0 2 » 6) 7 8) ‘Theory 1 Hour & 15 Minutes 1) Signing off a product or Duties of Senior Welding Inspector 2) 5 Questions will be given in this we have to write 3 questions Multiple Choice Questions Radiography (20 questions) 30 minutes (This portion will not be covered in the class) Weld Symbols (12 symbols) { Hour 1) Engineering drawings (Piping) 2). Structural (This portion will be covered in the class) NDT Reports Scrutiny 1 Hour ‘Three reports will be given 1) RT, UT, MT& PT Among this four RT & UT must MT or PT Oral 15 minutes (Nothing to worry only basic things) te 1) Ifyou want to inspect a vessel what will be the course of action from safety point of view? Fracture analysis (2 Specimens) 1 Hour (This portion will be covered in the class) Please try to check all the pieces which they are displaying in the class sure we will get any two among that 1) Sensitivity Calculation (5 Questions) (This portion will not be covered in class) ple 1) Find the sensitivity ifthe third wire is visible & thickness of the pipe given? b) Find which wire should be visible ifthe sensitivity% & Thickness is given? 2) Densitometer Calibration (5 Readings) Five readings we have to take from the strip 1) Calibrate the densitometer 2) Write in the answer paper ‘Top column actual reading of the strip Middle column recorded reading from the strip Bottom column difference of actual and recorded readings Radiography Interpretation (6 Films will be given) 1 Hour (This portion will not be covered in class) is in Calcutta Dec2005 1) Signing off a product in Structural or pipeline 2) 4) Transition Joint of different thickness from 50mm to 25mm. b) Transition from different base metal (CS to SS) 3) Notes on a) Lamination b) Laps ¢) Bands 4) Course of investigation for a vessel ruptured with loud bang 5) a) Explain Preheat & inter pass temperature ) Brief note on inter pass temperature estiIn an Engineering fabrication industries the last activity in the sequence manufacture is load out or dispatch. This activity cannot be initiated unless the product is signed off. As a matter of fact signing the product off assurance of quality which is authenticated by a technically competent person such as “Senior Welding Inspector” who makes sure that complete manufacturing of product has been carried out in accordance with applicable standards and sound engineering practi How ever before signing off the documents he should make enquiry which can give him the in the past while product was being manufactured. 1) What was the repair rate during production? 2) Weather any concession or wavier were given, if yes why? 3) How were the weather conditions? 4) Weather there was any safety issues, fatalities, major accident/ incidents ete. 5) Weather there was any labor problem? These are the questions can be clarified Further to this he can start reviewing of documents and he should make sure that he attaches the following documents as a minimum requirement 1) Quality control plan ensure all the stages are completed and signed off pection Check list ensure all the stage are completed and signed off 3) Verify material certificates such as mill test certificates ete 4) Verify the following procedures 1) Welding 2) Repair 3) NDT 4) PWHT 5) Hardness 6) PML 7) Hydro testing 8) Coating y the qualification level and validity of the welders and NDT personals ection reports of following discipline and ensure that they cover all appropriate joints and structure 1) Visual 2) NDT 3) Dimensional Control ete 7). Verify the calibration Certificates of equipments and instruments such as pressure gauges, welding machines etc. 8) Verify hardness test reports ty PMI inspection reports fy PWHT reports/charts ete fy Hydro test, pneumatic test reports fy as build drawings are completed 14) Verify name plate rubbing details are available when applicable 15) Verify the concession request site query ete 16) Verify permit to work/degas certificate ete ‘As a part of his own he may be obliged to witness final hydro test, visual inspection of completed ‘ts. AS a matter of quality assurance he may view some radiographs at random and may even conduct a radiographic audit.Define Quality Assurance: - All the planned and systematic action and activities required providing adequate confidence in a product What is wanted? Quality Control: - The operational Techniques and an activity used to fulfill quality. ‘What must be done in order to achieve, what is wanted? In process inspection: - Luspection and surveillance carried out during production Non Compliance: - A written report that states that a clause or instruction in the control documents. Code or standard cannot or was not met Concession: - An agreed deviation (with the customer) from a pre agreed path, or specification Inspection Specification: - A document containing or referring to all information required in the level of inspection for a product Certificate of Conformance: - A signed Certificate declaring that a product has been produced in accordance with a specification Defect: - A welding imperfection that falls outside of a level of acceptance in an applied standard Minor defect: - Unlikely to cause failure of the product Major defect: - Unlikely to cause failure, but small risk of loss of life Cri tremely likely (0 cause failure with high risk of loss of life Lamination: - In the steel mill molten steel is poured into moulds to form ingots. While solidification is taking place huge amounts of gases are released. It is quite possible that some of these gases may remain trapped in the solidified steel. This ingot when rolled the gas pocket inside gets flattened in the forms of lamination. This discontinulty adversely affects through ‘thickness strength of the steel and is not traceable by MPI or RT. The only way to detect lamination is by UT. This discontinuity may also contribute to lamellar tearing in thick section Laps: Laps are basically chunk of material that has flown away from the desire profile during operation such as hot forming. This chunk of material is connected to the base metal at some location and over hanging portion of the chunk simply lies on the metal with out being the homogeneous part of it. As it is surface defect it can be found visually and can be confirmed by MPI, Bands: Pre heat temperature: - ‘The temperature which is before starting the welding