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Name & Sign: _____ARJED ALI_

Company__NSHC________ DATE__15-09-2011__

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

2. How will you qualify welder for on-plot process piping?
3. Write 4 common welding defects in SMAW process?

c) LOP

d) LOF

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?


It slows the cooling rate in the weld metal and base metal,
producing a more ductile metallurgical structure with greater
resistance to cracking;
The slower cooling rate provides an opportunity for hydrogen that
may be present to diffuse out harmlessly, reducing the potential for
It reduces the shrinkage stresses in the weld and adjacent base
metal, which is especially important in highly restrained joints;
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 setin fittings less than 2 inch NPS?

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

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

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

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_________


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.


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

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

For P no 8(Stainless steel), SS material normally PWHT is not

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
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
doesnt 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?


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

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

46. Unless specified otherwise, the maximum interpass temperature shall be ______C
for P1 and P4 materials.

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 weldolets, sockolets 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.