NAME :

CONTACT NUMBER :

AGE :

TOTAL MARK :

MOCK UP QUESTION FOR GRAPHITE QC TEAM.

1. Explanation regarding welding process

ANSWER :
a. SMAW
b. GMAW
c. FCAW
d. GTAW 10 Marks

2. Please explain about pipeline quality in construction work

ASNWER :
a. Receiving material
b. Stringing pipe
c. Fit up
d. Welding
e. Ndt
f. Site coating
g. Holiday test
h. Excavation
i. Lowering
j. Backfill 20 marks

3. Requirement fit up , max miss alignment on pipeline

ASNWER : 1.6mm according to PTS
: 3mm according to API 1104

3 marks

4. Pipeline off set – LW TO CW Minimum requirement ?

ANSWER : AT least 120 DEGREE Offset and above

3 marks

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 5. Weld numbering for pipeline ?
ANSWER :
a. S – normal road crossing
b. H – Normal pipeline
c. FT – Final tie in
d. V – valve station
e. W- water crossing 10 marks

6. Please explain regarding site coating

ANSWER :
a. HSS – Using hot medium or epoxy to protect pipeline
- Wrapping with continues fire
- High quality for site coating
b. Wrapping Viscotaq – using wrapping methods as medium
- High quality protection but not suitable for HDD , Road crossing .
c. Concrete coating - using concrete as medium for protection
- Usually used for water crossing pipeline to replace sand of weight .
- High quality of pipeline but more expensive
- High grade concrete needed , usually grade 30 and above.
6 marks

7. Please explain about bending

ANSWER :
a. Hot bend – using hot machine as medium for bending
- Usually for 45 SR, 60 SR / LR , 90 SR / RL
- Fully UT on seam to detect micro crack on weldment after bending

b. Cold bend – using bending machine as medium for bending

- Usually small amount of bending can be done
- Maximum bending value is 12/13 degree for 12m of total length of pipe
- Ovality test is compulsory after cold bend is done to avoid any dentate on
pipeline using internal ( ID ) Gauging
4 marks

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 8. Code and standard explanation
Answer :
a. API 1104 – code for pipeline construction
- Normally for new , hot tapping , and replacement of pipeline
- NDT, DT , WPS , WQT , IN- Service and Hot tapping
- Grouping material, diameter, thickness limitation, essential variable, non
essential variable including on this code.
b. ASME IX – specification for welding and brazing qualification
- NDT, DT, Grouping material, essential variable, non essential variable,
supplementary essential variable, F , A, NUMBER, including on this spec
c. ASME V – specification for NDT Requirement
- RT, UT , MPI, PT, AUT And others specific NDT Procedure was establish from
this code.
- ASNT LEVEL III Normally using this code to establish NDT Procedure.
d. PTS 15.12.04 - Specification for new pipeline construction.
- Special requirement such Impact test, hardness and others from company
- Golden rules such tie in, final tie in , golden joint , NDT, DT, Covered on this
spec 10 marks

9. please explain regarding welder qualification ?

ANSWER :
a. Qualification limit –
- Thickness limitation
- OD Pipe qualified
b. Material essential variable
- Grouping on class A.B. and C
c. Weld position
- Qualification during testing and limitation
- 6G Cover to all position
d. Weld Consumable
- Essential variable for welder qualification,
- A Number , F Number on ASME IX
4 marks

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 10. Please explain about WPS
ASNWER : - One document was establish to make a good weld soundness for welding, good
mechanical properties, and will be become a guideline for welder to produce a good weldability
during welding. This can be establish after some variable information already get such material
type, thickness , OD Of pipe, and welding process. This WPS can be done using ASME IX , PTS
15.12.04, API 1104 and etc
a. Meaning for essential variable and example
- Its compulsory item on this WPS That can’t to change during welding such
material, consumable, weld progression, type of gases , type of flux and etc.
- Any change on this item have influence on mechanical properties and
required to re qualified WPS .
b. Non essential variable and example
- Its non compulsory item on Wps that not significant change during welding
such diameter electrode, flow rate gas, preheat and etc
- This change have no influence on mechanical properties and not required to
re qualified WPS 10 marks

11. Please explain regarding NDT Methods :

ASNWER :
a. RT – Gamma vs X-Ray
- Gamma ray is using Stable isotope as penetration medium for RT
- Example of isotope is IR192, and cobalt 60 Is popular selection during
Gamma ray depend to thickness limitation
- Gamma ray normally using for station piping due more faster, efficient but
harmful to RT Operator
- X ray using KV machine to produce RT
- This Kv machine can be produced variable thickness selection depend to
power of KV during setting
- The image using X Ray is more clear, and safely to RT Operator.
- Very popular using for pipeline due can used Internal Crawler using
panoramic technique.
b. RT- Different class 1 and 2
- Class 1 film produce more sharpness on image
- Class 1 film exposed time is less than Class 2
- Forging impurities in this class is less and more extended year can be done
using this film
- Class 2 film produce more exposed time to develop a good quality with
assume using the same queries ISOTOPE
- Forging issue on this film.

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 c. RT- density requirement and tools for measurement
- Using densitometer for measure light or darker on parent and weldment
area 5 marks

12. Please explain regarding NDT Methods:

ANSWER :
a. UT- Minimum dead ZONE
- Minimum thickness for UT IS 8mm
b. UT- UTTG For..?
- For thickness checking
c. UT- UT FLAW for
- For scan on weldment on welding.
- Can be done using 45,60,And 70 Probe
- The technique can used either half skid or full skid
- Normally for half skid technique root fusion defect is priority
- And for full skid technique, normally lack of fusion on side wall area.
5 marks

13. Please explain regarding NDT Methods :

ANSWER :
a. MPI- Material suitable for MPI
- All material can be done except for Austenite stainless steel SUS 316 L due
non magnetic
b. MPI – AC YOKE VS Permanent Magnet
- AC Yoke Using electrical magnet for magnetism
- Sub surface maximum 3mm depth can be detected .
- Permanent magnet normally used when no electrical availability
c. MPI – Sequence for MPI
- Cleaning surface
- -apply white contrast , after that apply with black in or iron powder spray
and Move slowly

5 marks

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 14. Please Explain regarding NDT Methods :
ASNWER :
a. PT- Sequence of PT
- Clean the surface with cleaner.
- Apply penetrant and wait for 10-15 minute for capillary action ( dwell time )
- Re clean using clean cloth , and apply with developer for differential the
defect
b. PT – Suitable material for PT
- ASS ( Austenite stainless steel SUS 316 L )
c. PT – Maximum temperature for PT
- Max 50 Celsius or above or as per manufacture recommendation
5 marks

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 PERSONAL INFORMATION AND MOCK UP ACTIVITY

1. PERSONAL QUALIFICATION

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2. PERSONAL STRENGTH

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3. WORK ATTITUDE

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4. KNOWLEDGE ON WELDING / PIPELINE / MECHANICAL

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5. OTHERS ADVANTAGES

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Prepared By:

_________________________________

( Mohamed fahmi )

Pipeline / NDT / Mechanical Graphite

Review and Approval

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( Mohd Shafarizal )

QA / QC Engineer PTSSB / PGB

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