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3. ASME SECTIONS
a) SECTION I
Materials
Part A - Ferrous Material Specifications
Part B - Nonferrous Material Specifications
Part C - Specifications for Welding Rods, Electrodes, and Filler
Metals
PartD - Properties (Customary)
PartE - Properties (Metric)
c) SECTION III
Subsection NCA ---- General Requirements for Division 1 and Division 2
Division 1
Subsection NB-Class 1 Components
Subsection NF Supports
Appendices
d) SECTION IV
Nondestructive Examination
f) SECTION VI
Vessels
i) SECTION IX
k) SECTION XI
a) V Groove
b) U Groove
c) Double V Groove
5. What are the different types of Base Material with Grade?
CS
i)A 106 GrB
ii)A53 OrB
iii) API 5L Gr B
SS
i)A304
ii) A 304L
iii) A 316
iv) A 31 6L
v)A321
vi) A 322
vii) A 347
viii) A 348
ALLOY
A335 -P11
A335-P22
MONEL
ASTM B 165 No: 4400
ALUMINIUM
SB 241 Grade 5083
7. Materials
(F Nos) GTAW SMAW
CS 6 4
ALLOY 6 4
SS 6 5
MONEL 42 42
8. Material Consumables:
GTAW SMAW
CS ER 70S 2/3/4 7018,7018 1
SS ER 308, ER 308L E308,E308L
ER 316, ER 316L E 316, E316L
E. z-132
cs-
i-
9. Specify Electrode Trade Name
ESAB, LINCON, ADOR, GEKA, METRODE
10. Welding Position
Pipe 1GR, 20, 50, 60, 6GR
Plate 10,20, 3G, 4G
PIPE:-
10: A Pipe is Horizontal Position and weld beed is a vertical position. The Pipe
-
will be rotated.
20: A Pipe is Vertical Position and weld beed is Horizontal Position
-
PLATE:
10: Plate is Horizontal and weld is Horizontal
-
11. What is pre-heat temperature for CS, SS, ALLOY, and MONEL?
CS Less 25 mm 10C Mm Above 25 80 C
SS Max 10C
ALLOY P 11 150C, P 22 149C
MONEL - Max 10C
12. Interpass Temperature
CS 250C
SS 150C
ALLOY P11 260C
ALLOY P22 - 3 00C
MONEL - 200C
13. Types of Welding Position?
Uphill Position and Down Position.
14. What is PWHT?
Post Welded Heat Treatment, To Remove Residual stress.
CS Above 19 mm
- 593C to 647
Alloy Above 13 mm 704C to 760! High Alloy 730C to 790C
15. Gas Backing
When we are using SS material must use Purge Gas
May be Argon I Nitrogen
16. What is Pipe?
It is a tubular item made of Metal, Plastic, and Glass etc.
17. What is the width of Weave Bead?
Max. Weave width 3x Electrode dia.
18. Write the weld layers?
1. Root
II. Hot Pass
III. Fill
IV. Cap
19. PWHT for Ni Alloy?
13mm *550C to 585C
20. What are the main Responsibilities of Welding Inspector?
To Observe, To Record, To compare (acceptance levels)
21. Type of Common Welds?
Groove Welds
Fillet Welds
Spot / Seam Welds
Plug / Slot Welds
Edge Welds
22. Type of Common Joints?
But Joints
T Joints
Lap Joints
Open Corner Joints
Closed Corner Joints
23. Types of Joint Preparation?
Bevel, V, J, S (Single & Double Sided)
24. What are the Weidment Terms?
i. Weld Face
ii. Weld Root
iii. Fusion Zone
iv. Fusion Boundary
v. Heat Affected Zone (HAZ)
vi. Weld Toes
vii. Weld Width
25. What are the Welding Imperfections?
I. Cracks
II. Gas Pores and Carities
III. Sold inclusions
IV. Lack of Fusion
V. Surface and Profile
VI. Mechanical / Surface damage
VII. Misalignment.
26. What is the major Inspection of Material Receiving?
a) Size
b) Condition
c) Type / Specification / Schedule
d) Storage
e) Heat Number
27. Pipe Inspection (Material)?
i) Welded Seam
ii) Inside 0
iii) Out side 0
iv) Length
v) Wall Thickness
28. What is Steel?
An Alloy of the Iron with the Non Material Carbon
(0.01 -1.4% C)
29. What is Plain Carbon Steel?
Steel that contain only Iron & Carbon are main elements,Traces of Mn,Si,Al,P&S
may be also present from refining.
30. Low Carbon Steel?
6.01 0.3%C
31. Medium Carbon Steel?
0.3 C
0
0.6
32. High Carbon Steel?
6.6 l.4oC
33. Low Alloy Steel?
Steel Containing Iron and Carbon and other alloying elements.
i.e.:- Mn, Co, Ni, Mo 7% Total
34. Which of the following is a function of a flux coating of a SMAW electrode?
All, Insulation, Alloying, De oxidation shielding.
35. Write Pipe Specification?
Material Pipe, Size, Length of Pipe, Size of Bore
36. Types of Gasket?
F.F Float Face - Metallic Gasket
R.F Raiced Face - Non Metallic Gasket
37. Types of Metallic, Non Metallic Gasket?
Metallic Non Metallic
Spiral Wound Gasket Rubber Gasket
Octagonal Ring Gasket Asbestos Gasket
Plat Ring Gasket Tufflon Gasket
Oil Paper Gasket
38. Write Small Bore Fittings?
Weldolet
Sockolet
Threadolet
Elbolet
Neppolet
39. Types of Flanges?
Weld Neck Flange
Slip On Flange
Socket Flange
Screwed Flange and Blind Flange
40. Types of Nipples?
Plain
Threaded
Swage
41. Types of Caps?
But weld Caps
Threaded Caps
End Cap
42. Types of Coupling?
Full Coupling, Half Coupling, Threaded Coupling, Reducer Coupling.
43. Types of Boss?
Weld Boss, Socket Weld Boss
44. Types of Orifice Plates
Concentric Orifice
Electric Orifice
Segmetal Orifice
45. Types of Electrodes?
Coated Electrode
Bare Electrode (Non Coated Electrode)
46. Size of Electrode?
1.6 mm
25mm
3.15 mm
4 mm
5 mm
6 mm
47. Duties of Welding Inspector?
I. Pre heating (Method & Control)
II. In Process distortion control
III. Consumable Control
IV. Welding Process
V. Welding run sequence and Interpass temperatures
VI. Mm / Max Interpass temperatures
VII. Full compliance with all elements given on the WPS
48. Duties of Welding Inspector after Welding?
i) Visual Inspection
ii)NDT
iii) Repairs
iv) Repair Procedure (NDT / Welding)
49. Tool Box
a) A Welding Gauges
b) Tap
c) Torch
d) Mirror
e) Pen Report
50. Fillet Weld Profiles
Convex, Concave, Mitre
51. What is the Profile Imperfection?
i) Spatter
ii) In Completely filled Groove
iii) Lack of Root Fusion
iv) Incomplete Root Penetration
v) Shrinkage Grooves
vi) Root Concaring
vii) Crater Pipe
viii) Excess Penetration
ix) Bum Through
52. Accepted Mis Alignment?
1.5 mm as per ASME 31.3
53. What is Mechanical Testing?
Hardness, Toughness, Tensile Strength, Ductility.
10
54. Major things of welding Procedurc?
a. Pipe Dia & Thickness
b. Welding Position
c. Process
d. Material Group
e. Consumable
f. Heat Input range (Kg / mm)
g. Preheat & PWHT
55. Explain E 8018
E Electrode
80 Tensile Strength
1 Position
8 Coating
56. Inspection of Before Welding?
1. Application Std
2. WPS
3. Welder Qualification
4. Material Composition
5. Condition of Material
6. Types of Edge Preparation
7. Consumables
8. Welding Process.
57. Inspection of after Assembly
Clearance dimensions
58. What is soluble dam?
Soluble dam is water solute material used for refracting the purging gas
with in the pipe.
59. What should be the radius of long radius elbow?
I .5D (D is diameter of the pipe)
60. What is the true welding inspector certifications covered in AWS QC -1?
CWI, CAWI, SCWI
61. What are is generally considered to be the most important quality of a Welding
Inspector?
Professional attitude
62. The vision requirements for a CWI are near vision acuity on:
Jaeger J2 at 12 inches, with or with out corrective lenses.
63. The a Welding Inspector should have a basic understanding of
Welding Process
Nondestructive testing methods
Code and Standards
64. The term used to describe delay in the production schedule to permit inspection is
Hold point
65. Inspection report correction should be made by:
Single line out the error correct the error, date end initial
66. A definition of ethics is:
1. Using common sense and honesty
2. Living by the rules
3. Being faire and impartial
4. Basing decisions on facts
67. For communication to be effective it should form a continuous ioop
1. True
68. Proper usage and handling of compressed gas cylinders include.
Not welding on cylinders
Not including the cylinders in the ground or electrical circuit
Securing them properly.
Identifying the gas prior to use.
69. Acetylene becomes unstable above what pressure?
15 psi
70. Oxygen is a flammable gas
False
71. Electric currents above approximately 6 milliamperes are considered
Primary currents, Harmyel
72. When operating gas cylinders the primary value should be opened
One turn or less onan acetylene cylinder.
All the way onan oxygen cylinder to backseat the value
73. Why is there an increasing need for weld quality?
Safety
Economics
Less conservatives design
Government regulations
74. What AWS documents describe the rules for the CWI certification program?
AWS QC -l
75. Weld quality control should begin after welding has been initiated
False
76. The a acronym KASH stands for
Knowledge, Attitude, Skills and Habits.
77. A metal that is difficult to magnetize is said to have?
Low Permeability
78. Ferromagnetic Material is?
Strongly attracted by a magnet.
Capable of being magnetizer
79. A circular field may be induced in to a specimen by which of the following methods?
a) Direct Induction (Head Shot)
b) Direct Inductions (Prods)
c) Central Conductor
80. The permeability of a material describes?
The easy with which it can be magnetized.
81. In which material can be magnetized?
Iron, Nickel, Cobalt
82. The magnetic Field is Stronger when?
The magnetizing current is flowing
83. The unit usually used to denote flux density is the?
Gauss
84. Materials which are repelled magnetically are called?
Dia magnetic
85. Materials which are attracted magnetically are called?
Ferromagnetic
86. The interpretation of magnetic particle indications may be aided by?
Observing the indications as they are formed
87. Materials which are strongly attracted to a magnet are called?
Magnetic Materials
88. During magnetic Particle testing generally leakage field caused by discontinuities
which are?
Transverse to magnetic Field
128. In penetrant testing the time period from developer application to inspection
after
refereed to as?
Development time
129. The method used to remove excess visible dye penetrant from a test part
is primarily
deferment by the?
Surface roughness of the part under test
130. A discontinuity that must be found in welding?
Crack, lack of penetration
132. For applying non aqueous developer is normally considered most effecti
ve?
Spraying
133. Developer assists in the defection of the visible dye penetrant lot indicat
ion by?
Providing a contracting back ground
136. In which conditions will decrease the life of a black light bulb?
Line voltage fluctuations
138. When using the dry developer, the drying operation is performed?
After application of the developer and before inspection
18
141. In a post emulsifiable dye penetrant the emulsifies time?
Is the faire needed to rise the emulsifies and excuses pnetrant from the surface
152. Emulsifies?
Is a liquid act with surface penetrant to make water wasable after penetration time
the surface penetrant is clean with water so the surface to be drayed by hot air than
apply
developer than evaluations
156. By spraying?
Is advantages because the solvent enter to the discontinuity and Cary out the penetra
te
and solvent can be evaporate the penatrant will form the cane indication very well
and we
cant early see the defect
Solvent
20
158. Soliable
Particle diluted with water this developer will term fungus but ready to use
159. Suspended:
Water is only the curies this will slot form fungus but an Every way we have to
Shake.
160. Filter:
Will charge the while light to UV light 365 NM of wave length
161. Lipophilic emulsifies:
Is act with surface penatrant by diffusion process
VT Visual testing
AET Acoustic Emission Testing
TIR = Thermal Infrased Real Testing
NRT = Neutron Radiographic Testing
ET Eddy Current Testing
LT Leak Testing
V.A.T. = Vibration Analysis Testing
RT Radiographic Testing
UT Ultrasonic Testing
PT = Penetrant Testing
MT = Magnetic Particle Testing
Designation number
-
,v,
2
Contrast 0 0 0
Level X
4T iT 2T
Sensitivity level
yt/T
No e
-0.693 x
No e e
0 462 0.95
24
Fixes is used to remove thc developed silver bromide lmts.
Fixing has a solvable compound with silver bromide
Fixes is a sodium thiosuiphate a cleaning agent.
Dryer
182. Stages
Avoid guide to be bend
Use minimum guide tube length
Use collimeter
Survey meter
Area cordon
Bate return of source
Emergency requires proper procedure
Camera back to storage room
Camera maintenance at least once in three month
Collimeter tungsten
Porosity due dirty electrode wire, dirty base metal, improper technique
Undercut current too high, welding speed too high, arc length too long
Incomplete fusion due to faulty joint, improper weld rod diameter,
improper weld polarity
Incomplete penetration faulty joint design, welding speed too rapid, weld
current too low, arc length too long.
26
Process defect
189. Principle of Ui.
Reflection of Sound
190. Sound
Sonic
Subsonic Ultrasonic
Industrial Purpose
Above 204 Hz
Ultrasonic Waves
V1,V2
197. UT Machine
Flow Detector
+
1.) mod sonic
2.) Sonatest
a.) site scan 140
b.) site scan 240
c.) site scan 444
28
d.) sitc scan 346
3.) Kraut Grammes
4.) Panameterix
5.) P x 10
6.) P x 20
198. What is the use of couplant?
To remove the air gap between the transducer and object.
29
t.) Amptitude control linearity
203. Resolution
Place the normal probe at a focal point in V, block for a 100mm
range.
The echo will comes at 85, 91, 100 mm separately
204. Penetration
Place the normal on perspex, the echo will come out 50mm based
upon
velocity station perspex & steel [2730:5920j 23.5 mm Perspex is
equal to
50mm of steel.
205. Sensitivity
Place the probe towards 1.6mm hole the echo will come at 15 (01)35
.
209. DAC
Distance Amplitude Correction Curve
A scan -1605 mHz
30
210. Types of Probe.
Normal probe, Angular probe, triangular probe (45, 60, 70).
211. Normal probe, Triangular probe.
Normally used for thickness check-up only.
212. Angular Probe
Used to find the weld defect.
213. Size of the probe.
8 x9,20x22
214. Formula
2 beam path
V t /cos 0
Full beam path 2t/cos 8
1 V2 beam path 3tlcos 9
2 beam path 4t/cos 0 215. Skip distance
2 skip distance
V t x tan 0
Full skip distance = 2t x tan 0
1 V
2 skip distance =3t x tan 0
2 skip distance 4t x tan 0
215. Depth
V
d
2 epthbeampathxcos 0
Full depth 2t-beam path x cos 9
1 /2 depth beam path x cos O-2t
2 depth = 3t-beam path x cos 0
216. Location
Beam path x sin 0
219. Below 38mm we use 4mHz probe, above 38mm we use 2mHz probe.
220. V
2 Block
Notes:
Based upon V 2 block, echo pattern facing the angle probe towards 25mm
radius the 1
St
echo will come at 25mm make the echo to 2.5 divisions. The
next echo will come in an increment of 75mm to 100mm automatically at
th
10
division. A 100mm range facing the probe towards 50mm radius the
l echo will come at 50mm make this echo at 4 th
division, the next echo
will increment at 75 to 125mm at the 10
th
division.
221. V
1 Block
Notes:
Based upon Vi block echo pattern face that angle probe towards 100mm
radius at focal point echo will come at 100mm make this echo at 4th
224 Protective Equipment not suitable for Eye protection from welding Radiation Includes:
Clear Safety Goggles
226 Before Working on Equipment Where Machinery Guards Have been Removed a Lock
Tag and Try Procedure should be Completed:
TRUE
227 n Avoiding Jumes During Welding the Most Important Factors is.
The Position of the Welders Head
228 It is not Important to Consider Ventilation During Welding and Cutting Operations:
Fiase
230 Some of the Toxic Material the Welder may be Exposed to are:
Cadmium,Chromium,Nickel,Lead
231 The Welding Inspector is Exposed to Which of the Following Safety Hazards:
(i)Rediation (ii)Jalling Objects (iii)Eletrical Shock,(iv)Eye Hazards
233 The Most Important Component of an Effective Safety and Heath Programe is:
Management Support
237 Empolyes Must Make all Applicable MSDS data Aviable to their Empolyes
TRUE
240 NDE personnel (other than CWI ) should be certified to what document
AS NT. SNT- TC-IA
242 The CWI Exam has several parts,these are fundamentals pratical code
TRUE
243 The CWI Exam requires that the Dl .1 code be used for the open book code test
FALSE
245 API Standard 1104 Corers the Fabrcation of Gross Counter Bridges.
FALSE
246 Some of the Apporval Codes/Standard for the Open Book, Portion of the CWI Exam are
AWS Dli, API 1104,AWSD1.5, and AWSDI5.1:
TRUE
247 Prior to Staring a Jop Assignment, the Welding Inspector should Determine:
(i) What code standard ,or Specifycation applics (ii) What Inspections should be Conducted,
(iii) When Inspections should be (iv)Where Records are Main Tamed
249 What is the Thumb Ruch to Calculate Spanner. Size of Given Bolt?
1.5 Dia of Bolt
250 What is the Thumb the to Calculate Current Required for Welding
Current (AMP) = (Diameter elevation (mm) *
40)
251 What are Items we are Remoting Before the Hydro Test in the line?
(I) Control Value (ii) Orgnic Plate (iii) Rote Mat (iv) Safety Values (v) Thermowells
252 What is use of Reduces?
To Joint Different Diameter of Pipes
Differend Bolt Stud Bolt
It has head It is thread Bolt End
One end and
Has therading
Other end
It is tightened
With_a_Nut
257 What is the ANSI/ASME Dimiensional STD for Steel Flange & Filling?
(i) B 16.3 (ii) B 16.5(iii) B 16.9 (iv) B 16.10