1. Which company you are working?

2 · How many years of experience?

3 . Currently how many years in the present company?

4. What is the reason you decide to move out?
A) Work load come down
B) Family reasons I decided to stay here
C) For better career and good future
D) There 1s no opportunities to exploit my abilities
E) Remuneration and other fac1lit1es from the current company offered to me at the
end of the contract is not satisfactory with respect to the current boom ln the
industry
F) The industry exposure of the current co mpany is limited
5. What is the cu rrent designation and pay scale?
QA/ QC engineer & welding inspector
Basic:
Allowance :
lOhrs/ day and 6days in a week
6. Can you explain you r current activities and responsibilities?
A) Preparation of ITP as per Project requirement
8) Material inspection
C) Physical and dimensional check as per applicable codes.
D) MTR review as per BOM, codes and specific project requirement.
E) Raising discrepancy report and NCR where ever necessary.
F) Documentation and material release.
7. Flt-up inspection:
A) Mark out & layout checking before cutting
B) Flt up inspection as per Fabrication Drawings and WPS
8. Welders Qualification checking
A) Welder Is qualified as per QW350
B) Welders surveillance check with respect t o WPS
• Welder diameter range
• Welder thickness range
• Welder material range
• Filler material range
• As per ASME IX QW· 350 and QW 452 for individual process
9. What are the parameters in a WPS?
A) As per ASME Sec IX, QW 250 & QW 451for1ndiv1dual process
QW-401
 QW-402-JOINT DESIGN
QW-403-BASE MATAL
QW-404-FILLER MATEL
QW-405-POSITION
QW-406-PREHEAT
QW-407-PWHT
QW-408-GAS
QW-409-ELECTRICAL CHARACTERSISTICS
QW-410-TECHNIQUE
10. Final weld visual acceptance criteria?
A) Undercut, crack, LP, spatter, Arc strike etc
AS per code crack not allowed {except API 1104)
ASME 831.3-table 341
11. Selection of NOT as per the project requirement and applic.able ta
12. Verification of preheating and PWHT reports as per the project r1qulrement Md
applicable code
13. Witnessing pressure test such as hydro & pneumatic
• Test pressure = 1.3 * MAWP*LSR (AS PER VIII)/ 1.5*.AWP*LSR (AS PEit Ul.IJ
• Test temp= should maintain b/w min 17.c(or abow the MDMT) to max4rct.
mini mize th e brittle fracture
• Gauge calibration = 6months
• Relief valve set pressure = test pressure*S" (as per sec viii)
• Relief valve set pressure= test pressure•t°" (as per 831.3)
• Pneumatic set pressure=l.1 *MAWP*LSR
• Gauge range= double the times Jn no case 1.5 to 4 t'mes of the test pressure
• Test medium Ph value should be less than 7 for the SS plpe/equtpnaents
• Final punch list preparation (punch list means uncompleted works IS per the
requirement listed like Insulation, touch up painting etc)
14 Hydro t est Package Preparation
• Welding Inspection & NOT Inspection sighed reports for the pairtlcu&lr Une.
• Hydro test loop drawing Including drain vent points, BHnd loatfons.
• Pressure Gauge, PSV, manifold calibration certificates
15. Final Dossier preparation
• Shop drawings •
• Weld map
• Inspection reports like flt up. visual weld traceability
• NOT reports
 • All MTR'S
• Hydro test reports
• Final painting reports
• Job completion certificate
16. Electrodes
• Baking - mostly it's the requirement of the manufacturer If 1t 1s vacuum packed
then no need any baking.
• In general for the Low hydrogen electrodes required 2 hours 350°C In baking
oven Then 1t will transfer to holding oven at 100°c.
• Electrodes ending 5, 6, and 8 called low hydrogen electrodes.
• Use portable ovens while welding after 8 hours need t o re-baking necessary
• Re- baking allowed only one times.
17. Gaskets
• Spiral wound gaskets
• Non metallic gaskets
• Metallic gaskets
• Rubber gaskets
• Ring type gasket for RTJ
• Graphite gaskets
• PTFE gaskets
18. Heat input= (voltage xamperage x60)/ travel speed
19. Chemical compositions:
Pl cs
P3 alloy steel Cr s ~%
P4 alloy steel VJ% < Cr S2%
PSA,PSB,PSC ally steel 2 1/4% scrs10%
P6 high alloy steel martensltic
P7 high alloy steel ferr1tic
PS high alloy steel austen itic
P9A, P98 nickel alloy steels
PlO Cr-Cu steel
PlOI 27Cr steel

20. PWHT as per 31.3:

• For carbon steels Pl greater than 20 mm thickness required PWHT l ")
• For alloy steels P3 greater than 20 mm thickness required PWHT
--. LSC...l- ~ \f .4/)
• For alloy steels P4 greater than 13 mm thickness required PWHT - ( ';\ob ., 7t
 • For alloy steel PSA,PSB,PSC if Cr~ 3% and S0.15" C ,thickness >Umnl
PWHT
If Cr>3%or C>0.15% required PWHT for all thickness
• For P6 required PWHT for all thickness

PWHT as per Sec VIII

• Welded joints over 11/2" (38mm) nominal thickness required PWHT
• Welded joint over 11.4" (32mm) nominal thickness unless preheat Is 1ppljed Ill a
minimum 2oo·F (95°C) during welding.

Rate of heating.

Soaking t ime

Rate of cooling·

21. Radiography •
As per UCS 57 full RT required for the following
• For Pl If thickness more than 32mm
• For P3 if the thickness more than 19 mm
• For p4 1f the thickness more than 16mm
• For PS need RT all thickness
• For P9 1f thickness more than 16mm

22. UG-80 out of roundness for cylindrical, con1cal/spher1cal shells

}> The difference between the maximum and m1nlmurn

Inside diameters at any cross section shall not
Exceed 1% of the nominal diameter at tht! cross section
Under consideration.

>- When the cross section passes through an

Opening or within 11 D of the opening measured from
The center of the opening, the permissible difference
In Inside diameters given above may be Increased by
2% of the Inside diameter of the opening.
 23. WPS:
A WPs ·15
a written qualified welding procedure prepared to provide direction for
making production welds to Code requirements
Variables: Essential, non-essential and supplementary
24. What are the types of SS?

» Austen/tic
Austen1t1c steels have austenite as their primary phase (face centered cubic
crystal). These are alloys containing chromium and nickel (sometimes
manganese and nitrogen), structured around the Type 302 composition of
iron, 18% chromium, and 8% nickel. Austenltlc steels are not hardenable by
heat treatment. The most familiar stainless steel Is probably Type 304,
sometimes called T304 or simply 304. Type 304 surgical stainless st eel ls an
austen1tic steel containing 18.- 20% chromium and 8-10% nickel.

Ferri t ic:
Ferr1t1c steels have ferrite (body centered cu bic cryst al) as thei r main phase.
These steels contain iron and chromium, based on the Type 430 composition
of 17% chromi um. Ferr1t1c steel is less ductile than austenltic steel and is not
hardenabJe by heat treatment.

» Mortensit1c:
The characteristic orthorhombic martensite m icrostructure w as first observed
by German m icroscopist Adolf Martens around 1890. Martensltic steels are
low carbon steels built around the Type 410 composition of iron, 12%
chromium, and 0.12% carbon. They may be tempered and hardened.
Martensite gives steel great hardness, but it also reduces its t oughness and
makes it brrttle, so few steels are fully hardened.

> There are also other grades of stainless steels, such as precipitation-hardened,
duplex, and cast stainless steels. Stainless steel ca n be produced in a variety of
finishes and textures and can be t inted over a broad spectru m of colors.
t

25. What is mean by llormaliztng?

» Normalizing 1s a technique used to provide unifo rmity 1n grain size and
compos1t1on throughout an alloy. The term is often used f o r f errous alloys t hat
have been austenitised and then cooled in open air.UZI No rma lizing not only
produces pearfite, but also bain1te and sometimes martensite, which gives
harder and stronger steel, but w ith less ductility for the same composit ion
than full annealing.

JL What Is tnean by annealing?

 ~ Annealing is a rather generalized term. Annealing
to a specific temperature and then cooling at a rate
microstructure.The rate of cooling 1s generally slow.
used to soften a metal for cold working, to improve
enhance properties like electrical conduct1y1ty.
>- In ferrous alloys, annealing 1s usually accomplished by
beyond the upper critical temperature and then cooling very
1n the formation of pearlite. In both pure metals and many~
be heat treated, annealing is used to remove the hardness CIUlll
• work1ng. The metal is heated to a temperature where
occur, thereby repairing the defects caused by plastic defOf'ntltloll. la....
metals, t he rate of cooling will usually have little effect. Most non-fenN
a'IJoys that are heat-treatable are also annealed to relieve the ha,.__,_..
working. These may be slowly cooled to allow full precipitation of the
constituents and produce a refined microstructure.
,,. Ferrous alloys are usually either "full annealed" or "process annealed.• M
annealing requires very slow cooling rates, in order to form coarse pearlte.tl
process annealing, the cooling rate may be faster; up to, and lndudlng
normalizing. The main goal of process annealing ls to produce a untfonn
mk:rostructure. Non-ferrous alloys are often subjected to a variety of
annea ng techniques, including "recrystallization annealing," "part\a\
annea ng," "full annealing," and "final annealtng.11 Not a\\ annea\\ng
techniques involve recrystallization, such as stress relieving.

27• •·1~t lS mean by stress relieving?

Stress retievang 1s a technique to remove or reduce the internal stresses created in a

metal. These stresses may be caused in a number of ways, ranging from cold wortr:tna te
non-uniform cooling. Stress relieving fs usually accomplished by heating a metal below
the lower cr1t1cal t emperature and then cooling uniformly

28. What rs mean by tempering?

» Tempering 1s a process of heat treating, which 1s used to Increase the tou&hnessaf. .

based alloys. Tempering is usually performed after hardening. to reduce IOl&te of...
excess hardness, and is done by heating the metal to a much lower temperlltWe.._
was used for hardening. The exact temperature determines the amount of~ ,-i]
removed, and depends on both the specific composition of the alloy Ind an tile~
properties 1n the finished product. For instance, very hard tools are often~

•
 low temperltures, while spnngs are tempered to much higher temperatures In glass,
tempenng ts performed by heating the glass and then quickly cooling the surface,
inausing the toughness.
29. What is mean by hardening?

> ltazdenlftl is a metallurgical and metalworking process used to increase the

hfrdness of a metal. The hardness of a metal 1s directly proportional to the
unlaxial v1eld stress at the location of the imposed strain. A harder metal will
have a higher resistance to plastic deformation than a less hard metal.

> more commonly known as guenching and tempering, 1s a hardening mechanism

specific for steel. The steel must be heated to a temperature w here the iron
phase changes from ferrite into austen1te, I.e. changes crystal structure from BCC
(body centered cubic) to FCC (face centered cubic). In austenitic form, steel can
dissolve a lot more carbon. Once the carbon has been dissolved, the material is
then quenched. It is important to quench with a high cooling rate so that the
carbon does not have time to form precip itates of carbides. When the
temperature is low enough, the steel tries to return to the low temperature
•
crystal structure BCC. This change 1s very quick since 1t does not rety on diffusion
and is called a martensitic transformation. Because of the extreme
supersaturat\on of sohd solution ca rbon, the crystal lattice becomes BCT (body
centered tetragonal) instead . This phase 1s called martens1te, and 1s extremely
hard due to a combined effect of the distorted crystal structure and the extreme
solid solution strengtheni ng, both mechanisms of whi ch resist slip dJslocat1on
> All hardening mechanisms introduce crystal lattice defects that act as barrJers to
dislocation slip.

30. What Is mean by solution annealing?

Solution anneaflng Is a process performed on steels. In our case, these are pr1mar1ty the
300 series stainless. The process consists of heating the material up to a temperature
above 106s•c / 19so•F and holding 1t long enough for t he ca rbon to go into solution.
Afttr this, the material Is quickly coo led to prevent the carbon from coming out of
tolutJon. Solution- annealed material is In its most corrosion-resistant and ductile
(fltruble) condition.

It. A5MC 831.3-2012 Process Piping

Fluld Sefvlce: The application of piping system, considering the com blnat1on of fluid .
~operating conditions and other factors that establish the basis for design of
r,aem. Appendi>< M
setvlce:
 » The fluid handled 1s nonflammable, nontoxic, and not dafnllinl to
tissues as defined 1n para 300.2
» The design gage pressure does not exceed 103SkPa (150 psi)
» The design temperature 1s not greater than 186• C(366.F)
» The flu id temperature caused by anything other than atmospheric candltloll
not less than -29•c (-20.F}

Category M Fluid Service:

» A fluid service in which the potential for personnel exposure is Judted to be

significant and in which a si ngle exposure to a very smaH quantity of a tC»Clc
fluid, caused by leakage, can produce serious irrevemble harm to persons on.
breathing or bodily contact, even when prompt restorative measures are takai.

Normal Fluid Service: '

» A fluid service pertaining t o most piping covered by this code, i e not subject to
the rules for category D, Category M , Elevated Temperat~ * high pressure, or
High purity fluid service