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    Paper 3 Study Guide

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    “THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY THIRD PAPER QUALITY CONTROL NON-DESTRUCTIVE TESTING AND WELD EVALUATION Student Study Guide ‘This publication © The Northern Alberta Institute of Technology (2000). All rights are reserved. No part of this publication may be reproduced, or transmitted in any form or by any means, or stored in a database and retrieval system, without the prior written permission ofthe copyright holder. Address all inquiries to: ‘THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY 11762 - 106 Street Edmonton, Alberta Canada TSG 2R1 Table of Contents ‘THIRD PAPER OUTLINE... OVERVIEW. PRE-TEST INFORMATION. PRE-REQUISITES... MODULE 1: QUALITY CONTROL evs LEARNING OUTCOME : 7 INTRODUCTION. —_— et RESOURCES., COBIECTIVE I: Desrbe the gous, purpose, seope and concepts stacy system for Performance Qualification Testing OBJECTIVE 2: Describe the system for preparing, revising and controling the libtion ofthe Quality Syste fr Performance Qualietion ‘Testing manual 2 = 10 OBJECTIVE 3: Describe the roles responsibilities, procedures, and duties of personnel who conduct and supervise performance qualification 2 OBJECTIVE 4: Describe the activities, procedure and requirements for esformance solifaon eng of Welder/Mactne Welding Operators... OBJECTIVE 5: Describe the radiographic examination that may be used to qualify Welders/Machine Operators. 16 OBJECTIVE 6 Desrit th ryt orienting, ocunenting an eng ‘non conform "MODULE 2: NON-DESTRUCTIVE EXAMINATION wns LEARNING OUTCOME, INTRODUCTION = RESOURCES 2 OBIECTIVE 1: Describe and explain Visual examination. 2B OBIECTIVE 2: Deserbe the details for Radiograph Examination. 26 OBJECTIVE 3: Describe the details for Ultrasonic Examination. OBJECTIVE 4: Describe the details for Liquid Penetrant Inspection. OBJECTIVE 5: Describe the details for Magnetic Particle Testing... 4 MODULE 3: WELD EXAMINATION seesnnninnnioninnnsonmnnnnsne LEARNING OUTCOME, sone 52 INTRODUCTION... 52 RESOURCES sev 82 ‘OBIECTIVE 1: ume te SMAW copons er seeptiliy ovarian referencing codes... w ‘OBJECTIVE 2: Examine the GTAW coupons for acceptability to various referencing codes OBJECTIVE 3: Examine the GMAW coupons for acceptability to various C0deS sun 62 OBJECTIVE 4: Examine the bend coupons for acceptability to ASME Section IX sou. 65 "THIRD PAPER SUMMARY venone oo 53 Third Paper Quality Control, Nor-destuctive Testing, and Weld Examination Third Paper Outline 1: Quality Control (weighting 30%) A quality system for the performance qualification testing of pressure welders and ‘machine operators in accordance with ASME Section IX and the Alberta Safety Codes ‘Act and Regulations. Concepts, Goals, Purpose, and Scope ii Roles Responsibilities and Duties of Personne! iii, Elements of a Quality Control Manval for Pecformance Qualification Testing, iv. Relationship between Codes and Regulations v. Accredited Organizations vi, Testing Standards and Procedures Module Non-destructive Examination (weishtng 35%) ‘The applications, examination processes, requirements, uses, benefits, limitations, Personnel qualification, physical weld defects and acceptance criteria of the following NDE methods. i. Visual Examination {i Radiographic Examination ill, Uleasonie Examination iv, Liquid Penetrant Examination \. Magnetic Particle Examination Module Weld Examination (weighing 25%) Candidates will examine and assess representations of coupons for weld defects and acceptability standards referenced in ASME Section 1, Section VIII Div. I, Section TX, 'B31.1, B31.3 (normal) and B31.3 (severe) Student Stdy Guide ia, Page 1 ‘Third Paper ‘Quality Control, Non-destucve Testing, and Weld Examination REFERENCE MATERIAL Pee Sample Quality Control Manval forthe Perfomance Qualification Testing of Pressure Welders and Machine Operators. + ASME Section 1 + ASME Section V + ASME Section VIII Div, I + ASME Section Ix + ASME RSL + ASMERS13 Student Susy Gude i, Page 2 ‘Third Paper (Quality Control, Non-destuctive Testing, and Weld Examination Overview ‘The Alberta Boiler and Safety Association (ABSA) has been charged by the Goverment of Alberta with the administration of the Welding Examiner Certificate of Competency Examination. This is the thed in a series of four papers, which have been prepared by ‘NAIT to assist candidates to prepare fr the required examinations. ‘This Third Paper will introduce the candidate to the concepts of a quality system for the performance qualification testing of welders and welding operators as well as the fundamentals of various non-destructive testing methods. In addition, the paper will close with illustrations of weld samples, which will be evalusted for defects and acceptability standards. Pre-test Information If you know the information that is covered in this module, contact the Alberta Boiler Safety Association (ABSA) to write the Thitd Paper of the Welding Examiners Certificate of Competency examination. nectar one i, — IEEE EEEEEEEEEEEEDEEOYYE: ‘Third Paper (Quaity Control, Non-destuctive Testing, and Weld Examination Pre-requisites ‘This General Information is intended to assist candidates studying for the Welding Examiner Certificate of Competency examination. ‘To qualify to take this examination, a candidate must satisfy atleast one of the following cligibilty requirements Certifications/Designations + PLEng. with a B.Sc, in Metallurgy, Welding, or Mechanical Engineering ‘+ First Class Power Engineers, Certificate of Competency ‘+ CET with a Diploma in Materials or Mechanical Engineering Technology + Diploma in Welding Engineering Technology + Grade "A" or "BY Pressure Welder (see note 1) + CSA WI78.2 Welding Inspector Level I + Safety Codes Officer - Boiler Diseipline + Designated Welder Testing Personnel (see note 2) + Other equivalent Qualifications (see note 3) Notes Note 1 Candidates who have successfully completed Papers 1 and 2 of the Grade "A" ‘Pressure Welders examination may be granted credit for these same papers on the Welding Examiners Certificate of Competency Examination, Note? Designated welder testing personnel who were authorized under a testing ‘organization's quality control program to conduct performance qualification tests as of October 1, 2002 are eligible to write the Welding Examiner Certificate of Competency examination Note 3 Other qualifications will be considered under the provisions, which wil allow the Administrator to accept equivalencies. The candidate must have relevant experience, which would include involvement in the pressure equipment industry related to fabrication, inspection, repair, welding design, quality control or operation. The candidate would also have suitable academic ‘qualifications in recognized courses in welding, materials, ASME Codes, and NDE. Student Sty Guide i, Page “Third Paper (Quaity Control, Non-destructve Testing, and Weld Examination Resources ABSA sample Quality Control Manual forthe Performance Qualification Testing of Pressure Welders and Machine Operators ASME Section I ASME Section V ASME Section VIII Div. I ASME Section IX ASME B31.1 ASME B31.3 ‘Student Study Guide Pages Thies Paper ‘Qualty Control, Non-destrucve Testing, and Weld Examination Module 1 Quality Control Student Study Guide Page 6 ‘Third Paper ‘Quality Contr, Non-destrucve Testing, and Weld Examination Learning Outcome and Objectives Learning Outcome ‘Upon completion of this module the candidate will be able to describe the concepts, goals, and the required elements needed in a Quality System Manual for Performance (Qualification Testing, Learning Objectives 1. Describe the goals and purpose of « Quality System Manual for Performance Qualification Testing. 2, Deseribe the system for preparing, revising and controlling the distribution of the Quality System manual 3. Describe the roles, responsibilities, and duties of personnel who conduct and supervise performance qualification testing 4, Describe the activites, procedures and requirements for performance qualification testing. 5. Describe the radiographic examination that may be used to qualify Welders! ‘Machine Operators. 6. Describe the system for identifying, documenting and resolving non conformities. Introduction All persons wishing to undertake pressure welding in the Province of Alberta must pass the performance qualification test required by the Administrator and conducted by an accredited organization, 'A Welding Examiner should be familiar with a Quality System Manual for Performance ‘Qualification Testing and the functions of an Examiner as defined in the manual Resources ‘The following resources are required in this module. © ABSA Sample Quality Control Manual for the Performance Qualification Testing ‘of Welders and Welding Operators Student Study Guide Gy Page 7 ‘Third Paper (Quality Contr, Non-destructive Testing, and Weld Examination Module ities and Practice Exercises Learning Acti Objective 1: Describe the goals, purpose, scope and concepts of a Quality system for Performance Qualification Testing. ‘Activity #4 In the ABSA sample Quality System Manual for the Performance Qualification Testing of Welders and Welding Operators read sections "A", "D", and "E”, a oe ee ee ee «iene tert 6. Who has theultimate responsibility forthe quality system? 7. Who has the responsibility of resolving any conflicis and what must they not ‘compromise? Student Study Gude fa, Pages ‘Third Paper Quaity Control, Nondestructive Testing, and Wels Examination Practice Exercises Answers Refer to the following sections in the ABSA Quality System for Performance Qualification Testing manual to check your answers to the practice exercises, 1. Seetion "A" 2. Section “AY 3. Section “AY 4. Section "D" 5. Section "D" 6. Section "E" 7. Section "E" ‘Student Study Guide ‘Third Paper Quality Control, Non-destructve Testing, and Weld Examination Objective 2: Describe the system for preparing, revising and controlling the distribution of the Quality System for Performance Qualification Testing manual. Activity #4 Inthe ABSA sample Quality System Manual for Performance Qualification Testing read Section 5. Practice Exercises 1. Who is responsible for implementing the Quality system? 2. Explain how revision tothe Quality Systom manual is implemented. 3. How does the system assure that all copies of the manual are revised? Student Study Guide Page 10 ‘Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answors Refer to the following sections in the ABSA Sample Manual for Performance ‘Qualification Testing to check your answers tothe practice exercises. 1, Section 5.1 2, Section 5.1 3. Section 5.2 Student Study Guide Page 11 Third Paper (Quotty Contre, Non-destructve Testing, and Weld Examination Objective 3: Describe the roles, responsibilities, procedures, and duties of personnel who conduct and supervise performance qualification testing. Activity #1 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 6. a, Practice Exercises 1, What are the duties of the Quality Control Manager when appointing the Wel Examiner? 2. What qualifications should the Welding Examiner have? 3. Who shall conduct andor supervise a performance qualification test? ‘Student Study Guide Page 12 “Third Paper Qualty Control, Non-destuctve Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System Manual for Performance Qualification Testing to check your answers tothe practice exercises 1. Section 6.1 2. Section 6.2 3. Section 63 Student Study Guide Page 19 Third Paper ualty Control, Nondestructive Testing, and Weld Examination Objective 4: Describe the activities, procedure and requirements for performance qualification testing of Welders/Machine Welding Operators. Activity #1 {In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 9 Practice Exercises 1. Can an Examiner issue a Performance Qualification card to himselOherself or to the ‘immediate Supervisor? 2. What are the Welding Examiners duties prior tothe test? 3. What are the Welding Examiners duties during the test? 4. What re the Welding Examiners duties after the test? 5. State the additional duties of a commercial testing facility, 6. What instructions should be provided to a Welder/Machine Operator performing a test? ‘Student Study Guide Page 14 ‘Third Paper (Quality Contol, Nondestructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System Manual for Performance Qualification Testing to check your answers tothe practice exercises, 1. Section 9.0 2. Section 9.1 3. Section 92 4, Section 93 5. Section 9 6. Exhibit 9.1 Student Study Guide Si, Page 15 Third Paper Quality Control, Non-destructve Testing, and Weld Examination Objective 6: Describe the radiographic examination that may be used to qualify Welders/Machine Operators. Activity #1 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 10, a Practice Exercises 1. What Code Section must a welder test to, fo renew his qualifications by radiography? 2. What qualifications must the radiographer be certified to? 3. What are the duties of a Welding Examiner in regards to the NDE subcontractor? 4 What level of certification must an NDE examiner have to interpreta radiograph? ere fl ‘Third Paper ‘Quality Control, Non-destrucve Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA. sample Quality System manual for Performance Qualification Testing to check your answers tothe practice exercises. 1. Section 100 2. Section 10.1 3, Section 102 4. Section 104 (@ Student Study Guide Page 17 ‘Third Paper Quality Cont), Non-destructve Testing, and Weld Examination Objective 6: Describe the system for identifying, documenting and resolving non conformities. Activity #4 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 11 Practice Exercises 1. Who shall be notified of a non conformance? 2, How musta non conformance be identified? 3. When can @ non conforming item be released? 4. Where should the report be filed? ‘Student Study Guide i. i ‘Third Paper Quaity Control, Non-estuctive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System manuel for Performance Qualification Testing to check your answers to the practice exercises 1. Section 11.1 2. Section 11.2 3. Section 11.3, 4. Section 11.4 ‘Student Study Guide Page 19 Thi Paper Quality Corto, Non-destructve Testing, and Weld Examination Module 2 Non-Destructive Examination ‘Student Study Guide Page 20 Third Paper ‘Qualty Contol, Non-destrucve Testing, and Weld Examination Learning Outcome and Objectives Learning Outcome Upon completion of this module the candidate will be able to describe the uses, requirements, benefits, limitations, personnel qualifications and acceptance criteria of ‘various inspection methods. Learning Objectives 1. Deserbe the details for Visual Examination 2 Deserie the details for Radiographic Examination 3. Describe the details for Utrasonic Examination 4, Deseribe the details for Liquid Penetrant Examination 5. Deseribe the details for Magnetic Particle Examination Introduction In today’s complex and competitive fabrication and maintenance industry, the use of non destructive examination is a must to ensure maximum reliability. The study of these ‘methods will help personnel to ascertain that the proper test technique is used to assure the quality of the finished product. ‘The study of non destructive testing will enable the Candidate to further his knowledge so that they may attempt to challenge the Welding Examiner Certificate of Competency ‘administered by the Alberta Boiler and Safety Association. ‘Student Study Guide Page21 fe EEE’ ~~ ‘Third Paper ‘Quality Control, Non-destrucve Testing, and Weld Examination Resources ‘The following resources are required for this module. ‘© ASME Section V Ifyou fee! that you are not familiar with the four methods of non-destructive testing we recommend the following additional resource materials that you can oblain in the following books. 4. Radiogrphle Testing CT-6-6 second eition ii. Utasoni Testing (CT-6-4 second edition i Liquid Penetrant (1-6-2 fourth eiton iv, Magnetic Pate (1-63 second etn Student Stdy Gude pio, Page 22 Third Paper (Quality Control, Nondestructive Testing, and Weld Examination Module 2: Learning Activities and Practice Exercises Objective 1: Describe and explain Visual Examination. Activity #4 In ASME Section V, read Article 9 Practice Exercises 1. Whatisthe scope of Acie 97 2, Does Visual Examination require a written procedure? 3. Who may perform visual examinations? 4. What are the essential and non essential variables of visual examination? 5, What needs to be done when an essential variable is changed in visual examination procedure? 6, What equipment might be used in visual examination? 7. What information shoulda written procedure contain? 8, What are the physical requirements of personnel? 9. What is visual examination used for? 10, What are the requirements for direct visual examination? Student Study Guide Page 23 sare “Third Paper ‘Quality Control, Non-destructve Testing, and Weld Examination Objective 2: Describe the details for Radiographic Examination. Activity #41 In ASME Section V, read Article 2 a Practice Exercises 1, What is the scope of Article 2? 2, Radiographic examination shall be performed in accordance with a written ‘procedure, What information shall be included? 3. What would constitute a procedure demonstration? 4. Why must the surface ofa material being radiographed be prepared? 5. In what condition musta weld be, on both surfaces, before radiography? 6. Whats the pupose ofthe letter “B"attached tothe back ofthe film? 7. A system of identification shall be used on a radiograph. What information shall be {included on the radiograph? 8, What isa densitometer used for? 9. How much ofa weld must be examined? 10, What type of image quality indicator can be used? Student Study Guide Page 26 ‘Third Paper (Quaity Control, Non-destructve Testing, and Weld Examination 11. What size of holetype and wire type 1QI designation would be used on 1” thick material? 12, What shall the favlities for viewing radiographs provide? 13, How often, and by what method, shall a densitometer be calibrated? 14, When sala step wedge or comparison film be verified? 15. What isthe single-val exposure technique? 16, Whatis the double-wall exposure technique? 17, Whats single-wall nd double-wall viewing? 18, Whatis location marker and how is it used? 19, What materi sal a TQ be made of? 20. On what thickness of the materia isthe selection ofthe IQ based? 21. Whereis the hole type 10H place for welds? 22, Whereis the wire type IOI placed for welds? 23. Where a series of exposures are used to examine a weld, how many IQI are required? ‘Studer Susy Guide in, Page 27 i Third Paper ‘Quality Control, Non-destueive Testing, and Weld Examination ‘24, When shims are used, what should be the dimensions? 25, What blemishes should not be on a radiograph? 26. What ate the minimam and maximum densities of a radiograph allowed? 27, What isthe required sensitivity of a radiograph? 28, What are the manufacturer's responsibilities for evaluation of a radiograph? 29, What information is required on the radiographic documentation? 30, What information shall a radiographic review form have? Student Study Guide i, Page 28 ‘Third Paper ‘Quaity Control, Non-destuctive Testing, and Weld Examination Practice Exercises Answers Refer to the following paragraphs in ASME Section V to check your answers to the practice exercises. 1.7210 2.72211 3.72212 4.72221 5.72222 6.7223 7.7224 8.7225 9.7226 10. 72933 11, Table 7-233.1 & 7-233.2 12. 7.234 13, T2621 14.7-262.2 18. T2714 16. T2712 17. T2712 (a) & () 18, 1-275 19, 7-276. 20, 7-2762 21. T2771) 2. T2771 @) ‘Student Study Guide A, Page 20 “Third Paper 23.1272 4.13 25.7281 26, 7-282.1 27.7281 28, 7-286 29,7291 30. 7-292 ‘Student Study Guide Quaity Control, Non-destuctive Testing, and Weld Examination i Page 30 “Third Paper ‘Quaity Contr, Non-destrucive Testing, and Weld Examination Activity #2, In ASME Section V, read Article 22 Standard Guide for Radiographic Testing, a Practice Exercises ‘What is the scope of Article 22? 2. What information does this guide cover? 3. What isthe quality level required for radiography? A. What io filter? 5, Where are filters usually placed? 6. What is masking or blocking? 7. How can the effects of back-scattr radiation be reduced? How would you determine the adequacy of protection from backscatter? 9. What i the purpose of lead sereens? 10, When should lead sereens be used? 11, When should fluorescent sereens be used? 12, What is geometric unsharpness? Student Study Guide Page 3t ‘Third Paper ‘Quay Control, Non-desuthe Testing, nd Weld Examination 13, Final acceptance ofa radiograph is based on the ability to see what? 14, How should radiographs be identified? 15. What is the suggested method of identifying repairs? 16, Where should location maskers be placed? 17, Whatis another use fr locaton markers in relation to repairs? 18, How should unexposed film be stored? 19. What are the proper cleanlnes and handling practices fr fii? 20, What is automatic processing? 21. Describe manual procesing? 22, When viewing radiographs wat mus the illuminator provide? 23. Desoribe the characteristics of viewing room 24. How should radiographs be stored? 25. How should radiographic records be kept? Student Sexy Guide Page s2 “Third Paper Quaity Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer tothe following pages in the General Dynamics Radiographic Testing handbook to check your answers to the practice exercises, hu 212 asa a4 5.93 aa au 9.24 10.1212 11.123 a2e4a Bas 14.18: 18.1812 16.1821 17.1822 18.191 9.21 20.23, 21.24 i i i ul i J i st i i 1 i l i | | 22.26. | ‘Student Study Guide Page 33 ‘Thicd Paper Qualty Control, Nondestructive Testing, and Weld Examination 23.27 24,28 25,29 ‘Student Study Gude “Third Paper ‘Qualty Conel, Non-destructve Testing, and Weld Examination Objective 3: Describe the details for ultrasonic examination Activity #1 In ASME Section V, read Article 5 ww Practice Exercises 1, Whats the scope of Article 5? 2. What are the procedure requirements of ultrasonic examination? 3, What ie the rango of froquoncy that should bo used with ultasonies? 4, How is checking and calibration of equipment accomplished? 5, What product forms may be examined with the ultrasonic method? 6. What isthe scope of paragraph T-542? 7. Describe a basic calibration block that would be used fo evaluate welds described in 1542. 8. Of what material must the calibration block be? Suen Sy Gude fio, Page 28 Third Paper (Qualty Control, Non-

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