion C linear porosity D _allofthe above 20. For fillet welds, tis normal practice in the UK & USA to measure A throat thicknesses Beg lengths penetration depths B bah ARCWelding Inspection - Steels Day 1 (Rey. 12) Multi-Choice Questions 21. tna bend test, when the face of the specimen is in tension and root is in compression, the test is called A aroot bend B aside bend © aface bend D a longitudinal bend 2» 22. Heavy porosity is seen on the surfac: Te most likely cause is f some MMA welds being made on a construction site the wrong class of electrodes was used the current was too high the electrodes had picked up moisture the electrode batch was ‘out-of specification’ vow 23. Slag inclusions may be preseat in ‘manual metal arc welds ‘metal inert gas welds submerged arc welds both A and C vag Y 2A. Undercut is principally caused by excessive ampel excessive volts excessive tavel speed all of the above vam Which group of welders is most likely to require continuous monitoring by a welding inspector ? concrete shustering welders overland pipeline welders tack welders maintenance welders com> 12. - feWELDING INSPECTOR - STEELS WIS 5 Training: Multi-Choice Answer Sheet Name Paper No.2 Answer each question by putting X in the appropriate box | Question | ANSWER { result No. [x] BIC lp | peete | Oe ge ee eee ee |e 16 | | 17 ee | | | x ay x n a x TOTAL NUMBER CORRECT .. 3Welding Inspection - Steeis Day 2 (Rev. 11) ABR CE Multi-Choice Questions Please do not_mark this paper Deflection ofthe are by magnetic forces, which can make welding difficult t control, is commonly known as are initiation are misalignment vow Which of the following electrodes would be classifi according to BS EN 499? A E383! Bo E6013 cE I8-G - D £51338 Which of the following electrode types is for “stove-pipe” welding ? A : i ic} . D i | 4. The three main types of MMA electrodes for C & C-Ma steel welding are A basic, cellulosic and rutile B neutral, cellulosic and rutile C basic, cellulosic and neutral a D ule, low bydrogen and basic 5. Welding using a ‘weave’ technique may A give higher heat input ie B _mproved toe blending C help to give good inter-ran & side-wall fusion e D allofthe above 6 You notice that MMA clectrodes, with the flux covering removed, are being uscd as filer rods for TIG welding This should aot be allowed because n A itis wasteful B the rod diameter be too large n C/the weld metal composition may be wrong D the rod is too short - According toa WPS, welds must be made using » controlled heat input. [fsvelds are made with heat input above the maximum specified this may give a poorer toe blend a larger grain size in the HAZ higher hardness in the HAZ lower weld metal ductility goer YhWelding Inspection - Steels Day 2 (Rev. 11) Multi-Choice Questions Please do not_mark this paper 8. Cellulosic elecwodes are often used for welding the root pass during overland pipeline construction, This is because A hydrogen control is needed B_ __iton powder in the electrade gives higher deposition rates CC hhigh speed welding with good penetration is possible D very short are lengths can be used 12 of power source haracteristic is normally used for mansal welding ? constant voltage flat charact constant current a motor generator ceristic voor 10. In MMA welding, penetration is principally controlled by are voltage welding speed ferro.silicon in the electrode coating, current vows LL. For certain pips materiats the bore must be purged with Argon re and during welding. This done to prevent porosity in the weld prevent bum-through prevent oxidation of the root bead eliminate hydrogen from the root bead vow> 12, The mechanical properties of a MMA weld made with a low alloy steel electrode are determined mainly from A the core wire composition B additions in the flux coating C iron powder in the flux coating D dilution from the base material 13. What must be added to the covering of a MMA electrode to prevent porosity when welding a rimming steel ? A cellulose B calcium fluoride C silicon D calcium carbonate 5Welding Inspection - Steels Day 2 (Rey. 11) Muiti-Choice Questions Please do not mark this paper 14. For MMA welding on a constuction site, ch welding equipment would you choose for safe working 7 single operator cansformers , ‘multi-operator transformers AC/DC composite power unit diesel engine driven welding generatots vam 15, You notice a vee-shaped ripple on a weld surface. This indicates A abasic electrode has been used B the welding position € —ahigh wavel speed has been used Dall ofthe above 16. Whea low hydr electrodes are specified for manual me are welding, the electrode covering would be ? A cellulosic Beastie D basic V7. You would always be able to recognise a hydrogen ntrolled MMA electrode from the A colour B alectrode length C Trade Name D AWS coiie number or EN code letter = 18, According to 33 which ofthe following symbols means that a weld has tobe ground flush on the L “other side’ ? A e r C © D fr 16 :Welding Inspection - Steels Day 2 (Rev. 11) Multi-Choice Questions ‘lease do not_mark this paper s would show porosity when autogs 19. Which of the following steel ously welded (welded without a fille’) ? a filly billed B semi-killed ie D 20, Which one of the following elements is used to give creep resistance to a steel ? A Tungsten B Manganese C Molybdenum D Aluminium ‘The steel being used for structural welding is changed from one with 0.15% C and 0.6% Mn, to one with 0 and 1.2% Ma. Ifthe same WPS is used, there may greater risk of A excessive porosity B cracking in the HAZ © deep undercut on fillet welds D lack of sidewall fusion Which one of the fallowing steels is non-magnetic ” A 5% Cr, %Mo B 12% Cr, 1%6Ni ic} 18% Cr, 8% Ni DD -9%Ni 2. spatter during MMA welding is most likely to be caused by excessive current incorrect baking and storage of electrodes inadequate cleaning of the weld preparation all of the above vow 24, A qualified Welding Procedure Specification is used to give instruction to the welder give information to the welding inspector give confidence that welds will have the specified properties all of the above vamp ‘An are strike (stray flash) om a steel component is regarded by some codes as unace table because it may cause copper contamination it may cause hard spots, it may give cracking of both B&C gow 4WELDING INSPECTOR - STEELS WIS 5 Training: Multi-Choice Answer Sheet Name Paper Ni Answer each question by putting X in the appropriate box Questica’ Question | ANSWER No. 7 oss ae Co om LESTE ' | Es | (ae 16) | St Txt [Per x A ayy | 19 mr 5 | lx - 20) a ee 6 i 21 - i 7 7 22 | m 8 | | 23) ee _ 9 _ - 24 | x] 10 - 25 z 1a] ee — 26 — 12 - Paap B R — 28 - 14 x| 29 15 x 30) | | TOTAL NUMBER CORRECT . 1g“Welding Inspection - Steels Day 3 (Rev. 10) 7 Multi-Choice Questions Please do not_mark this paper 1. Which type of submerged are welding flux is more re stent to moisture pick-up ? A fused B agglomerated Cc basic D they are all about the same A large grain size in the HAZ of a stee! weld joint may have A low ductiliyy B —lowsoughness » C high toughness D high rensile srength 3. ASTRA testis used 10 measure the tensile stress of the welded joint weasure the level of residual stress in butt joints is a fracture test to assess weld quality measure the ductility of a tec! plate in the through-thickness direction vam 4. The risk of drogen cracking is bigher when welding carbon mangane: austenitic stainless steels Jow alloy steels Jow carbon steels, your The property ofa material that has the biggest effect on welding distortion is the A yield strength B Flastic modulus C —_covefficient of thermal expansion D —_covefficient of thermal conductivity 6. Imperfections of size greater than the maximum allowed by the application standard should be A accepted if considered to be harmless B reported to the welder C subjected to other NDT methods D removed unless granted a concessionWelding Inspection - Multi-Choice Questions Day 3 (Rev. 10) Please do pot_mar! ‘The presence of irom suiphides in a weld bead may cause A solidificatio B hydiog: C lamellar tearing D weld decay 8. A macro section is useful for showing J the HAZ microstructure 1 the weld microstructure all of the above caw 9. A butt weld in a 15mm plate has to be made, Which of the follow procedures would be ex to produ A TIG weld single sided, muiti-pass B MMA weld single sided, muln-pass : © MMA weld double sided, multi-pass D SAW weld 1 pass per side es 10. A suitable gasigas mixmre, for GMAW of aluminium is A 100% CO, f Be 100% Argon © 80% Argon + 20% C \ D 98% Argon +2% Oy 11. A metallurgical problem ffequently associated with submerged arc welding is ? A hydrogen cracking in the ELAZ B. solidification eracking in the weld metal ! C weld decay . D lamellar tearing inthe base material 12, A code gives the azceptance criterion for the diameter (D) ofa single pore in a weld as D $0.35, max 3mm, 7 wheres nateral thickness. in which of the following situations is the pore acceptable ? 6mm, messured pore diameter 10mm, measured pore diameter 12mm, measured pore diameter s= 15mm, measured pore diameter = 4.0m A B ce DWelding Inspection - Steels Day 3 (Rev. 10) Multi-Choice Questions Please do not mark this paper 13, To measure are voltage as acc ile, the recommended point of ms across the power source terminals prior to striking the arc across the power source terminals during the welding operation as near as practical to the arc anywhere in che welding circuit paws 14. Lamellar tearing kas occurred in a steel fabrication. What technique could have been used to find it hefore welding started ? Xuray examination liquid penetranr examination ultrasonic examinations 5 could not have been found by any inspection method, vom low alloy steel prior to welding is done fo minimise the risk of porosity excessive distortion HAZ cracking lack of fusion caw 16, With using SAW for the root pass in an un-backed weld, which of the following needs particular control ? root gap) included angle linear misalignment surface finish vawey 17. ‘The are voltage for MIG/MAG welding may be affected by A wire diameter Ba loosely connected current-remum cable C gas flow rate D wire feed speed 18. Upre-heating is specified for MMA welding, it should be applied for A weld filling only B tack welding, root welding and filling C root welding only D root welding and filling only 19. A weld centreline solidification crack could be caused by use of damp flux lack of preheat are voltage being tao bi bead being t00 de oneWelding Inspection - Steels Multi-Choice Questions Day 3 (Rev. 10 Please do not_mark this paper 20. Cracks in welded joims may be due 10 A hot shortness B hydrogen © Jamellar tearing D —anyof the above 21, Low carbon austenitic stainless stecls are usually specified for welding in order A HaZ cracking Bo weld decay c weld metal cracking D distorion 22. Submerged are fh 4 agitated agitated and crushed ‘rushed and age Fused and aj vow are generally supplied in two forms. Thes to minimise the risk of erated. (cap ht) in a butt weld is given as sxeess weld metal and b = weld width. Metal acceptable, 'y MMA and the electrode un-out-lengths that have bee used ae A 0. measured excess weld meta B 19 measured excess weld metal c '8 measured excess weld metal D 5 measured excess weld 1 24. A carbon manganese steel is being welded by shorter than specified by the WPS, This deviation may give A am increased risk of hydrogen cracking 5 an increased risk of solidification cracking © lower values of HAZ toughness. ~ D higher values of HAZ hardness heat input is increased CEV is increased vow all of the above ‘The maximum hardness in the HAZ of a steel will increase if the sulphur level in the steel is increasedWELDING INSPECTOR - STEELS WiS 5 Training: Multi-Choice Answer Sheet ZL Paper No Answer each question by putting X in the appropriate box ANSWER | Question | ANSWER i Bl Cc Lp tt | Ne PAT sp |e pp se 46] | { 1 | [x x | | LxPiease do not_mark this paper wing symbols shews weld peneation depth ? BS EN 288 is a specification for. A welder approval testing B welding equipment calibration C welding procedure approval D _consurmabies for submerged arc welding For fill penetration single-sided but joints root bead penetration and-profile are mainly influenced by A root face Bo bevel angle C root gap D —imeluded angle ‘Which clement has the greatest effect on the HAZ hardness of a cazbon-manganese stes! ? A Molybdenum Bo Chromium Gs yraccin D Carbon, Presheatingastel plate with a carbon equivalent value (CEV) of 0.47 may be required in order to drive out moisture frora the plate Prevent excessive hardening in the HAZ Prevent the formation of carbides improve the mechanical propert vow of the weld metal Which one of the following welding processes is said to use the “Keyhole” weldi technique ? fiction welding diffusion bonding electron beam welding Aux cored are welding vaw> th 4hDay 4 (Rev. 9) Multi-Choice Questions Please do not_mark this paper In friction welding, the metal atthe int face when the joining occurs is deseribed as being in the A liquid state B inter-critical state Cc plastic state D elastic stare 8. When TIG elding 3161 stainless s 2, Argon backing gas is required in order to A> prevent 2o0t bead oxidation B prevent underbead cracking C prevent root porosity E control the penetration bead profile 9. Welding @ carbon steel using an oxy-acety feathered inner cone, may cause the weld A tbe hard and brinte B to be softened c to be excessively oxidised D tobe porous 10. Which of the following would be classed as the most serious ype of defect ? buried linear slag inclusions buried lack of inter-run fusion surface breaking lack of sidewall fusion surface porasity vow 1 E1, Ulcasonic testing has an advantage over other NDT methods for the detection of lack of side wall fusion root undercut incompletely filled groove root concavity vow {2 For some types of steel, tempering is cared out o improve toughness after which of the following heat treatment processes ? A annealing B solution heat treatment C quenching D stress relieving 13, MIGIMAG welding has # tendency to give lack of sidewall fusion when A spray transfer conditions are used B 200%CO, shielding gas is used C pulsed current is usec Dip wansfer conditions are used 14, Blectoslag welds are characterised by. and HAZ 1g (0 be normalised to give good toughness being produced by a resistive heating process having all the vow>Muiti-Choice Questions Please do not_mark this paper 3 QT steel (or a'Q & T stecl) will have improved strength because it has AS. A steel described been consol rolled been heat treated been Quality Tested . -a vacuum melted vous 15. Changing an essential variable (beyond the allowed limits) for a qualified welding proced! A may change the mechanieal properties of the joint B may adversely affect the quality of the weld C will requize a new welding procedure to be approved D —allofthe above 17. BS EN 970 allows a magnifying glass to be used for visual inspection but recommends that the m: should be A . Bo eos C Sexi D not grester than x20 18, For oxy-fuel curring, the oxygen pressure and the nozzle diameter have greatest influence on A the temperature achieved for cut initiation B the ability to cut stainless steels, © the depth of cur that ean be made D quality of the cut edge 19. Welding Zine and Cadmium plated fittings is not cecommended because there is a fire hazard the weld metal will crack metal vapour is a health hazard « - the toughness of the weld metal will be reduced vamp 20. Welds made with very high heat input will show a reduction in tensile ductility notch toughness fatigue strength creep resistance come 21, In submerged arc welding, the use of excessively high arc voltage will result in insufficient flux melting excessive flux melting oor toe blend c spatter vow 22. When MAG welding in dip transfer mode (short-circuiting mode) the appearance of finished weld can be - improved by A increasing the wire stick-out length Busing 100% CO; ia C using Ar +30%He D using inductanceMutti-Choice Questions Please do not_mark this paper rnd equipment may be more difficult than making repairs during initial 23, Repair welding of in-service pl fabrication because the material may be contaminated of restricted access to repair area positional welding may be needed of any of the above vowe For gamma radiography of a steel weld at 40mm thick, the recommended isotope is A Thulium 170 B Yaerbium 169 © diridium 192 D Cobalt 50 The sensitivity of a radiograph is assessed by using a densitometer by using an image qualiry indicator ( 1QL) the KVA used om stand-off used. gage 78 Atmansverse tensile test, from a Weld Procedure Approval Record (WP.AR) test plate is used to meastse the tensile suength of the weld the tensile strength of the joint the stress/strain characteristics of the weld the stress/strain characteristics of the joint vam 27. Which electrodes should be baked prior to use ? all types cellulosic basic rutile vow 2S: 1f4 30mm thick carbon sunganese steel with good toughness has to be welded using MMA, the eectrove covering is most likely to be A rutile Br basic C cellulosic D dependent on the welding position 29. The dip tansfér mode (or short-citculting mode) of meta tansfer used for MIGIMAG welding is characterised by A giving deep penetration ~B being suitable for positional welding C giving low spaner DD allof the above 30, Carbon equivalent values (CEV) are used to determine the how to avoid the risk of. A’ hydrogen cracking B lamellar tearing C solidification racks Do weld deWELDING INSPECTOR - STEELS WIS 5 Training: Multi-Choice Answer Sheet Name Paper No Answer each question by putting X in the appropriate box [Question | ANSWER -_ [ exstion | ANSWER | No Talspicip is! % Fats lerp ire iE 3] eel | f 16) | Pofx | 7 | 2) jee | ¥ u ls | pv po TT tar tye i 4| | | | x Va 19] lee | / 5 I x eu x ! 4 | $| Lx | "| a 7 x 22 | x lv sre tt Wa 23 alee DT x 7 ts x 7 10 Re wy, 25 4 uf, yA 261 | 12 x We 27 x v 13] ey, 28, x / 14 “ 7 29 “ | a 15 x| v 30) vA TOTAL NUMBER CORRECT ....Paper #5 — (Rev.8) Electrodes with a basic covering are used A. forwelding high strength low alloy steels B. when low temperature toughness is specified for the weld meta! C. avten low hydrogen electrodes are specified 1D, when any of the above are applicable ‘The main reasoa for pre-heating steel prior to welding is A. toredusedisionion B, to eee residual steses inthe fished joint Cf to moc te sk of hydrogen cracking D. touiveout any moisture fom the base materials ‘The heat-affected zone (HAZ) of a C-Mu steel welded with very low heat input may show: When welding in a tench, a weldet could be in danger of asphyxiation duc to welding gasifisme being lessdense than air heavier than air being odourless pase A fusible insert is: filler material placed in the weld joint before welding permanent backing strip the core wire in a manual metal arc welding electrode applicable only to brazing pom To ensure that low hydrogen Jectrodes have very low moisture content, a typical baking temperature would be C. 450°C D. 200°C For dip transfer (or short circuiting) mode of metal transfer inductance has the effect of. reducing spatter aie of droplet eransfer srasion depth 4 B ie x5. Which of the following statements is true? a. Electrode d.c. positive produces a deep narrow weld pool. b. The Word rutile means calcium carbonate Porosity is always repaired. 74. Da. electrode positive is used for the MAG welding of steel 6. Which of the following welding processes is likely to produce the lowest hydrogen content in the weld zone? 7. What is the heat affected zone? a, Itis the melted portion of the parent material. 7». Its the area immediately adjacent to the weld metal, which has undergone a microstructural change. ©. Itis the weld area plus the parent material, which has undergone microstructural change. 4. Itis the area in the weld region with the lowest tensile strength, 8. Which of the following statements is tre regarding hydrogen cracking? a. Itis.a type of hot crack. b. Itis most commonly found in ductile grain structures. e. d nly ecours in the HAZ. _/4. Its the most common type of crack encountered in steel weldments 9. ‘The heat input during 2 fusion welding process: Does not affect the grain structure of steel, unless itis very high. Must be as high as possible to avoid tack of fusion. Affects the width and metallurgy of the HAZ. Alof the above. er 10. The HAZ essociated with a fusion weld: a. Can not be avoided. b. Usually has the highest tensile strength. ©. Botha and b, d. None of the above.Welding Inspection General Theory Paper QWI-2 This column is for official use only Results Marker 1: Marker 2: 1. Which of the following is not an inert gas at welding temperature? a. Argon b. Neon. © Carbon dioxide. 4. Helium, 2. Which are welding process uses a non-consumable electrode? a. MAG. 6. TIG. ©. Sub-are d. Electro-slag. 3. Which of the following is not a fusion welding process? a. Electro-siag welding b. Oxy-gas welding. %. Forge welding, 4. Tungsten inert gas welding, ! 4. Which of the following current types would be used for the welding of aluminium with the TIG welding process? | a Ac. a b. D.c positive electrode. ©. De. negative electrode. d. Both a and b.17. What is lameilar tearing? a. A product defect caused through steel manufacturing >. A type of crack, which occurs in the parent material due to welding stresses acting ina short transverse direction of the parent material. ©. A type of hot crack associated with poor through thickness ductility d. A type of crack found in welds, which are subjected to cyclic stresses. 18. What is a crater pipe? a. Another term for to concave root. b. Another term for a bum through. c. A type of gas pore found in the weld crater. _7& A shrinkage defect which may be found in a weld crater. 19. Which of the following is true for none planar defects found in welds? a. They are always acceptable. b. Their existence will result in the removal of the entire weld if they brake the surface. ve. They are not usually as significant as planar defects. 4. They can only be detected using radiography as the inspection medium. 20. Cold lapping is another term for: Lack of fusion at the toe of a weld reinforcement, Undercut at the toe of a weld. Lack of root penetration. Entrapped gas caused through contaminated joint preparations DEN11. Why is the arc shielded when using an are welding process? a. To eliminate hydrogen from the region of the arc b. To retard the cooling rate of the weld. To exclude the atmosphere from the region of the are. 4. Allofthe above. 12. Which of the following will vary the most when varying the arc length using the MMA. welding process? p72 Voltage. b. Amperage, c. Polarity d._ None of the above. What is the possible result if the amperage is too low the welding ofa root bead using an arc welding process with a consumable electrode? Incomplete root penetration. Lack of root fusion. The freezing of the consumable electrode to the work piece. Al. All of the above eG 14. Why have a high o.c.v. with MMA welding? eoe _-%. To initiate the are. b, To ensure good penetration. ¢. To avoid lack of fusion 4. Allof the above 15, What is another term for suckback? --@ Concave root. b. Root piping. c. Incomplete filled groove. d. A slag line between root run and hot pass nder most conditions which of the following welding positions will deposit the most weld metal 16, a. PG. b. HLOSs. c. PF, PA aess on a mitre fillet weld with Whit is the ratio between the leg length and the throat t equal leg lengths? ae ig b. 22k ve. 14l4el ~~ d. Depends on the fillet welds dimensions and the fit up conditions. 6. LapJoint contain: _* 4. Fillet welds b. Comer joints, c. Bett welds. 4. Si: gle bevel butt welds. 7. Complete the sentence to make a true statement. When welding high integrity structures, the toes of the cap on a butt weld: a. Must always be ground to reduce stress raisers. b. Must always overlap onto the external surface of the pipe or plate by at least 1.5 mm. Must always be checked by NDT. are _—4. None of the above can be selected ~ the specification requirements of unknown. A duty not normally undertaken by a welding inspector is to: a. Check the condition of the consumables. b. Check the bevel angle for damage. -e. Measure residual stresses. dd. Measure pre-heat temperatures. 9. What action should a welding inspector take if arc strikes are found adjacent to a weld on high tensile strength material (specification does not reference are strikes)? a. Have the total weld and parent material cut out _-. Have the are strikes checked with either MPI or DPI c. Accept the weld area, 4. Have the welder re-qualified. 10. Is it permissible to allow a single vee but weld to coal down between passes? It depends upon the welder . Tt depends upon the specification/procedure. It depends upon the welding inspector. . No, all welds shall be completed before being allowed to cool to ambient temperature. iWelding Inspection General Theory Paper QWI-1 a This column is for official use onk Results Marker 1 Marker 2: 1. Which of the following best describes the duty of a welding inspector? a, To carry out inspection and NDT in order to find all weld defects present. >. To attempt to ensure that all welding and any associated actions are carried out ‘n accor reed specification. c. To carry out welding inspection and radiographic interpretation in accordance with the agreed procedures for the work being carried out. . To ensure that all welds, which undergo inspection or defect free. ce with the agi 2. Which of the following butt weld preparations is usually the most susceptible to lick of sidewall fusion during the manual metal are process? _-—t A double U butt weld. b. A Single V butt weld. c. Adouble V butt weld. d._Itis not possible to induce lack of sidewall fusion during MMA welding, 3. What is the leg length of a fillet weld? a The distance from the toe to the face. b. The distance from the root to the face centre. _2© The distance from toe to root. d. The distance from the toe to toe. 4. What is the throat thickness of a mitre fillet weld with equal leg lenghts? a. The distance from the toe to the face. _-®. The distance from the root to the face centre. c.. The distance from the root to the toe. 4. The distance from toe to toe.16. 17. 18, 19. 20. Page 4 of 4 7 al inspection of a fillet weid with even leg lengths of 15mm and a throat measurement of $mm . A cross section is not available. The weld profile is: (a) Concave eee (b) Convex _ (©) Mitre (@) Notable to be determined Which of these statements relating to carbon steels is false (a) High heat input results in high hardness (b) High heat input may result in large grains (c) Loss of toughness may result from weaving (@) Toughness may be restored by normalising a Which of the following parameters presents the welding inspector with the greatest difficulty to monitor during fully manual welding operations? (a) Current (b) Travel speed (c) Arc length (2) _ Interpass temperature You are the only welding inspector overseeing 4 welding stations, producing circumferential single V butt welds on a pipeline. For which of the following stages would you consider your closest scrutiny to be required? (2) Completion of capping run (b) Cleaning of completed weld (c) Radiography (4) Root pass deposition Which of the following processes would be potentially most capable of producing weldments that are low in Hp (a) MMAusing basic type electrodes = (b) SAW using correctly treated flux (c) Electron Beam (d) Mice Which of the following tests would you normally not expect to be performed during a welder approval test? (a) Bend (b) Nick break Fy (c) Macro _ vs (4) TensileWIS 5 M4 11. “Autogenous welding’ basically means: (2) Fully automated process (b) Fusion welding (c) Fully mechanised process (4) Welding without filer wire 5 12. According to ISO 2553 which of the following symbols represents a permanent backing strip:- (a) ea al [ows b () [ PB (a (d) None of the above qo 13. Which of the following radioactive terms do we not normally associate with NDT (2) Gamma (b) Cobalt 60 (c) Thorium* Z (4) Iridium 192 14. Which submerged arc flux may be described as “powdery” or “ball like"? (2) Basic (b) Fused _ (Cc) Agglomerated @) Acid5. During TIG welding the are volt is controlied by: The welder The voltage control on the power source The power source giving out a constant voltage . The electrode polarity aeop 6. Which one of the following statements is correct: (2) SMAW may use either AC or DC (b) GTAW may use either AC or DC (c) SAW may use both AC and DC (d) Allof the above 7. Suckback is a commonly slang term used to describe: (a) _ Lack of penetration (b) Root concavity (©) Underfill (4) Incomplete root penetration 8 Atypical temperature specifically for hydrogen removal for a carbon — manganese weldment is: (a) 150°C (b) 600°C (c) 350°C (d) 900°C 9 A typical angle of bevel used for MAG welding 12mm carbon steel could be: (a) 120° (b) 35° (©) 70° (6) 90° 10. In arc welding processes, excess weld metal profile is mostly affected by: (a). Arclength (b). Open circuit voltage (c). Amperage - (2). Root gap Page 2 of 4 2WELDING INSPECTION TRAINING ONLY MULTI CHOICE PAPER 4 20 questions total Name: AVL AW “Dastoy3, Date: 4 (- / Answer all questions, Which of the following would be a typical MAG, individual pass, heat input (2) 4.2 jmm eames (0) 65 kiimm (©) 6.5 k/mm _ (8) 1.2 kjimm 2. The term “Skip” refers to what in welding/fabrication terms 2 (2) A production scheduling term (6) A secure location for quarantined goods (©) An Australian marsupial (@) Arun sequence 8. Aprod may be used for which NDT process (a) Eddy current (b) Radiography (c) Ultrasonic testing. (4) Magnetic particle inspection 4. Which of the following is a typical electrode classified as E7016 according to AWS 5.1 (a) _ Iron powder electrodes (b) Rutile electrode (c) Cellulosic electrode (4) Basic electrode to(2) Once, after etching (©) During preparation and after etching (©) Using a microscope (4) By penetrant inspection 29. Which of the following may be classed as a ‘more serious defact (@) Slag inclusions (b) Fusion defects (interun) (c) Fusion defects (surface) (d) Porosity 30. A code of practice is: (2) A standard for workmanship only (b) Asetof rules for manufacturing a specific product (c) Levels of acceptability of a weldment (d) None of the above Page 8 of 8 nvWis 5 M3 Rev. 03/03 24. Awelded product has failed in service. This has been confirmed as being caused by material overload due to a design fault. What would you expect the appearance of the fracture surface to be? (a) Rough and torn (b) Flat and crystalline (c) Flat and very smooth (d) Showing beach marks 25. “Stray arcing" may be regarded as a serious defect. This is bocause (a) _ It may reduce the thickness dimension of a component (b) It may cause liquation cracks (c) It may cause hard zones (d). All of the above 26. Overlap in welds is : (a) Anon planar defect () Where the 2 plates to be joined are overlapping (0), Lack of fusion defect found in the root or cap region (4) Another name for linear misalignment 27. Flame cut edges would normally be required to be ground back to a distance specified in a procedure because: (2) If the HAZ is left on the prep it may result in weld decay In service _ (b) The HAZ would have become sensitised (©) There is a strong potential for hardening in this region (¢) To reduce weight loading on the completed structuredeiectabie by Radiography: (a) () (c) (a) 6 fotiowing a: 2mm deep/4mm iong cenireline cracking in weld root 200 mm long Lamination _ 10 mm deep lack of sidewall fusion on a single U butt Gas poor 1.5mm g — 21. Cracks in welds may be due to: (a) (b) (co) (a) Solidification problems pane Hydrogen problems — Excessive stresses — All of the above 22. Welding a single V butt with laminations showing on the sidewall may give rise to: (b) (©) (a) Lamellar tearing _ Solidification cracking Martensite a Undercut _ 23. With reference to a root penetration bead, you could certainly assess: (a) (b) (c) (9) Page 6 of8 Root fusion and penetration Toe blend Overlap All of the above. WIS 5 M3 Rev. 03/03 16. 17, 18, 19. Penetrant inspection and magnetic particle inspection are mainly used to: (a) Aid visual inspection (b) Because the application standard says so (c) To confirm “visual uncertancies” (d) — Allof the above Defects outside of the limits specified in a standard should always be: (a) Repaired (b) Reported to “a senior person” (©) Radiographed (2) Allof the above When MIG welding aluminium alloy in the overhead position which current type would normally be expected to be used: (a) ac (b) DC negative . (c) Drooping (4) DC positive, Manual metal arc electrodes can be grouped into three mai (a) Basic, cellulosic and rutile ( (>) Neutral, cellulosic and rutile (c) Basic, cellulosic and neutral (d) Fused, agglomerated and basic(a) Change the properties of the wald (b) Influence the visual acceptability (c) Require re-approval of a weld procedure (4) Allof the above 13. Weld samples prepared for micro examination would typically require a which of the following levels: finish to (@) 1200 grit —_ (b) 500 grit oe (©) 3000 grit - (4) 3micron 14. When visually inspecting a fillet weld, it would normally be “sized” by: (a) The leg lengths (b) The actual throat thickness (C) The design throat thickness (@) Botha&c 15. Which of the following relate to the term “planar defect”: (a) Alamination (b) _ A.serious defect likely to lead to failure of the product (c) Slag inclusion (4) Bothaandb Page 4 of 8 hyWIS 5 M3 Rev. 03/03 8. Slag inclusions may occur with: (2) Manual Metal arc (b) Metal Inert gas (c) Submerged arc welding (@) » Botha&c 9. Undercut may be caused by: (2) Excessive amps (b) Excessive volts (©) poor weaving technique in vertical position with MMA (d)__ Allof the above 10. Which of the following materials would be considered to represent the greatest problem from a weldability aspect when using SMAW: (a) Carbon Manganese with CE of 0.28 (b) Free machining stee! (c) Carbon Manganese with CE of 0.45 (2) Low carbon steel 11. The abbreviation POR is otherwise known as: (a) Provisional Qualification Record (bs) WPAR (c) Personnel Qualification Record (d) wat(2) Linear misalignment (b) Incorrect tit angle (c) Differing root face widths (d) Allof the above 5. Which of the following tests would you normally expect a test house to use for the assessment of HAZ hardness, for procedure approval in the UK: (a) Rockwell (®) cToD (0) Brinett - (@) Vickers 6. You notice a very “veed" ripple shape. This may indicate: (a) Poor consumable choice (©) The use of a fully automated welding process (c) Excessive travel speed (@ Bothbandc 7. "Toe Blending” is important as it may affect: (a) Toughness (b) Fatigue life, (c) Penetration (4) Alllof the above Page 2 of 8Wis 53 Rev. 03/03 WELDING INSPECTION TRAINING ONLY MULTI CHOICE PAPER 3 Date: _ 2 Answer all questions, 1. The BS EN code for welder approvals is: (a) BSEN 4872 eee (>) BS EN 499 ae ‘(c) BS EN 287 a (d) None of the above _ 2, A Code of Practice for Visual Inspection should cover the following: (a) Before, during and after welding activitied (>) Before welding activities only (C) After welding activities only _ (4) None of the above _ 3. Incomplete root penetration in a butt joint could be caused by: (a) Excessive root face width peeeeiet (b) Excessive root gap size _ (Cc) Low current setting _ (4) Bothaac ,2 hs 0 2 using g penetration allowance: h < 1mm +0.6 b up to a maximum of 4mm (Where ‘h"is the penetration height and "b" is the penetration width) Which of the following root heights is acceptable? (a) h=0.5mm b= 5.0mm (0) h=46mm — b=6.0mm (©) h=38mm — b=4.0mm (4) None of the above 28. Which of the following statements is correct: (a) Copper inclusions are usually grouped with slag and other Solid inclusions for sentencing purposes (b) _ Undercut lengths at both weld toes in the same longitudinal Location are added together for sentencing purposes (©) Ameasurement for maximum penetration height is always specified in Application standards (4) None of the above BS EN 22553 29. According to. 88a weld on the “other side” is shown by a symbol: (a) On the dotted jine (b) Below the reference line (c) On the solid fine (d) Above the reference line 30. What defect would appear as “bright white specks’ on a radiograph? (a) Gas pores (b) Stag inclusions (c) Tungsten inclusions (d)— Undercut Page 8 of 8WIS 5 M2 Revo3/03 24. What is the maximum allowable HI/LO for 8mm material if the code States the following- “Linear misalignment is Permissible if the maximum dimension does not exceed 10% of t up to a maximum of 2mm” (a) 2mm _ (©) 8.8mm (c) 0.8mm (4) | could not sentence this defect as an incorrect term has been used 25. When visually inspecting the root of a pipe weld, in a single V butt, with the cap ground flush. You have identified root concavity, which has a depth of 0.5 mm ~The application standard you are using contains the following statement “Root concavity shall be acceptable provided the density of the radiographic image does not exceed that of the parent material” Which of the following is correct: (2) You must have the pipe radiographed (6) Sentencing may only be performed by a qualified radiographic interpreter (c) It should be rejected (4) You should accept, as there is no radiograph to view 28. Which of the following statements is correct regarding gas welding low carbon steel: (2) Itwill give a low heat input (6) Acetylene or propane are normally used as fuel gasses (c) A low skill level is required to produce sound welds (2) * It may be used for autogenous welding