Professional Documents
Culture Documents
5) What is WPS?
The WPS is a written document that provides direction
13)
Mention the drying temperatures for low hydrogen
SMAW electrodes?
260-430C for 2 hrs min (A5.1)
370-430C for 2 hrs min(A5.5)
120-250C for 2 hours minimum. (SS and
Non-Ferrous electrodes)
14)
15)
21)
ii)
iii)
NCR: (Non Conformity report): A record reporting the variation from the
specified requirements.
28)
HP Service : 100% RT
SC Service : 100% RT
30)
31)What factors (give at least four) are taken into account when selecting and
designing a joint for a welding application?
Strength
Accessibility for welding
Minimize distortion
Cost of welding
Accessibility for inspection
32)What is the difference b/w stud bolt and machine bolt?
Machine bolt has a head on one side and nut on other side but stud bolt
have nuts on both sides.
33)Which standard do you refer for the welding equipment calibration?
BS 7570.
34)What are the tests required for verifying supplementary essential variables?
Notch toughness tests Charpy V- Notch test
Drop weight.
35)
What is the chemical composition of a low hydrogen
electrode E7018?
E7018 C 0.15, Mn 1.60, Si 0.75, P 0.035, S 0.035, Ni
0.30, Cr 0.20,
Mo 0.3, V 0.08.
36)
37)
Mention the drying temperatures for low hydrogen
SMAW electrodes?
260-430C for 2 hrs min (A5.1)
370-430C for 2 hrs min(A5.5)
120-250C for 2 hours minimum. (SS and
Non-Ferrous electrodes)
37)
is within tolerance accept it otherwise submit the report to higher authority for
further action.
42)You have observed in the specimen certain defects, why do you consider it as
important and do the report of it, state two planar defects? What are causes for
the occurrence of it and how will you avoid it?
Defects: Is a rejectable one i.e., a discontinuity which exceeds the code limits is
defects. Depending up on the conditions and severity it has to be repaired.
The two planar defects are i) Lack of side wall fusion ii) Undercut.
i) Lack of side wall fusion: Contaminated surface may due to oil, grease, and
rust etc., and too narrow gap, current very low and improper manipulation of
electrodes.
Prevention: Bevel ends shall be thoroughly cleaned and free from detrimental
contaminants, appropriate root gap, welding parameter within the WPS range
and right manipulation of electrodes.
ii) Undercut
Prevention
: Appropriate travel speed, welding parameters under control and
shall be within the WPS range.
43)What is the P No; for CS & SS?
CS- P1
SS-P8
44)Buttering or weld build up on the prepared surface shall not exceed
Exceed the lesser of 1/3rd of base metal thickness or 10mm without the
prior approval of the company.
45) Internal misalignment of Butt joints shall not exceed
1.5 mm
46)Fillet Weld Profiles
Convex, Concave, Mitre
47)Explain E 8018
E Electrode
80 Tensile Strength
1 for all Position
8 Coating
56)Why post heating is done on some pipe after the welding is over?
To maintain uniform homogeneous structure.
57)What are weldolets and sockolets? And where they are generally used?
Weldolets and sockolets are self reinforced fittings.
Weldolets are used for butt welded branch connections where standard
tee is not available due to size restrictions and the piping is at a
critical/high pressure service.
Sockolets are used to socket welding branch connection which requires
reinforcing pads.
58)What is the density of steel?
7.86 kg/m
59)In 316L, what is the L stands for?
L stands for low carbon steel
60)If heat input increases what will happen?
Yield strength decreases
Tensile strength decreases
Percent in elongation increases
Notch toughness slightly increases and then decreases
Hardness decreases
Cooling rate decreases ( R 1/ T0H) Where R is the cooling rate, T0 is
the preheat temperature, H is the heat input.
61) What is the cause of porosity?
The presence of gas pores in a weld caused by entrapment of gas during
solidification is termed as porosity. The pores are in the form of small
spherical cavities either clustered locally or scattered throughout the weld
deposit. Sometimes entrapped gas give rise to a single large cavity called
Blowholes.
Cause: A.
Chemically imperfect welding consumables, for example, deficient
in deoxidiser.
B.
Faulty composition of base material or electrode, for example, high
sulphur content.
C.
Presence of oil, grease, moisture and mill scale on the weld
surface.
D.
Excessive moisture in the electrode coating or submerged-arc flux.
E.
Inadequate gas shielding or impure gas in a gas shielded process.
F.
Low welding current or too long an arc.
G.
62)
Calculated by throat
Fillet weld size is the leg length of the largest isosceles right triangle which
can be inscribed within the fillet weld cross section.
67)What are the tests required for verifying supplementary essential variables?
Notch toughness
69)
Densitometre
70)
What are the factors on which the density of radiographic film depends?
The density of radiographic films depends upon the following: A. Total amount of radiation emitted by X-ray or gamma ray.
B. Amount of radiation reaching the specimen.
C. The amount of radiation passing through the specimen.
D. Intensifying action of the screen if used.
71)How will you calculate the geometric unsharpness in radiographic film?
Geometric unsharpness of the radiograph shall be determined in accordance
with:
Ug = Fd/D
where
Ug = geometric unsharpness
F = source size: the maximum projected dimension of the radiating source
(or effective focal spot) in the plane perpendicular to the distance D from
the weld or object being radiographed, in.
D = distance from source of radiation to weld or object being
radiographed, in.
d = distance from source side of weld or object being radigraphed to film.
72)What is the welder qualification based on f number?
Root
Hot Pass
Fill
Cap
Weld Face
Weld Root
Fusion Zone
Fusion Boundary
Heat Affected Zone (HAZ)
Weld Toes
Weld Width
79)Dry developers?
80)Principle of UT.
Reflection of Sound
81)What is the use of Couplant?
To remove the air gap between the transducer and object.
82)What is the Welding Process?
a)
b)
c)
d)
e)
f)
GTAW
SMAW
SAW
FCAW
GMAW
PAW
83)Welding Position
Pipe 1GR, 2G, 5G, 6G,
Plate 1G, 2G, 3G, 4G
PIPE:1G: - A Pipe is Horizontal Position and weld beed is a vertical position. The
Pipe will be rotated.
2G: - A Pipe is Vertical Position and weld beed is Horizontal Position
5G: - A Pipe is Horizontal Position and weld beed is Vertical Position
6G: - A Pipe is a 450 Position
PLATE:1G: - Plate is Horizontal and weld is Horizontal
2G: - Plate is Vertical and weld is Horizontal
3G: - Plate is Vertical and weld is Vertical
4G: - A Plate is in Overhead Position weld is Horizontal Position
84)
PREHEAT REQUIREMENTS
WALL THICKNESS
MIN PREHEAT
Upto 30mm
20*
30-50 mm
20**
> 50 mm
100
ALL
150
ALL
250
SS
ALL
10
* If ambient temp. is below 5C, preheat to 40C is mandatory.
** 80C min, if specified UTS 490 Mpa & heat i/p < 20 KJ
Max interpass temp. for SS( P8) : 177C
Max interpass temp. for CS, alloy (P5,P9,P11) :315C
85)Why we maintain the interpass temperature?
The yield and ultimate tensile strengths of the weld metal are both a
function of the interpass temperature.
High values of interpass temperature tend to reduce the weld metal
strength. Additionally, higher interpass temperatures will generally provide
a finer grain structure and improved Charpy V notch toughness transition
temperatures.
86)What is the difference b/w tensile test & yield test?
A tensile test is a test to obtain an accurate assessment of the strength and
ductility of a material or a weld, or in an all-weld-metal test, to determine
mechanical properties such as tensile strength, yield strength, elongation,
and reduction in area.
A yield test is to obtain the strength at some arbitrary amount of extension
under load or a permanent plastic strain (offset).
88)While welding of pipe trunion to pipe/reinforcement pad you have to put a hole
or leave some portion of welding why?
For venting of hot gas which may get generated due to welding.
89)
90)
91)Why dont we take a branch for Cryogenic Service from bottom side though
the fluid is in liquid state?
There is the chance of Ice formation during normal operation and since
ice flows from the bottom of the pipe it will block the branch pipe
connection.
92)From which side of pipe will you take a branch connection?
When Fluid is Gas, Air or Steam and Cryogenic Service Topside.
When Fluid is Liquid Bottom Side.
93)
94)
95)
A. Prior to application of wrapping & coating, the surface of pipe should be made
free from all loose Mill scale, dirt, rust, grease, moisture and other foreign
material. This is achieved by blast cleaning to grade Sa 2 .
B. The pipe exterior surface or blast surface shall be coated with primer within
four hours of shot blasting. The primer shall not be applied when the pipe surface
temperature is below 7C and above 70C. When moisture is present on the
surface, the same is heated for sufficient time to dry the surface.
C. The pipe after priming shall be coated with two-flood coat of hot enamel
incorporating the simultaneous application of inner & outer wrapping.
96) How you will measure linear indications and acceptance?
Material thickness
size
thk16mm
1.6mm
16mm thk < 50mm
3.2mm
thk 50mm
5mm
97)What is a duplex stainless steel?
The term duplex stainless steel describes steel with microstructure
containing austenite and ferrite in which the lesser phase is at least 30%
by volume. First generation duplex stainless steels (typically 26% Cr, 4.5%
Ni, and 1.5% Mo) were about 5 to 80% ferrite.
98) What is DIRECT CURRENT ELECTRODE POSITIVE (DCEP)?
The arrangement of direct current arc welding leads in which the electrode
is the positive pole and the work piece is the negative pole of the welding
arc.
99)What is DIRECT CURRENT ELECTRODE NEGATIVE (DCEN)?
The arrangement of direct current arc welding leads in which the electrode
is the negative pole and workpiece is the positive pole of the welding arc.
100) What are grains?
Groups of crystals presenting metal after it have solidified.
101)
Based on construction
A. Full face.
B. Spiral wound metallic.
C. Ring type.
D. Metal jacketed.
E. Inside bolt circle.
Based on material
A. Synthetic rubber
B. Solid Teflon
C. Compressed Asbestos
D.CS (High pressure fluid)
E. SS (High fluid corrosive)
F. Spiral Wound a) Teflon b) CS c) SS
1) What are the types of flanges?
Based on pipe attachment
Slip on. - The Slip-on type flanges are attached by welding inside as
well as outside. These flanges are of forged construction.
Socket Weld. : - The Socket Weld flanges are welded on one side only.
These are used for small bore lines only.
Screwed: - The Screwed-on flanges are used on pipe lines where
welding cannot be carried out.
Lap Joint. : - The Lap Joint flanges are used with stub ends. The stub
ends are welded with pipes & flanges are kept loose over the same.
Welding Neck. : - The Welding neck flanges are attached by butt welding
to the pipe. These are used mainly for critical services where the weld
joints need radiographic inspection.
Blind. : - The Blind flanges are used to close the ends which need to be
reopened.
Reducing. : - The reducing flanges are used to connect between larger
and smaller sizes without using a reducer. In case of reducing flanges,
the thickness of flange should be that of the higher diameter.
Integral. : - Integral flanges are those, which are cast along with the
piping component or equipment.