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Welding Inspector Interview Question
Welding Inspector Interview Question
5) What is WPS?
The WPS is a written document that provides direction to the welder
for making production welds in accordance with Code/Standard
requirements.
6) How is the Procedure Qualification Record (PQR) different from the WPS ?
Procedure Qualification Record certifies that test welds performed in
accordance with the WPS meet Code requirements and summarizes
the specific test results.
7) What is PQR?
A record of welding variables used to produce an acceptable test
weldment and the results of tests conducted on the weldment to qualify a
welding procedure specification.
13) Mention the drying temperatures for low hydrogen SMAW electrodes?
260-430°C for 2 hrs min (A5.1)
370-430°C for 2 hrs min(A5.5)
120-250°C for 2 hours minimum. (SS and Non-Ferrous
electrodes)
20) The term used to describe delay in the production schedule to permit
inspection is __________
Hold Point
31) What factors (give at least four) are taken into account when selecting and
designing a joint for a welding application?
Strength
Accessibility for welding
Minimize distortion
Cost of welding
Accessibility for inspection
32) What is the difference b/w stud bolt and machine bolt?
Machine bolt has a head on one side and nut on other side but stud bolt
have nuts on both sides.
33) Which standard do you refer for the welding equipment calibration?
BS 7570.
34) What are the tests required for verifying supplementary essential variables?
Notch toughness tests-
Charpy V- Notch test
Drop weight.
37) Mention the drying temperatures for low hydrogen SMAW electrodes?
260-430°C for 2 hrs min (A5.1)
370-430°C for 2 hrs min(A5.5)
120-250°C for 2 hours minimum. (SS and Non-Ferrous
electrodes)
41) If Mechanical damage occurred on base metals what will be your course of
action?
If any Mechanical damage found on the base metal, conduct the thickness
measurement and Magnetic Particle Test or Penetrant Test to be conducted, if
it is within tolerance accept it otherwise submit the report to higher authority for
further action.
42) You have observed in the specimen certain defects, why do you consider it as
important and do the report of it, state two planar defects? What are causes for
the occurrence of it and how will you avoid it?
Defects: Is a rejectable one i.e., a discontinuity which exceeds the code limits is
defects. Depending up on the conditions and severity it has to be repaired.
The two planar defects are i) Lack of side wall fusion ii) Undercut.
i) Lack of side wall fusion: Contaminated surface may due to oil, grease, and
rust etc., and too narrow gap, current very low and improper manipulation of
electrodes.
Prevention: Bevel ends shall be thoroughly cleaned and free from detrimental
contaminants, appropriate root gap, welding parameter within the WPS range
and right manipulation of electrodes.
44) Buttering or weld build up on the prepared surface shall not exceed
Exceed the lesser of 1/3rd of base metal thickness or 10mm without the
prior approval of the company.
i. Check the Test Certificates (T.C.) of each batch of electrodes for the
conformance of parameters with respect to project requirements.
ii. Check the availability of labels on each package units (Pack or Box) and
completeness of the information in them.
iii. Check the condition of the package and electrode / filler wire. If any
damage found, it is reported for the corrective action.
iv. Check the correctness of the batch No.; Electrode/Filler wire diameter and
other data with respect to the Test Certificate.
a. After inspection, the welding materials are stored in the warehouse or in
the welding consumables control room under ambient temperature.
b. All welding consumables shall be stored in racks, off the floor, in such a
way as to prevent any physical damage or contamination. Consumables
for the use on various types and grades of material shall be clearly
segregated by type and size to minimize possibility of error in distribution.
56) Why post heating is done on some pipe after the welding is over?
To maintain uniform homogeneous structure.
57) What are weldolets and sockolets? And where they are generally used?
Weldolets and sockolets are self reinforced fittings.
Weldolets are used for butt welded branch connections where standard
tee is not available due to size restrictions and the piping is at a
critical/high pressure service.
Sockolets are used to socket welding branch connection which requires
reinforcing pads.
Calculated by throat
Fillet weld size is the leg length of the largest isosceles right triangle which
can be inscribed within the fillet weld cross section.
67) What are the tests required for verifying supplementary essential variables?
Notch toughness
70) What are the factors on which the density of radiographic film depends?
The density of radiographic films depends upon the following: -
A. Total amount of radiation emitted by X-ray or gamma ray.
B. Amount of radiation reaching the specimen.
C. The amount of radiation passing through the specimen.
D. Intensifying action of the screen if used.
71) How will you calculate the geometric unsharpness in radiographic film?
Geometric unsharpness of the radiograph shall be determined in accordance
with:
Ug = Fd/D
where
Ug = geometric unsharpness
F = source size: the maximum projected dimension of the radiating source
(or effective focal spot) in the plane perpendicular to the distance D from
the weld or object being radiographed, in.
D = distance from source of radiation to weld or object being
radiographed, in.
d = distance from source side of weld or object being radigraphed to film.
72) What is the welder qualification based on f number?
I. Root
II. Hot Pass
III. Fill
IV. Cap
i. Weld Face
ii. Weld Root
iii. Fusion Zone
iv. Fusion Boundary
v. Heat Affected Zone (HAZ)
vi. Weld Toes
vii. Weld Width
Weldolet
Sockolet
Threadolet
Elbolet
Nippolet
PREHEAT REQUIREMENTS
MATERIAL WALL THICKNESS MIN PREHEAT
Upto 30mm 20*
CS/LTCS 30-50 mm 20**
> 50 mm 100
P 4( P11) ALL 150
P5B( P5, P9) ALL 250
SS ALL 10
* If ambient temp. is below 5˚C, preheat to 40˚C is mandatory.
** 80˚C min, if specified UTS≥ 490 Mpa & heat i/p < 20 KJ
Max interpass temp. for SS( P8) : 177˚C
Max interpass temp. for CS, alloy (P5,P9,P11) :315˚C
86) What is the difference b/w tensile test & yield test?
A tensile test is a test to obtain an accurate assessment of the strength and
ductility of a material or a weld, or in an all-weld-metal test, to determine
mechanical properties such as tensile strength, yield strength, elongation,
and reduction in area.
A yield test is to obtain the strength at some arbitrary amount of extension
under load or a permanent plastic strain (offset).
88) While welding of pipe trunion to pipe/reinforcement pad you have to put a hole
or leave some portion of welding why?
For venting of hot gas which may get generated due to welding.
89) What is the affect if the quantity of hydrogen induced in weld metal is
more?
When hydrogen is more in weld metal, it tends to make the material
brittle & subsequently leads to cracking. These cracks are called
hydrogen induced cracking or delayed crack. To avoid this the electrode
before using is backed at 250˚C to 300˚C for one hour in mother oven &
then cooled down to 100˚C in the same oven & finally transferred to
portable oven for use where temperature is maintained at 60˚to 70˚C
91) Why don’t we take a branch for Cryogenic Service from bottom side though
the fluid is in liquid state?
There is the chance of Ice formation during normal operation and since
ice flows from the bottom of the pipe it will block the branch pipe
connection.
92) From which side of pipe will you take a branch connection?
When Fluid is Gas, Air or Steam and Cryogenic Service – Topside.
When Fluid is Liquid – Bottom Side.
93) What are the different types of hardness tests carried out?
Brinell hardness Test.
Rockwell Hardness Test.
Vicker Hardness Test.
104) What type of cutting used is SS? Types of Grinding wheel and how to
identify them?
Plasma arc cutting and grinding wheel
Types for grinding wheel are: Iron oxide, zirconium, Aluminum oxide.
Identification by color coding.( blue)