Self-Analysis Paper

Q:- What is the standard for Process (or) Plant piping

systems?
Answer: ASME B 31.3
Q:- What is the standard for Power Piping systems?
Answer: ASME B 31.1
Q:- What is the standard for liquid Petroleum Transportation
piping systems?
Answer: ASME B31.4
Q:- What is the standard for Gas Transmission and
Distribution piping systems?
Answer: ASME B31.8
Q:- What is the Code for Welding of Pipelines and Related
facilities?
Answer: API 1104
Q:- What is the standard for welding rods Electrodes and filler
metals?
Answer: ASME Sec-IIC
Q:- What is the standard for Non-destructive Examination?
Answer: ASME Sec-V
Q:- What is the standard for welding and Brazing
Qualifications?
Answer: ASME Sec-IX
Q:- Which type of process we are using in field/fabrication
shop?
Answer: Fusion welding
Q:- What is the specification/classification for carbon steel
filler wire?
Answer: AWS 5.18/ER70-Sx
Q:- What is the specification/classification for carbon steel
Electrode?
Answer: AWS 5.1/E-XXXX
Q:- Where we can use E-6010 type electrode?
Answer: we can use at root pass for deep penetration
Q:- What is the meaning for ASME?
Answer: American Society for Mechanical Engineering
Q:- Which type of electrode we are using in GTAW process?
Answer: Non-Consumable Tungston Electrode
Q:- How Many times we can dry the electrodes?
Answer: Only one time
Q:- Why we are baking the electrodes?
Answer: To remove the moisture content from the Electrodes.
Q:- What is the standard for Structural steel fabrication?
Answer: AWS D1.1
Q:- What is the standard for Welding symbols?
Answer: AWS A2.4.
Q:- What is the hydrotest pressure?
Answer: 1.5 Times of design pressure.
Q:- What is the drying temperature for Stainless Steel
electrodes?
Answer: 120 to 250 degree temperature.
Q:- What is the drying procedure procedure for Low hydrogen
electrodes?
Answer: 260 to 430 degree temperature.baking for two hours
Q:- What are the defects we can find in visual Inspection?
Answer: Porosity,Undercut,Surface crack (HIC),Side wall
fusion on fusion boundary.
Q:- What is the Procedure for Fit-Up inspection?
Answer: Base metal classification,cleaning,Alignment,root
gap,root face,bevel angle & mismatch (or) overlap.
Q:- What is the internal overlap (or) mismatch for piping?
Answer: 1.5 mm.
Q:- How much root face are allowed?
Answer: As per WPS (or) 0.8 to 1.6 mm
Q:- What is meaning for F – Number?
Answer: F- is filler metal grouping Number.
Q:- What is meaning for P – Number?
Answer: P – is base metal grouping Number.
Q:- What is meaning for A – Number?
Answer: A – is electrode chemical analysis number.
Q:- How much bead width we can allow?
Answer: Max 3 times of electrode diameter.
Q:- How much area is required for Pre-heat?
Answer: 75 mm minimum from both end of the Joint.
Q:- Which section we are using for NDT?
Answer: ASME Sec-V
Q:- What are the essential variables for SMAW process?
Answer: In base metal thickness, P-number, dia of pipe, pre,
post weld heat treatment
In filler metals F,A-numbers, dia
Q:- What are the essential variables for GTAW process?
Answer: In Base Metal thickness, P-number, dia of pipe, pre,
post weld heat treatment… In Filler Metals F, A-numbers,dia
of filler metal
Q:- If welder made test by 2’’ dia, what is his range qualified?
Answer: He has qualified 1’’-dia and above.
Q:- If welder made test by 14 mm thickness, what is his
thickness range qualified?
Answer: He has qualified unlimited thickness.
Q:- What is carbon % in low carbon steel?
Answer: Max 0.30 %
Q:- What is the interpass temperature for carbon steel
materials?
Answer: Max 315’C
Q:- What is meaning for SAES,SAEP and SAMSS?
Answer: Saudi Aramco Engineering Standards
Saudi Aramco Engineering Procedures
Saudi Aramco Materials System Specification.
Q:- How much under cut depth allowed in piping?
Answer: 0.8 mm
Q:- How much area is required for Pre-heat?
Answer: 75 mm minimum from both end of the Joint.
Q:- How much percentage is allowed more than test pressure
in Pressure relief device?
Answer: Test pressure plus10% (10% should be lesser than
50Psi).
Q:- How much gap is allowed in socket weld?
Answer: 1.5 mm minimum before welding.
Q:- What is the minimum fillet size in socket weld?
Answer: Minimum 3 mm fillet size.
Q:- Hydro test.
1. Piping Internal Cleaning
a. Air compressor
b. Air blower
c. Electrical cable
d. Generator
c. Wire brush
d. cotton waste cloth
e. water tanker water with pump
2. Testing
a. Pressure gauge-(30days calibration valid, range 1.5 to 2
times test pressure)
b. Test manifold (calibration validity)
c. Pressure relief valve( Set to 5% above test pressure)
d. Test pump
e. Water tank
f. Hoses
g. Test blind
h. Test water (refer as per project specification)
II. Test package
1. Calibration Certificates of Gauges ,relief valves
2. P&ID and ISO Drawing
3. Test Package Control sheet
4. Marked up P&ID
5. As built Drawing
6. Welding log
7. NDE report
8 .Punch list –all punch list cleared (category one)
9. Pressure test Check sheet
10. Safety check lists

1. Describe why and how corrosion occurs?

Corrosion occurs when the material tries to revert back to its
natural state by an Electro-chemical process.

2. Describe what is meant by Bi-metallic corrosion?

Bi-metallic corrosion is when one metal attached to another metal
sacrifices itself to protect the other.

3. Describe the following

a) The galvanic series?
The galvanic series list metals, which are more or less noble
than one another and how they will affect each other when
attached together i.e., zinc will sacrifice itself over steel.

b) Millscale?
Millscale is a thin iron oxide layer formed on the surface of the
steel during making.

c) Rust grades to SIS 05-59-00?

A Millscale
B Light millscale and rust
C Rust and Light pitting
D Heavy rust and Heavy pitting

d) Blast cleaning grades to SIS 05-59-00?

S.A.1 light blast clean
S.A.2 thorough blast clean
S.A.2 ½ very thorough bast clean
S.A.3 Blasted to visually clean steel

4. Describe the difference between water blasting and pressure washing?

 Water blasting uses pressures of approximately 60,000p.s.i and will
take off paint, rust etc.; pressure washing uses pressures of
approximately 100p.s.i. and is used for washing.

5. Name two tests used to determine the presence of hygroscopic salts left on a blast cleaned surface?
Two tests used to determine the presence of hygroscopic salts are
Potassium-ferrocyanaide and silver nitrate.

6. Name four expendable abrasives and state the difference between an expendable and a reusable abrasive?
Four expendable abrasives are:
a) copper slag
b) crushed ice
c) crushed walnut shells
d) sand (not recommended)
The difference between expendable and reusable abrasives is that
expendable abrasives explode upon impact and become useless reusable
can be filtered and used up to 3 times

7. Name the three basic constituents of a solvent carrying paint and the functions that each performs in the paint?
a) Binder – to hold the constituents together and give a flexible
tough impervious finish
b) Pigment - to give colour and opacity resistance to acids/alkalis
c) Solvent – to evaporate in the drying process also to thin paint
and degrease

8. Name six pigments and there respective colours?

a) Coal tar black
b) Carbon black
c) Titanium dioxide white
d) Calcium plumbate white
e) Red lead red
f) Zinc phosphate yellow

9 Describe what qualities a laminar pigment gives to a paint and name four laminar pigments?
Qualities of a laminar pigment are the particles overlap and form a
thick impervious coating
a) Micacious iron oxide
b) Aluminum oxide
c) Glass flakes
d) Zinc oxide

10 Describe
a) A barrier paint system?
A barrier paint system is a coating that form a continuous even
flexible coating which is impervious.
b) A sacrificial paint coating?
A sacrificial paint coating is a coating, which will protect but
at the expense of itself i.e. it will break down.

11 Describe what a tie coat is and give three reasons why we may require one?
A tie coat is a coat of paint, which will tie to different systems
together:
 a) Maintenance painting
b) Adhesion problems
c) Bleeding through of primer/undercoats

12 Describe a typical paint manufacturing process and give two types of paint mill, which could be used?
a) Assemble ingredients together
b) Mill ingredients to right consistency and proper mix
c) Can and ware-house
d) Distribute
Two types of used mill are direct charge mill and ball mill

13 Describe what you know of viscosity and outline one method of testing?
Viscosity is the measurement of a paint resistance to flow and can
be measured in an able type cup.

14 Describe what you know of density?

Density is the weight of paint per unit volume.

15 Can you use a banana gauge over

a) An M.I.O coating?
No the coating is magnetic
b) An aluminium substrate?
No the substrate is non-magnetic
c) A galvanised surface?
Depending on the substrate, whether magnetic or non-magnetic and
on the thickness of the galvanising

16 Describe a destructive test for determining the dry film thickness of a paint?
Paint inspectors gauge (cut and measure).

17 Give four artificial weathering devices and describe what they simulate?
a) Salt spray box to simulate a marine environment
b) Cold check to check for brittle cracking and shrinkage in cold
climates
c) Tropical box to check for high humidity
d) Alternating temperatures to check for elasticity of coating

18 What is the name of an instrument, which measures opacity and gives two examples?
The instrument that measures opacity is a Cryptometer, examples are
hiding power charts and a pfund Cryptometer.

19 Describe a dolly test for adhesion?

a) Paint and fully cure specimen
b) Roughen and degrease surface and attach dolly using regular
araldite and keep at 200c for even results
c) Let fully cure
d) Cut around dolly down to substrate using special tool
e) Attach puller and pull off note force at which dolly lets go
f) Check if failure is adhesive or cohesive

20 How do the following work

a) Conventional spray setup?
 Paint is held in a can then pressurised and fed through a nozzle
where it atomises and the pressure propels it onto the surface
being painted.
b) Airless spray system?
Paint is held in a non-pressurised container and is then pumped
to a nozzle where it is propelled onto the surface at high
pressure.
c) Electrostatic spray system?
The item to be coated is negatively charged and the paint
discharged from the gun is positively charged and this attracts
the paint onto all surfaces to ensure full and complete coverage.

21 How is B.S. 4800 used in the construction industry?

B.S. 4800 is used in the construction industry for selecting paint
colours and types for structural steelwork.

22 What are the essential differences between a blister and an osmotic blister?
A blister is a dry bubble in the paint, which may be caused by
adhesion problems, or tapped air. An osmotic blister is caused by
trapped salts or by water ingress through the paint system.

23 What shall painting equipment comply with when used on a B.Gas site?
Painting shall comply with P9, Health and Safety at Act, C.O.S.H.H,
and relevant specifications and contract details.

24 How do the following display their characteristics

a) Bleeding?
When an underlying coat comes through on the next coat i.e. red undercoat bleeds through on white to give pink.
b) Blooming?
Paint that has an pocked effect on the surface.
c) Chalking?
When the pigment starts to breakdown and a white powder forms on
the surface.
d) Cissing?
When the paint refuses to cure properly i.e. linseed oil based
not properly cured before overcoating.
e) Grinning?
When an underlying coat comes through on the next coat because of
poor coverage.
f) Flocculation?
When paints constituents in the can, separate and resist mixing
together.
g) Lifting?
When paint that has been applied does not adhere to the surface.
h) Ropiness?
Any thing to do with being out the night before? I don’t know!
i) Solvent stripping?
When solvent is used to soften and remove paint.
j) Oxidation?
 When the surface takes on an oxygen atom i.e. hot steel worked
air cools and millscale formed millscale is oxidised steel.
k) Chemical curing?
When a chemical has to be added to a paint to allow it to cure
i.e. two pack paints.
l) Overspray?
Overspray is when a light coating is noticed on adjacent items
that do not require painting only found when spraying may be
cause by air blowing a fine mist of paint away from surface being
painted.

25 Define the following

a) Dewpoint?
Dewpoint is the temperature that condensation will form on a
surface.
b) R.H.?
Relative humidity is an expression of the amount of water present
in the air.
c) Induction period?
The time a two-pack paint must be left to stand after mixing to
allow for chemical reactions.
d) Pot life?
The time in which a two-pack paint must be used in after mixing.
e) Flash point?
The lowest temperate at which solvent vapour will ignite.
f) Shelf life?
The maximum time, which a paint can be stored without using
according to, manufactures recommendations.
g) Batch number?
A unique number to a tin of paint which will allow the
manufacturer to trace the paint if problems arise.
h) Masking out?
Covering an area which does not require painting with removable
sheeting.
i) A.G.I.?
Above Ground Installation.
j) Rust blooming?
Rust blooming is when small areas of rust start to appear though
a coating (like a rash).
k) Water borne coating?
A water borne coating is a water-based paint.
l) B-SA2 ½?
Rust grade B (Light millscale and rust) blast to the stated grade
(thorough blast clean).
 m) Feathering?
Creating a smooth transition at an edge.
n) A-ST3
Rust grade A (Millscale) Hand clean with mechanical wire brush
(note millscale is not allow to be taken off by this method only
by blast cleaning).
o) P.a.9?
Method of painting items to Bgas specifications.
p) P.a.10?
Method of testing paint to Bgas specifications.

26 Give as much detail as you can for the following

a) S.P.A 1?
Painting of pipeline which operates below 1000c paint to have
D.F.T of 275m when finished.

b) S.P.A.2?
Standard of preparation and paint systems only.

c) S.P.A 3?
Painting of items which are above 5000c at works or on site.

d) S.P.A 4?

e) S.P.A 6?
Maintenance painting.

Don’t know much on the last 7 specification questions (guessing) will read more on the subject.