QA/QC WELDING INSPECTOR CBT Q & A MUHAMMAD WAQAS / MUHAMMAD TABISH

CBT WELDING QUESTION

1. Heating and cooling general for material soft?
Ans: normalizing.

2. False Indication occur in film is rejected?

Ans: False

3. Grove Slope surface against weld applied for what?

Ans: Grove angle

4. Work place the electrode –ve in current polarity?

Ans: Straight

5. Cross country pipeline welding qualification?

Ans: API-1104

6. Storage Tank welding qualification or acceptance criteria?

Ans: ASME SEC VIII DEV 1

7. WPS, PQR, WPQ are abbreviations for what?

Ans: WELDING PROCDURE SPECFICATION, PROCDURE QUALIFICATION RECORD,
WELDER PERFORMANCE QUALIFICATION.

8. NDT STANDS FOR?

ANS: NON DESTURCTIVE TEST.

9. 3G QUALIFIED?
ANS: PLATE: 1G & 3G OR IN PIPE ONLY 1G POSITION.

10-LOW HYDROGEN ELECTRODES.

ANS: 8ml for per 100g

10. How to reduce the moisture pickup on the electrode.

Ans: proper consumable handling and storage.

11. Apparent from bevel in lamination how to find?

ANS: PENETRATION TEST (P.T)

12. Cross country pipeline heat input should not exceed?

Ans: 0.8kj/mm
QA/QC WELDING INSPECTOR CBT Q & A MUHAMMAD WAQAS / MUHAMMAD TABISH

13. Pipeline acceptance standard?

Ans: API 1104

14. The pipe is vertical and weld is in vertical what the welding position is?
Ans: 2G Position

15. The welder welded 6” pipe and the minimum weld length how much required for RT?
Ans: Full Length

16. What are the documents referred by welding inspector?

Ans: WPS

17. Visually unlike to find the defect less to find in vt?

Ans: lamination

18. In plant piping mostly effected defects are?

Ans: internal, surface & sub surface.

19. Most affected element in steel?

Ans: C CORBON

20. Pipeline misalignment how much?

Ans: 3mm as per API 1104

21. How to find mismatch for plant piping?

Ans: HI-LOW GAUGE

22. Which flame using for shielding in steel?

Ans: natural gas, combination, propane, oxidizing

23. Primary element in weld symbols?

Ans: Reference line.

24. RT/VT acceptance standard?

Ans: B31.3

25. Mostly commonly used NDT on surface defects?

Ans: Penetration Test (PT)
QA/QC WELDING INSPECTOR CBT Q & A MUHAMMAD WAQAS / MUHAMMAD TABISH

26. Which grade material using for above 400c?

Ans: A335

27. Welder qualified in 3G pipe position what positions he is qualified?

Ans: There is no 3G position in Pipe welding only 1G,2G,5G & 6G)

28. A welded joint has hoop stress of 20% in B31.8 what is its acceptance standard?
Ans: API 1104

29. Electrode E-6010 required how much time drying in oven?

Ans: 6010 and such should not be stored in an oven. They have a cellulose
based coating which needs a little moisture to work right. Really, only 'low
hydrogen' rods are required to be stored in an oven.

30. STRA TEST is used for?

Ans: Through thickness propertied in Z direction.

31. Convex fillet weld size determined by?

Ans:
32. SFA NO: for electrode E 8010?
Ans: SFA 5.5
33. NDT method for testing fillet weld?
Ans: PT (PENETRATION TEST)
34. NDT method for surface defects?
Ans: (P.T) Penetration test
35. In FCAW how can you protect the arc from windy climate?
Ans: use welding booth for wind protection.
36. Duties of the welding inspector in WPS/WPQT?
Ans:
37. Due to what crater pipe defect Accor?
Ans: poor technique
38. Which ndt method is to be used for surface defects in mig welding process in aluminum
alloy pipe?
Ans: PENETRATION TEST

39. Which ndt method is used for detecting lamination in non-bevel area of pipe?
Ans: Ultrasonic Test.
40. What defects comes due to usage of dump electrodes?
Ans: Porosity.
41. Welding machine calibration standard?
Ans: BS-7570
 SAUDI ARAMCO QUESTIONS FOR WELDING INSPECTOR:-
1) Duties of welding Inspector
ANS: - There are three stages of duties as follows:-
BEFORE WELDING
1) Joint fit up inspection (Root gap, bevel angle etc) . 4) Calibration of welding Machine & ovens.
2) Welder ID card . 5) Base metal, Thickness of base meta & consumable as per WPS.
3) WPS application . 6) Pre heat requirement.

DURING WELDING
1) Welding Parameters like current, Volt & travel speed. 4) Gas flow rate .
2) Welding process must be verified. 5) Consumable brand.
3) Interpass tempreture measurement.

AFTER WELDING
1) Weld Visual Inspection.
2) Any PWHT requirement.
3) NDE requierement.

2) What is WPS
ANS: - WPS is stands for Welding Procedure Specification.
It is a written document which provides the direction to the person applying the material joining process.

3) What is PQR
ANS: - PQR is stands for Procedure Qualification Record.
PQR is record of variables recorded during the welding of test coupon & to fulfill the required Mechanical properties.

4) Difference between WPS & PQR

ANS: - WPS contains the qualification ranges & PQR contains the actual value recorded during welding of test coupon.

5) What is essential Variable

ANS: - A Change in a welding condition which will effect on Mechanical properties of weldment & it shall require re-
qualification of WPS. Example: - P-Number, PWHT, F-Number & Pre-heat.

6) What is non-essential Variable

ANS: - A Change in a welding condition which will not effect on Mechanical properties of weldment & Changes may be
made without re-qualification of WPS.
Example: - Groove design, Root Gap, Electrode diameter.

7) What is supplementary Variable

ANS: - A change in a welding condition which will affect the notch – toughness properties of the weldment. In this condition
supplementary essential become as additional essential variable.

8) What is Polarity
ANS: - Polarity is determined whether the most of the arc energy is concentrated at the electrode surface or surface of the
parent material

9) What is straight Polarity

ANS: -When the electrode is connected to the negative terminal of the power source.
10) What is reverse Polarity
ANS: - When the electrode is connected to the positive terminal of the power source.

11) Define Low hydrogen Electrode

ANS: - Electrodes which contain hydrogen level less than or equal to 8ml/100gm of deposited weld metal.
Measured accordance with AWS A4.3

12) Explain E – 7018

ANS: - E - electrode
70 - Minimum tensile strength (KSI)
70000 – Minimum tensile strength (PSI)
1 – Welding position
8 – Type of coating & current characteristics.

13) Explain E - 70S-6

ANS: - ER – electrode rod
70 - Minimum tensile strength (KSI)
S – Solid bare wire
6 – Chemical composition

14) Define SATIP, SATR, SAES and SAEP.

ANS: - SATIP – Saudi Aramco typical inspection plan.
SATR – Saudi Aramco test report.
SAES – Saudi Aramco Engineering Specification.
SAEP – Saudi Aramco Engineering Procedure.

15) Thickness Limitation for Procedure qualification

ANS: -
16) Thickness Limitation for performance qualification
ANS: -
17) Plate Welding Position’s
ANS: -

18) Pipe Welding Position’s

ANS:
19) Difference between 1G & 5G in pipe positions
ANS: - As above explained. (1G Pipe Rotated & 5G Pipe Constant).

20) If Welder qualified in 1 ½” Pipe diameter then what is his qualified range

ANS: - From 1” to unlimited diameter.

21) What is “ P ” Number & why it assigned

ANS: - “P” Number is assigned for base metals to reduce number of welding procedure.

22) What is “ F “ Number

ANS: - “F “Number is grouping of electrodes & welding rods.
F number is fundamentally determines the ability of welders to make satisfactory welds with a given filler metal.

23) What is “ SFA ” Number

ANS: -“SFA” Number is an ASME specification.
Example: - Steel and steel alloys
Aluminum and aluminum alloys etc.

24) What is “ A “ Number

25) ANS: - “A “Number is identified of weld metal chemical composition or weld metal analysis.

26) For What diameter GTAW process shall be used for all Pass of weld
ANS: - The GTAW process shall be used for all passes for butt welds and socket welds in piping & nozzles less than 33.4mm
outside diameter (1” NPS). This does not apply to weldolets, sockolets, threadolets & welding bosses.

27) If Welder qualified in “3G “then can he qualified to weld on pipe?

ANS: - Yes he can able to weld as Flat & Vertical position for pipe over 24” inch diameter.
And also able to weld in flat position for pipe less than or equal to 24” inch diameter.

28) What is the time limit for welder expiration?

ANS: - No greater than 6 months from the date of qualification.

29) What is the time period for welder renewal & what are the tests are required for renewal
ANS: - Welder renewal time period is within 6 months with below requirements:-
A) Welder shall have passed Mechanical & visual examinations.
B) Alternatively welder may be qualified by volumetric NDE.
C) Renewal of qualification may be done on production work.
30) What type of inspection required during incoming consumable inspection.
ANS: - A) Physical inspection any damaged or rusty
B) Comply the heat number of each pack against MTC.
C) Tensile test, elongation test, impact test & radiography etc.

31) Why tensile and bend test required for PQR

ANS: - Mechanical test is required to PQR qualification the PQR gives suitability of weld for required mechanical properties.
Tensile test indicates the strength of weld.
Bend test indicates the ductility of the weld.

32) What is the application of impact test

ANS: - Impact test helps in ensuring that the material is best for an application where it is subjected to such impacts.

33) What is heat input

ANS: - Heat input is the arc energy; it is the amount of heat generated in the welding arc per unit length of weld.

34) Formula of heat input

ANS: - Heat input = Current X voltage X 1000
Travel Speed (mm/sec)

35) How much illumination is required for visual inspection

ANS: - Minimum 1000 Lux light intensity & surface to be examined at an angle of not less than 300 degree.
The eye is within (24”) 600mm of the surface to be examined.
36) What are the additional tests are required for “ SS “ consumables
ANS: - PMI (Positive Material Identification).

37) For 20mm thickness how much impact test are required
ANS: - If PQR thickness exceeds 12mm & multiple processes or multiple consumables used, separate impact test specimens
shall be conducted for each process or each consumables.

38) “ DUCTILITY ” where you found in below test

A) Tensile test
B) Bend test
C) Impact test
D) None of the above

ANSWER. (A) Tensile test (After elongation) .

39) E-7018 What specify digit Number 3 & 4

A) Coating Characteristics , Position
B) Position , Coating Characteristics
C) Above A & B
D) None of the above

ANSWER. (B)
40) Which Welding process is less sensitivity related to wind
A) SMAW
B) GTAW
C) GMAW
D) None of the Above

ANSWER (A) SMAW.

41) Considering material which material get more distortion

A) Carbon steel
B) Alloy Steel
C) Stainless Steel
D) All of the above

ANSWER (C): Stainless Steel because of high heat input.

42) Define Plasticity

ANS: - The property of the material by virtue of which it tends to retain the altered size and shape on removal of deforming
force.

43) Define Elasticity

ANS: -The property of the material by virtue of which it tends to its original shape on removal of deforming force.

44) Define Ductility

ANS: - ductility is the ability to undergo tensile stress without fracture or damage.
Example: - ability to draw a material into a wire by pulling at the ends.

45) Define Malleability

46) ANS: - Malleability is the ability to undergo compressive stress without fracture or damage
Example: - Hammered or pushed into thin sheets without breaking.

47) Define Hardness

ANS:- The hardness of a metal is its resistance of plastic deformation.

48) Define Toughness

ANS: - Toughness is the amount of energy per volume that a material can absorb before rupturing.

49) Define Stress

2
ANS: - Force per unit area. N/M

50) Define Strain

ANS: - it is the ratio of change in length to the original length.

51) What is SOUR SERVICE

ANS: - Sour service refers to H2S (Hydrogen sulfide)

52) What is NON SOUR SERVICE

ANS: - Non sour services are those which do not include these harmful substances.

53) IF the surface with GAS then PQR have to prepare with IMPACT TEST
54) For “ SOUR SERVICE “ PQR is prepared with hardness

55) What is inert gas & active gas

INERT GAS: - Inert gas has no effect or no reaction with the welding process.
Example: - ARGON GAS.
ACTIVE GAS: - Active gas does have an effect on the welding process.
Example: - NITROGEN, OXYGEN, CARBON DIOXIDE, HYDROGEN USED FOR GMAW ON FERROUS METALS.

56) Types of consumables

A) Basic electrodes E-7018 (HIGH QUALITY) LOW HYDROGEN ELECTRODE
B) CELLOLOSIC E-6010 ROOT PENETRATION
C) RUTILE E-6013 MECHANICAL PROPERTIES

57) Susceptibility of hydrogen cracking

ANS:- Hydrogen cracking in the HAZ of a steel occurs when four (4) conditions exist at the same time
A) Hydrogen level > 15ml/100gm of weld metal deposited.
B) Hardness microstructure > 400HV hardness
C) Stress >0.5 of the yield stress
D) Temperature < 300 0C.

58) Delayed cracking

ANS: - Cracks may occur sometimes after welding has finished (Possibility up to 72 hours).

59) Weldolet :-
ANS: - Weldolet is used for butt weld branch connection where standard TEE is not available due to size
restrictions.

60) Sockolet :-
ANS: - Sockolet is used for socket welding of branch connection where require reinforcing pad.

61) Difference between pipes and tubes :-

ANS:-

PIPES TUBES
1) Pipes is identified by NB 1) Tubes is identified by OD
2) Thickness is identified by schedule 2) Thickness is identified by Birmingham wire gauge
62) Pre heat
Pre heat is done to slow down the cooling rate; pre heat temperature for CS above 19mm is 800C.

63) PWHT (POST WELD HEAT TREATMENT)

PWHT is done to remove residual stress from the weldment.

64) Post heat

To maintain uniform homogenous structure.

65) PWHT for Carbon Steel

A) Pre heat temperature above 19mm is 800C.
B) Soaking temperature during stress relieving is 6200C +/- 200C
C) Soaking time during stress relieving is 1 hour.
D) Rate of heat / cool is 1500C / hour.

66) PWHT for Alloy Steel

A) Pre heat temperature is 1800 C.
B) Soaking temperature is 7200C +/- 200 C.
C) Soaking time is 2 hours
D) Rate of heat / cool is 1000 C / hour.
E) Post heat is 3000 C.

67) Consumables used for different pipes.

PIPES FILLER WIRE ELECTRODE

1) A106 Gr.B ER70-S2 E-7018
2) A312 TP 304 ER308 E308
3) A312 TP304L ER308L E308L
4) A312 TP316 ER316 E316
5) A312 TP316L ER316L E316L
6) A335 P11 ER80S-B2 / ER515 E-8018-B2
7) A335 P91 ER90S-B2 E9018-B2

68) Current calculation for welding

ANS: - Current = (Diameter of electrode X 40) +/- 20

69) Alloying elements & effects

A) C- Carbon for strength
B) Mn – Magnese for toughness
C) S – Silicon for < 0.3% deoxidizer
D) Al – Aluminium for Grain refiner
E) Cr- Chromium for corrosion resistance
F) Ni – Nickel for Low temperature application
G) Mo – Molybdenum 1% creep resistance
H) V- Vanadium for Strength
I) S-Sulphur for residual element
J) Titanium for grain refiner
K) Nb- Nobium for grain refiner
L) Cu- Copper for weathering steel
70) CEV (Carbon equivalent value ) in steel
ANS: - Carbon equivalent value of a steel alloy refers to method of measuring the maximum hardness & the
Weldability of the alloy based on its chemical composition.
For, good weldability, CEV value must not exceed 0.45.

71) Consumable General Information

SMAW GTAW
A) SFA 5.1 SFA5.18
B) F.No 4 F.No 6
C) A.No 1 A.No 1
D) E-7018 ER 70S-2

ARAMCO STANDARD QUESTIONS SAES W-012.

72) Minimum circumferential distance (ARAMCO STATNDARD)

 The minimum distance (circumferential offset) between longitudinal welds (including spiral weld seams) of adjacent pipe
o Joints shall be 100mm.

100MM

73) Minimum distance between parallel girth weld (ARAMCO STATNDARD)

20mm or 3Tw whichever greater.

74) Interpass temperature

Ans :- 1) For P.No 1 ------ ------------- 3150C
2) For P.No 8 & P.No 4x ------- 1770C

75) Pre heat distance (ARAMCO STATNDARD)

75mm 75mm
76) Conditioning, storage, and exposure of SMAW Electrodes.

77) High Frequency Welding Machine :-

Except for P.No 1 base materials, all manual GTAW shall be used a high frequency start, post purge gas flow for
the torch & filler metal shall be added.

HIGH FREQUANCY MACHINE HAVE BELOW CHARECTERSTICKS

1) Quick arc ignite
2) Automatic pulsed
3) Post purge gas flow for torch

78) GTAW Process shall be used for all the passes for butt weld

Groove weld
Nozzles < 33.4mm OD or 1” NPS
Socket weld
79) GTAW Process shall be used for root pass for butt weld

Groove weld
Nozzles 60.3 mm OD or less
Socket weld

80) When internal coatings are specified on pipe lines , the GTAW process shall be used for the root pass of butt
welds ie for below 24” O.D.

81) Welding consumable shall be selected based on their mechanical properties.

82) Dissimilar metal welds are defined as any weld joint between ferritic steel & austenic steel, duplex stainless
steel or nickel base alloy.

83) Joint Preparation:- Oil, moisture, rust, scale, sand, paint or other foreign material shall be removed from the
weld surface & at least 25mm adjacent base metal prior to welding.

84) Buttering: - Buttering or weld build up on the prepared surface shall not exceed the lesser of 1/3 rd of the base
metal thickness or 10mm. Without the approval of CSD.
 The buttering operation shall be witnessed by Saudi Aramco inspection.
 The buttering shall be inspected by PT or MT after completion the build up but before final welding of the joint.
 Buttering of joints between dissimilar metal joints requires prior approval by CSD.

85) Welding Environment: - GTAW, GMAW, FCAW shall not be used for field or yard fabrication unless adequate
windshields are used.
 Wind velocity in the weld area for GTAW, GMAW or FCAW shall not exceed 8 KPH or 2.2 M / Sec.

86) Line up clamps :-

 An internal line up clamp shall be used if the pipe diameter is 16” inches or larger.
 An external line up clamp may be used for pipe diameter is 16” inches or larger if approved by CSD welding
engineer with a condition that 100 % RT is performed to the production welds.
 Internal line up clamp shall not be removed before the completion of the root bead.
 External clamps, the root bead must be at least 50% complete prior to removal.

87) Welding Sequence:-

 Pipe lines greater than > 16” diameter at least two welders shall be used.
 Welding shall be operating simultaneously & in opposite quadrants.
 The second pass or hot pass shall be added as soon as possible after completion of root pass but shall not exceed
5 minute for vertical down welding with cellulosic electrode.
 Shall not exceed 15 minute for vertical up welding.
 The hot pass shall be made while pipe is fully supported by the side boom tractor or supports.
 The Pipe shall not be lifted or moved during welding.
 The weld joint shall be completed within 24 hours of starting.
88) Tack Welds :-
All tack welds shall be made by qualified welder.
 Recommended tack is 3.2mm to 4.8 mm.
 Length 12.5mm to 25mm.
 Pipe O.D 101.6mm (3.5”) or less 3 equally spaced tacks are acceptable.
 Pipe O.D above 101.6mm minimum 4 equally spaced tacks.
 Bridge tacks (located above the root area) are acceptable but such tacks must be made completely within
the groove.

89) Back Purging :-

An inert backing gas shall be used for GTAW or GMAW root passes on single sided groove welds ,
For ASME P.No 5 & above means alloy steel & stainless steel.
 Nitrogen backing gas is prohibited for stainless steel.
 Oxygen level for back purge For P5 below 1%
 Oxygen level For P8 (Stainless steel & nickel alloy) below 0.05%

90) Pre heat :-

For carbon steel all ASME P.No 1 materials including API grades up to & including X70 minimum preheat
Shall not be less than 100C.
 Pre heat required if the wall thickness exceeds 25mm.

91) Where 100 % radiography required :-

 First three ( 3 ) production groove welds by each new contract welder shall be 100% radiographed.
 All welds on submarine pipelines require 100 % radiography.
 All welds on offshore pipelines require 100 % radiography.
 All P4, P5 & P6 welds require 100 % radiography.
 All stainless steel (except type 304 & 316 ) and nickel alloy require 100 % radiography.
 Hydro carbon lines at road crossing (carrier pipe only) requires 100 % radiography.

92) Maximum root reinforcement :-

93) Production welds hardness testing (For SAES W-012 Pipelines).

94) Production welds hardness testing (For SAES W-011 on plot piping).

95) Define Piping Line Class 3CS2P2 (SAES – L-105) :-

 3 indicate Flange rating 300#.
 CS indicate Carbon steel.
 2 indicate (3mm) Corrosion allowance.
 P indicates Main service type, Process or General hydrocarbon.
 2 indicates Modification suffix for sour service.
 3CS1P1 Last digit 1 indicate as base line class .

96) PMI (Positive Material Identification ) SAES – A- 206 :-

PMI shall be performed to verification that the nominal chemical composition of an alloy material.

PMI VERIFICATION COVERAGE:-

 Alloy materials
 Base metals
 Shop & field fabricated welds
 Material used for repair & replacement of pressure components.
 Incoming stainless steel consumables

97) PMI testing of welding consumables :-

 One consumable from each lot shall be tested.
 PMI testing of weld metal (e.g. deposited or undiluted weld buttons) is acceptable alternative to
PMI testing of an electrode or wire.
Immediately before welding.
During the welding process.

98) Button test :-

Button test is conducted when in case PMI testing of the completed weld is not possible
due to geometry.
 Small fillet weld
 Narrow root beads
99) Methods of PMI Test :-
 XRF (X – RAY FLUORESCENCE) :-
By this method or technique cannot be used to detect carbon because of inherent limitations of some
XRF analyzers.
 OPTICAL EMISSION SPECTOGRAPH :-
By this method may be used to check for all the required elements, including carbon.

100) PMI Acceptance Criteria :-

 For acceptance, it must be demonstrated that materials contain the amounts of alloying elements shown
in the material specification; alloys shall be acceptable if the alloying elements are each within 10 % of the
specified range of values.
 Welds with consumables that match, or nearly match, the base metal composition shall be within
+/- 12.5 % of the ranges allowed in ASME SEC IIC for each element.

101) Welder category according to SAEP – 324.

Contract welders & welder operator’s performance criteria to meet 0.2 % linear & 5 % joint basis, with linear
being the over-riding factor. From the performance data the welders shall be categorized from the linear WRR
criteria as follows:-
 0 – 0.2 % Level A.
 > 0.2 % - 0.4 % Level B.
 > 0.4 % - 0.5 % Level C.
 > 0.5 % Level D, Revoke.

102) Welder Re testing period according to SAEP-324.

Job clearance cards shall be returned to the project welder tracking coordinator when the contractor welder goes
on home leave or is terminated from the project.
Contractor welders that return to work within three months from home leave (to the same project) may be
reinstated without retesting.
103) Gap Control socket welds according to SAIC-W-2037, Attachment 1.
A maximum of (1) one weld repair attempt shall be permitted for socket welds in all cases before replacement of
material. “RT “is an option for project inspection here.
Reason: - Due to small diameter fittings lose their form & become distorted at the root.

104) Socket Welds (SAES – L-110) :-

 The maximum size of socket welded joint in hazardous services shall be 11/2“inch for new construction.
 Maximum 2” inch may be used for hazardous service for maintenance.
 For sour service, socket welded joints should be avoided. In case they could not be avoided, the
maximum size of socket welded joints shall be 1” inch.
 Socket welded joints are not permitted in location where high vibration can occur
Example: - high velocity gas control valves & reciprocating pumps.

105) Socket weld joints axial gap :-

The axial gap between male & female component, as per fig 328.5.2C of ASME B31.3

 Maximum gap 3 mm
 Minimum gap 1.5 mm BEFORE WELDING.

106) Seal welding of threaded joints :-

Seal welds are permitted to be used to prevent leakage of threaded joints.
It shall not be considered as contributing factor to the strength of the threaded joints.

107) Minimum thread engagements (SAES – L-110) :-

108) API 5L (SPECIFICATION FOR PILE LINE) :-
SCOPE: - The purpose of this specification is to provide standards for pipe suitable for use in as follows
Conveying gas, Water & Natural gas industries.
This specification covers seamless and welded steel pipe , it include
 Plain end
 Threaded end
 Belled end pipe

109) Product Specification Level (PSL) :-

There are two types of Product specification level
 PSL 1
 PSL 2 Major difference for PSL 2 has mandatory requirements for
Carbon equivalent, Notch toughness, Maximum Yield strength, Maximum tensile strength.
110) Short summary for welding of on plot piping :-
 SATIP No : W-011-01
 Activity No: 3.6 Pre-Welding & Weld Joint Fit-Up Inspection & Check list SAIC-W-2005.
 Activity No: 3.7 In-Process Weld Inspection & Check list SAIC-W-2006.
 Activity No: 3.8 Inspect Welds for Socket Joints and Seal Welded Thread Jts. - Gap Control & SAIC-W-2037.
 Activity No: 3.9 Post-Welding Visual Inspection & Check list SAIC-W-2006.

111) Short summary for welding of pipe lines :-

 SATIP No : W-012-01
 Activity No: 3.7 Pre-Welding & Weld Joint Fit-up Inspection & Check list SAIC-W-2048.
 Activity No: 3.8 In-Process Weld Inspection Formerly SAIC-W-2049) & Check list SAIC-W-2048.
 Activity No: 3.9 Post-Welding Visual Inspection (Formerly SAIC-W-2050) Check list SAIC-W-2048.

112) Inspection Responsibility Assignments :-

 Surveillance:
QA/QC organization to monitor work in progress without notice from Construction Organization
 Witness:
QA/QC organization shall be notified of the timing of Inspection or test in advance. However, the
inspection or test shall be performed as scheduled if the QA/QC organization representative is not
present.
 Hold:
QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test
shall not be carried out without the QA/QC organization representative in attendance.
 Review: Review of Documents.

113) Pipe Straightness :-

 Pipe smaller than size 4 ½ “in grades A25, A & B shall be reasonably straight.
 All other pipe shall be randomly checked for straightness , deviation from a straight line shall
Not exceed 0.2 % of the length.
 Measurement may be made using a taut string or wire from end to end along the side of the pipe.
Measuring the greatest deviation.
114) Dents :-
Pipe shall not contain no dents greater than 6.4mm deep and length shall not exceed 1/2 diameter of pipe.

115) General notes on consumable :-

SFA No ELECTRODE F.No WELDING PROCESS
5.1 (CS) E-7018 F4 SMAW
5.4 (SS) E-316 F5 SMAW
5.5 (CS) E-8018, E-9018 F4 SMAW
5.18 (CS) ER 70S -2 & ER 70S- 3 F6 GTAW
 SAUDI ARAMCO QUESTIONS FOR NDT CO-ORDINATOR:-
116) Difference between destructive & nondestructive test :-
 Destructive test
Destructive test includes methods where the material is broken down in order to determine mechanical
properties.
Example: - Tensile test, bend test.

 Nondestructive test
Nondestructive testing is a method that does not damage or destroy the material or product being tested.
Example: - Radiographic test, Ultrasonic test, Magnetic particle test, Liquid penetrant test etc.

117) RADIOGRAPHIC TEST (SAEP-1143) :-

Radiographic test is a NDT technique that involves the use of either X ray OR gamma rays in order to view
the internal structure of a component.

 Back scatter radiation :-

A letter “B” with minimum 13mm height & 1.5mm thickness shall be attached to the back of each film
holder during each exposure to determine if backscatter radiation is exposing to the film.

 Radiation sources :-
X rays
Gamma rays (iridium 192)
Cobalt 60
Selenium 75

 Radiographic film :-
Industrial radiographic film shall be either Type I or Type II.
Film shall be selected to produce radiographs possessing acceptable sensitivity, density & contrast.
Type I film shall be used for radiography of pipe diameters of 8 inch or less NPS.

 Radiographic contrast :-
Radiographic contrast is the degree of density difference between two areas on a radiograph.

 Radiographic density :-
The overall degree of darkening of an exposed film is referred to as radiographic density.

 Radiographic sensitivity :-
Radiographic sensitivity is the combination of radiographic contrast and radiographic definition.
Sensitivity is judged by IQI also called as penetrameter.

Minimum wire visible diameter X 100

% Sensitivity = Job thickness
 Intensifying screens :-
Only lead intensifying screens shall be used. The main function of intensifying screens it intensifies the
radiographic images on the film.

 Film develop temperature & time :-

Below 180 C and above 240 C developing is not recommended.

 IQI (Image quality indicator) :-

IQI is used to get better sensitivity & IQI shall be selected from either same alloy material group or grade
as identified in ASTM SE-747 or from an alloy material group or grade with less radiation absorption than
the material being radiographed.
Following are the types of IQI:
1) DIN Wire type IQI
2) ISO Wire type IQI
3) ASTM Wire type IQI
4) EN wire type IQI

 Densitometer :-
Densitometer shall be used to measure the density of the film. The densitometer shall be calibrated
(12 month) annually in accordance with ASTM E-1079.
Periodic calibration verification check shall be performed at the beginning of each shift. After 8 hours of
continuous use.

 Radiographic Technique :-
A single wall exposure technique shall be used for radiography whenever practical. When it is not
practical to use single wall technique, then a double wall technique shall be used.
1) Single wall technique
2) Double wall technique

 Single wall technique :- ( Known as Panoramic).

When a radiographic source is centered in the pipe for exposing a butt weld.
One exposure is adequate for the radiographic inspection of the complete weld.
 Double wall technique :-
1) Double wall single image
2) Double wall double image

 Double wall single image (< 13 mm at least 3 exposure by 1200).

When radiographic source is outside but not more than 13mm from the weld surface.
At least 3 exposure separated by 1200 shall be made to complete weld.

 Double wall single image (> 13 mm at least 4 exposure by 900).

When radiographic source is outside and more than 13mm from the weld surface.
At least 4 exposure separated by 900 shall be made to complete weld.

 Double wall double image :-

When the outside diameter of the pipe containing the weld is 88.9mm or less (3 1/2 “ or less) then,
Double wall double image procedure may be used.

There are two types of double wall double image technique

A) Elliptical (at least 2 exposure)
B) Super imposed (at least 3 exposure).

 Elliptical (at least 2 exposure ):-

For the elliptical technique the radiation beam shall be offset from the plane of the weld at an angle
sufficient to separate the image of the source side & film side portions of the weld. So that there is no
overlap of the areas to be interpreted.
The elliptical technique requires at least 2 exposures 900 to each other for each weld to be radiographed
to achieve complete coverage.
 Superimposed (at least 3 exposure) :-
In the superimposed technique, the source shall be at right angle to the weld and images of both walls are
superimposed. The superimposed technique, at least minimum 3 exposure taken to each other 600 or
1200 for each weld to complete all coverage area.

 Single wall single image technique :-

The radiation passes through only one wall of the weld, which is viewed on the radiograph for
acceptance.
 Double wall single image technique :-
The radiation passes through two walls and only one wall weld on the film side wall is viewed for
acceptance on the radiograph.
 Double wall double image technique :-
The radiation passes through two walls and both walls are viewed for acceptance on the radiograph; this
technique shall be used for welds in piping 3 1/2” or less.
 Geometrical unsharpness :-
It refers to the loss of definition. It occurs because of the radiation does not originate from a single point.

Ug = Ft / do
Ug = Geometrical Unsharpness
F = Greatest dimension of source
do = Source to object distance
t = object to film distance
118) MAGNETIC PARTICLE EXAMINATION. (SAEP-1144) :-
Magnetic particle examination use for the examination on ferrous materials for surface indications by using wet
or dry method.

 Magnetic Particle Test Technique :-

A) Prod Technique
B) Yoke Technique
C) Direct contact method

 Yoke Technique :-
There are two types of yokes technique
A) AC yoke
B) DC Yoke

 AC Yoke Technique :-
AC yoke method should be used for surface discontinuities, AC yokes shall be tested prior to use each day
with minimum 4.5 kg (10 lb.) lifting capacity.

 DC Yoke Technique :-
DC yoke method should be used for subsurface discontinuities, DC yokes shall be tested prior to use each
day with a minimum 18 kg (40 lb.) lifting capacity.

 Yoke Leg Space :-

The yoke leg space shall be between 3 to 8 inches.
Minimum 10% overlap required @ adjacent examination area.

 MPT examination illumination :-

MT exams performed in the field or shop requires a minimum of 1000 Lux of white light illumination at
the examination surface for adequate evaluation of indications.

 Surface Preparation :-
All surfaces to be examined and dry adjacent area within 1” inch of the examination area shall be free
from rust, scale, slag, sand, grease & paint etc.

 Surface Temperature :-
A) Surface temperatures shall not exceed 3160C when using dry particles.
B) Surface temperatures shall not exceed 500C when using wet particles.
Clean the examination surface and adjacent area within 3” inches of the examination area.

 Sensitivity Verification :-
Pie gauge or burmah Castrol strip may be used to verify adequate magnetization of part.

 Post examination cleaning :-

The part being examined shall be cleaned to remove all residual magnetic particle materials.
  Demagnetization :-
Demagnetization shall always be performed on parts, which are to be welded after an MT examination
has been performed to “prevent arc blow “.
The presence or absence of residual magnetism shall be verified & demonstrated using a calibrated gauss
meter. Residual magnetism shall not exceed +/- 2 gauss.

 Prod technique :-
The prod technique should not be used on highly polished or machined surface due to the possibility of
arc damage to the surface.

 Direction of magnetization :-
For welds on flat surfaces, the yoke shall be placed across the weld at an angle of 300 to 450 from the long
axis of the weld. The second examination shall be perpendicular to the first examination forming an “X”
pattern.

For examining circumferential pipe & fillet welds, the yoke shall be initially positioned, so the legs straddle
the weld & applied field is perpendicular to the long axis of the weld.
For second examination the yoke leg shall be positioned parallel to the long axis of the weld.

119) LIQUID PENETRANT EXAMINATION. (SAEP-1145) :-

This engineering procedure establishes the minimum requirements & describes the techniques for
performing liquid penetrant examination of welds.

 Penetrant system classification :-

1) Fluorescent penetrant inspection
A) Water washable
B) Solvent removable

2) Color contrast (visible) penetrant inspection

A) Water washable
B) Solvent removable

Solvent removable color contrast (visible dye penetrant examination):-

Dwell time
A) Cleaner :- 5 minute allow to dry before to proceeding with the test
B) Penetrant :- 10 minute
C) Developer :- 7 minute

Standard Saudi Aramco developer is non aqueous is an aerosol can sprayed at 10” to 12” from the surface.
(From 250 to 300mm).

 Inspection lighting :-
White lighting minimum 1000 lux.
  Post cleaning :-
Wipe surface clean with dry cloth. Post cleaning shall be performed on all components that have been PT
tested.

 Interpretation :-
Final interpretation shall be made within 10 to 30 minutes of applying the developer.

 Safety (540):-
Penetrant materials shall not be heated above 540C or exposed to open flames.

 Surface Preparation :-
Welds or area to be examined & 1” (25.4mm) on either side of the weld or area, shall be dry & free from
all dirt, grease, scale, welding spatter, welding flux, paint, oil & any other foreign material.

 Developers should be applied (smoothly) lightly, if it is necessary to remove developer which was
determined to be excessive, the test shall be restarted at the pre cleaning step.

 Distortion :- Distortion occur by welding due to :-

A) Highly localized heating of joint edges
B) Non uniform stresses in the component because expansion & contraction of heated material.

120) ULTRASONIC THICKNESS TEST (UTT) (SAEP-1146) :-

 Instruments :-
The UTT instrument shall have an A-scan display to assist the operator in discrimination of
test results. Only portable hand held ultrasonic thickness instruments from the Saudi
Aramco approved equipment list are acceptable.

 Transducers :-
Transducers shall be within the manufactures operating specifications for the instrument
being used. When selecting a transducers consideration shall be given to the
surface temperature, expected thickness of the specimen and the resolution required.
Transducers may contain single or dual elements. Digital thickness meters with A-scan
presentation shall use only manufacturers provided transducers.
 Calibration Blocks :-
Shall have a sound velocity within +/- 5 % of the material to be tested.
Use of SAMMS 4340 material is acceptable for most carbon and stainless steel application.

When absolute precision is required calibration shall be performed on blocks made of the
same material being tested or on known thickness values of the specimen.

 Couplant :-
Couplant selection shall be depending on chemical compability with the surface and the
temperature of the specimen.

 Calibration :-
The proper functioning of the examination system shall be checked and the equipment
shall be calibrated by the use of the calibration standard
1) At the beginning & end of each shift.
2) Every four hours during examinations.
3) When examination personnel are changed.
4) Any equipment is changed.
5) At any time that malfunctioning is suspected.

Calibration blocks shall be at ambient temperature during calibration. Calibration blocks

shall not be cooled or heated for cryogenic or high temperature applications.

A low viscosity couplant such as ultragel II shall be used for calibration.

 Apply couplant to the step wedge or calibration blocks and apply firm steady pressure to
the transduced during calibration.
 All calibration values shall be within +/- 0.05mm of the known thickness value.

 Examination :-
Surface Preparation
The test area shall be free of corrosion, insulation, weld spatter, surface irregularities or
foreign matter that might interfere with the examination.
Where coatings interfere with the examination, the coating shall be removed and
recorded.
 Measurement :-
Examination shall be conducted from the OD surface or ID surface, as applicable.
It is necessary that the examiner take into consideration the surface temperature of the
component.

 If the surface temperature is below 00c and above 1010c, the surface temperature shall be
measured and recorded.
 Apply couplant to the probe or surface of the specimen.
 For high temperature measurements, couplant should always be applied to the face of the
probe, not the hot part.
 All digital readings shall be verified by viewing the A-scan presentation on the instrument
 Thickness readings shall be measured and recorded to three decimal places when working
in inches.
 Thickness readings shall be measured and recorded to two decimal places when working
in millimeters.
 The transducer face shall be cleaned before each measurement at temperature greater
than 4000F as evaporated couplant can leave deposits on the transducer face.
 The transducer shall not be held against “hot surfaces” for long time. It shall be held for
few second to establish steady reading and then removed immediately.
 Use the “touch test” to monitor the transducer temperature. If the transducer face is too
hot to be held against your skin then it shall be cooled in air or water prior to taking
readings.
 High viscosity couplants are not acceptable for calibration but are usually required for high
temperature measurements.

 Post Cleaning :-

All water based couplant shall be completely removed from the specimen i.e., wiped with
a dry absorbent cloth or towel, fresh water wash etc.
121) ULTRASONIC EXAMINATION OF WELD JOINTS :- (Manual Shear Wave).
 Scope :-
This procedure is applicable for the ultrasonic examination of butt welds using pulse echo,
contact, manual technique based on the requirements of ASME Section VIII Division I and its
references. This procedure may be used for thickness from 6mm to 100mm.
This procedure is not applicable for TKY & Nozzle joints.

 Calibration :-
 Side drill hole shall be used for calibration to identify the discontinuity of weld joints.
 VI Block shall be used to calibrate the ultrasonic instrument to verify the beam of exit
point.

 DAC CURVE :-
Distance amplitude correction to be drawn by using (SDH) side drill hole
 First indication from 1/4T to 20% of sweep
 Second indication from 3/4T to 60% of sweep
 Third indication from square notch on the opposite surface of 80% of sweep.

 Type of Defects :-
 Planer defects: - Cracks, lack of side wall fusion and lack of penetration are unacceptable
regardless of length.
 Non Planer defects: - Porosity, slag etc.

 With respect to DAC during scanning: - Acceptance Criteria.

 Below 20% any non-planer defects within the permitted length is acceptable.
 Below 40% any non-planer defects within the permitted length is acceptable and shall be
recorded its location i.e. length, height.
 All other linear imperfections are unacceptable if the amplitude exceeds the reference
level & the length of the imperfection exceeds the following :-
A) ¼” for T up to ¾”
B) 1/3” T for T from ¾” to 2-1/4”
C) ¾” for T over 2-1/4”

 Probe selection :-
 700 Angle beam for root.
 600 Angle probe for side wall.
 450 Angle probe for high thickness to identify toe crack at weld reinforcement.
 Probes :-
2.25 MHz nominal frequency probe are recommended.
It is also permissible to choose other frequencies between 1 to 5 MHz
 For Flat surface use a ½” to 1” diameter probe.
 For curved surfaces below 18” diameter use a 10mm diameter probe.

 Materials with diameters greater than 20” (500mm):-

 For examinations in materials where the examination surface diameter is greater than 20” inch
(500mm), a block of essentially the same curvature, or alternatively, a flat basic calibration block,
may be used.

 Materials with diameters 20” (500mm) and Less :-

 For examinations in materials where the examination surface diameter is equal to or less than
20” in (500mm), a curved block shall be used. Except where otherwise stated in this article.

 The material for the blocks shall be of the same product form and equivalent P number
grouping as one of the materials being fabricated. P-Numbers 1,3,4,5 being considered equivalent.

 Scanning :-
 The scanning shall be carried out from one face of the plate or from outside if a pipe weld is
being examined.
 The scanning speed shall be less than 150mm per sec.
 The scanning shall be 100%, i.e. the entire examination volume shall be scanned by moving the
search unit in parallel paths with 10% overlap of the transducer in a direction perpendicular to
the scanning direction.
 The scanning shall be done at a gain setting 6dB higher than the DAC reference; it is however
recommended to increase the gain 14dB above DAC.
 This will bring 20% DAC to 100% DAC on the screen and ensure all indications 20% of DAC are
clearly observed.

 Post Examination Cleaning :-

After conclusion of the examination clean the job of all couplant and any other material on the
surface.
 Recording :-
Recording shall be done manually, record all indications 20% of DAC and over as follows:-
1. Position the search unit to give maximum amplitude from the reflector. read and record the
maximum amplitude in percent of DAC.
2. Read and record the sweep reading (at the leading edge of the indication).
3. Read and record the position of the search unit with reference to the reference line.
4. Read and record the discontinuity location echo amplitude along and perpendicular to the
weld.
5. Move the search unit towards and away from reflector until the amplitude falls to 20% DAC
and record through thickness dimension of discontinuity.

The record of all indications shall be made in terms of the shape, location, depth and identity
of the reflector. The record shall include a sketch of the job showing clearly the location of all
recorded indications.