QA/QC WELDING INSPECTOR

(INTERVIEW QUESTIONS & ANSWERS)

1. Which element could affect the hardness of carbon steel material?
CARBON

2. How will you qualify welder for on-plot process piping?

BY PERFORMANCE TEST (WQT) PER ASME-IX

3. Write 4 common welding defects in SMAW process?

a) POROSITY b) SLAG c) LOP d) LOF

e) SPATTERS f) ROOT CONCAVITY g) UNDERCUT (ROOT & TOE)

4. What are the causes of weld defect Porosity?

Improper baking of Low Hydrogen electrode, inadequate shielding of welding area,
improper cleaning of joint surface, inadequate preheating

5. Why pre-heat is done on some pipes before start welding?

i. It slows the cooling rate in the weld metal and base metal, producing a more
ductile metallurgical structure with greater resistance to cracking;
ii. The slower cooling rate provides an opportunity for hydrogen that may be present to
diffuse out harmlessly, reducing the potential for cracking;
iii. It reduces the shrinkage stresses in the weld and adjacent base metal, which is
especially important in highly restrained joints; and
iv. It raises some steels above the temperature at which brittle fracture would
occur in fabrication

6. If welder qualifies on 2G and 5G positions, how many positions he can qualified?

All positions

7. Name the 2 types of flux used in SAW

Neutral & basic

8. Which welding process shall be used for all passes for butt welds in piping and set-
in fittings less than 2 inch NPS?
GTAW

9. DMW means ?
Dissimilar Metal Weld, such as CS to SS
10. The maximum weekly repair rate for each welder should not exceed %
Weekly Linear Repair rate should not exceed by 2%.

11. Internal misalignment of butt joints shall not exceed mm.

1.6mm OR as per approved WPS

12. The maximum allowable SMAW electrode size for low hydrogen electrodes for all
positions (except 1G/1F position) would be
4mm (dia.)

13. A minimum of mm depth shall be removed by grinding or machining from

thermally cut or gouged surfaces of air-hardenable materials.(chrome moly steels)
1.5 mm

14. Buttering or weld build-up on the prepared surfaces shall not exceed the lesser of
of the base metal thickness or mm without the approval of company.
Lesser of the 1/3rd of the base metal thickness or 10mm without company
approval

15. How many tack welds required for 4inch diameter pipe joint?
Minimum # 3

16. The back purge for low alloy steel shall reduce the oxygen level below %
By 1%

17. Seal welding of threaded connections shall cover all

Exposed threads and shall have a smooth contour between the two surfaces

18. The minimum distance between parallel butt welds shall be mm or

times the wall thickness of the joint, whichever is
20mm or three (03) times the wall thickness of the joint whichever is greater

19. All socket welds shall be at least minimum pass weld.

Two (02) passes

20. Minimum pre-heat temperature for 5Cr-0.5Mo material for any thickness would
be

250°C

21. How many thermocouples shall be used for 20’’ dia pipe during PWHT?
Two

22. PWHT temperature recorders calibration period shall be every

Three months, May be extended up to 12 months if company approved
23. Maximum hardness limit for P No 1 material would be
200BHN

24. The acceptance criteria for Magnetic particle examination shall be ASME SEC VIII,
Appendix number
Appendix number-6

25. The acceptance criteria for Liquid penetrant examination shall be ASME SEC VIII,
Appendix number
Appendix number-8

26. Heat input formula is

HI (J/Inch or J/mm) = (Volt X Amp X 60) / Travel speed

27. Potable electrode oven heated to deg centigrade minimum.

65°C

28. What are the essential variables in WPS?

‘P’ no, ‘F’ no, ‘A’ no, Base metal thickness, PWHT

29. What are the essential variables in PQR?

‘P’ no, ‘F’ no, ‘A’ no, PWHT

30. Electrode, filler wires and fluxes shall conform to ASME Section Part
Section II part C

31. Define Low hydrogen consumable?

Consumable having less than or equal to 8ml of hydrogen per 100 gm of deposited
weld metal

32. ”Tack welds shall be sufficient size to maintain joint alignment’’ The recommended
tack thickness is
3.2 to 4.8mm

33. Tack welds shall be sufficient size to maintain joint alignment’’ The recommended
tack length is
12.5 to 25.4mm

34. How much required ferrite content in austenitic stainless steel materials?
3% to 10%

35. Minimum calibration for pyrometer should be

Six months

36. Minimum holding time for P4 materials during PWHT should be hours if
thickness more than 13mm?
2 hours
37. Minimum pre heat temperature for carbon steel materials would be as per
JERES-W-011.
20°C

38. PWHT holding time for 25mm thickness of P8 materials should

be hours?
For ‘P’ no 8(Stainless steel), SS material normally PWHT is not required.

39. API SPEC 5L stands for

Specification for line pipe

40. ‘‘If welder welded a joint without JCC card’’, what is your action as a welding
inspector?
If the welder is actually having JCC card & qualified for the joint he welded, but
forget to keep the JCC with him during the time of weld, he may be given one more
chance with warning letter. And if doesn’t have the JCC at all, he should be revoked
from the project and welded joint shall be cut & re-welded with qualified welder.

41. How much RT % required for P4 materials?

100%

42. Category M equal or less than 600# coverage of RT on onshore piping is

100%

43. PMI means

Positive material identification
44. Difference between MT and PT?
MT:- Only Applicable for ferromagnetic materials & able to detect both surface & sub
surface discontinuities, compare to PT examination it takes less time for testing &
inspection; Applicable for large temp range.
PT:- Applicable for both ferromagnetic & non ferromagnetic materials & able t detect
only surface discontinuities, It requires more time; Applicable for small temp range.

45. Can you allow using Nitrogen as a back purging for SS piping? If Yes Why? And If
NO reason?
No, nitrogen gas is slightly reactive, so the purpose of back purging (making
inert atmosphere at the root side) will not be achieved.

46. Unless specified otherwise, the maximum interpass temperature shall be °C

for P1 and P4 materials.
315°C
47. PWHT required for caustic services? Yes or No? If yes how much % and if no why?
Yes, 100%

48. ‘’Welder welded joint without your fit-up inspection’’ What is your action as a
welding inspector?
If visually accepted that weld joint, then it will be radiographed. Based on RT report
the joint will be accepted or rejected. At the same time welder should be given
warning for not repeating such mistakes in future.

49. How you will do welder identification and marking after complete of the joint?
From the information given close by the joint such: Line no; Joint no; WPS no; Fit-
up date, Piping QC sign; Welder no, date of joint welded; Sub con/Con signature.
Visual Acc/Rej:

50. All pressure containing welds other than butt welds including branch connections
such as weldolet, sockolet and weld bosses shall be 100% examined for what
type of materials and what type of NDT? As per JERES-W-011
P3, P4 & P5 materials shall be 100% examined with florescent MT.