1. What is welding procedure specification?

2. A PQR

• SA 516-70

SMAW = 3/4” • PWHT at 11000F for 1 hr.

T = 1”
• Satisfy UG-84 reqmn’t (impact test)
GTAW = 1/4”

Is this PQR can support the WPSs for the following production welding, where impact test is also
required ?
a. Shell to shell : SA 516-60, 1” Thk., SMAW only, PWHT 1 hr.
b. Shell to head : SA 516-70, 2” Thk., SMAW only, PWHT 2 hr.
c. Nozzle neck to Flange : SA 106-C to SA 105, 3/4” Thk, GTAW only, PWHT 1 hr.
D. Nozzle neck to Flange : SA 106-C to SA 105, 1/2” Thk, GTAW only, PWHT 50 minute.

3. Welder Qualification
A welder tested on a 1” NPS Sch 80, 6G position, SMAW. The Visual inspection &
Radiographs result comply to QW - 194 & QW - 191 (respectively) requirements.
Is the Welder qualified to weld 2” NPS Sch 80, 5G position using same welding process?

4. Who is responsible for preparing the foregoing and what are the requirements for
documentation under the Code ?

5. a) Who is responsible for the quality of welding produced in Code manufacturer's shop ?

b) Who is responsible for qualification of welding procedures, welders and welding

operators?
c) Who may ask for the re-qualification of a welder ?

6. a) How long does a welder's qualification remain valid ?

b) Who maintains the qualifications records of procedures, welders, and welding
operators?

7. For welder qualification tests :

Under what conditions may a welder be re-tested after one or more of his test specimen
failed to meet requirements ?

8. For welder qualification tests :

a) Will passing test on pipe specimens qualify welder on plate ?
b) How often should welders be required to make qualification tests ?

9. Under what conditions has an Authorized Inspector the right to call for re-qualification of a
welding operator or welder ?

10. What is a "backing strip" as used in metallic arc welding ?

11. What is meant by the terms " lack of fusion"?

12. What is meant by the terms " lack of penetration"?

13. What is meant by the terms " slag inclusion"?

14. a) Describe " Heat Affected Zone"

b) How can we reduce the effects of the "Heat affected Zone" ?

15. Name three arc-welding processes.

16. a) What is the basic difference between gas metal arc welding and gas tungsten arc
welding processes ?
b) In Submerged arc welding, what conducts the current between the electrode and the
base metal ?

17. What deficiencies would you look for on visual inspection of welded horizontal and
circumferential joints in a vessel shell ?

18. a) How must a welder identify the welding which he has performed in production ?
b) Why is this identification necessary ?

19. In procedure or performance qualification tests of welding, what is the difference

between a transverse face bend test and a transverse root bend test ? Youmay answer
this by description or sketches.

20. Three (3) lathe-turned tensile test specimens of welded joints confirming to Figure QW-
462.1 of Section IX are prepared from steel of the following ultimate tension strengths, are
of the following diameters and broke under the ultimate tension loads shown below. All
broken in base metal outside the weld and heat affected zone. Are tests satisfactory or
unsatisfactory. Give reasons for your answers.

Diameter Ultimate Ultimate

Tensile PSI Total Load (Broke)

1. .507" 60,000 PSI 12362 lbs.

2. .345" 75,000 PSI 6723 lbs.
3. .255" 90,000 PSI 4268 lbs.

21. If a tension test breaks in the plate, is it acceptable?

22. What are the various positions in which a welder may qualify and describe each?

23. What steps are necessary to qualify a welder for all position pipe welding?

24. What tests are required for the weldment made for qualification of a welding procedure?

25. What is an essential variable on a welding procedure specification ?

26. What is a non-essential variable on a welding procedure ?

27. Who is responsible for conducting tests of welding procedures and for qualifying welding
operators ?
28. What is a fillet weld & what is the throat of a weld ?

29. What is porosity as used in welding ?

30. In performance qualification of pipe groove welds to ASME Section IX, which position
requires more than two guided bent specimens for qualification ?

31. Name four causes of undercutting during the welding process. Give four methods of
correction.

32. A welder has been tested in 6-G position, using an E-7018 F-4 electrode, on 6” sch 160
(.718” nom.) SA 106-B pipe. Is this welder qualified to weld a 2” 300# ANSI schedule 80
bore flange to a 2” schedule 80 SA 106-B nozzle neck ?Explain your answer

33. You are reviewing a WPQ (QW-484) for a welder testing in the 6-G position, on SA-53
grade B pipe (TS – 60,000 psi). the test results indicate the following :
T1 - Tensile developed 61,000 psi, broke in the weld
T2 - Tensile developed 66,900 psi, broke in base metal
B1 - Transverse root bend satisfactory
B2 - Transverse face bend satisfactory

a) Would the test be acceptable ?

b) Explain your answer.

34. For ASME welders qualification tests:

a) Will qualification on pipe for all positions also qualify the welder to weld all positions
on plate ?
b) How may a welder who fails on one or more test specimens be retested immediately

35. For ASME welders qualification tests:

a) In Welding Procedure Qualification, if a tension test breaks in the plate, is it
acceptable?
b) A Welding Procedure Specification qualified on groove welds. Is the Welding
procedure Specification also qualified for weld repairs to groove welds and for weld
built up ? Explain your answer !

36. a) What steps are necessary to qualify a welder for all position pipe welding
b) A nozzle will be attached to the shell at the top side, the shell is in horizontal fixed
position. What is the minimum welder position required ?

37. In performance qualification of pipe groove weld 6G position, 2 side bend tests were taken
from the test coupon. A 1/16” open defect found on one of these two specimens. Is the
welder pass the qualification test ? Give reason for your answer.

38. In Welding Procedure Qualification, tension test breaks in the weld metal at 97% of
specified tensile strength of the base metal. Is the test satisfactory ?

39. What is the meaning of the third digit in the mild steel covered arc welded electrode E -
7018 ?
39. In performance qualification of groove welds using SMAW. Is the test coupons may be
examined by radiography? Explain your answer!
40. A Welder Qualified by 8” Sch 80 pipe (0.500"thk.) in 1G position, Is he qualified to weld a
0.750” thk. plate in horizontal position ? Why ?

41. A Welder Qualified using E-7028 electrode, is he qualified to weld using E-6010 electrode
Why ?

42. Plate 0.5” thk. In Flat position has been used toqualify a WPS. Is this WPS can be used in
production welding on 8” pipe 1” thk. Horizontal fixed position ? Why ?

43. A Qualified WPS without PWHT has been used in production welding of Pressure part.
The complete production welds are subject to PWHT according to Code requirements.Is
the weld acceptable ? Why ?

44. Reviewing the PQR No. 03 for Base Metal (QW-403), which of the following is most
applicable?
Anda me review PQR No. 03 untuk base metal (QW- 403). Pilihlah yang paling tepat dari
pernyataan berikut
a. All required, applicable, essential variables are defined on the PQR and are within the
limitations set by WPS
Semua variable esensial telah dicantumkan dalam PQR dan masih dalam limitasi
yang tertera pada WPS
b. The are no required, applicable, essential variable for the QW-250 rules,
Sesuai dengan QW-250, tidak ada esential variable yang dipersyaratan
c. One or more required, applicable, essential variables has not been listed on the PQR
Satu atau lebih essential variable itdak dicantumkan dalam PQR.
d. One or more of the required, applicable, essential variables listed exceed the
imitations set by WPS
Satu atau lebih essential variable melebihi limitasi yang tertera pada WPS

45. Reviewing the WPS No. 04 for Filler Metal (QW-404), which of the following is most
applicable?
Anda me review WPS No. 04 untuk Filler metal (QW- 404). Pilihlah yang paling tepat dari
pernyataan berikut
a. All required, applicable, essential variables are defined on the PQR and are within the
limitations set by WPS
Semua variable esensial telah dicantumkan dalam PQR dan masih dalam limitasi
yang tertera pada WPS
b. The are no required, applicable, essential variable for the QW-250 rules,
Sesuai dengan QW-250, tidak ada esential variable yang dipersyaratan
c. One or more required, applicable, essential variables has not been listed on the PQR
Satu atau lebih essential variable itdak dicantumkan dalam PQR.
d. One or more of the required, applicable, essential variables listed exceed the
imitations set by WPS
Satu atau lebih essential variable melebihi limitasi yang tertera pada WPS