SATORP/TR INTERVIEW QUESTIONNARE (WELDING)
1) What What is the packa package ge number number and and explai explain? n? • Package one stands fo D!st!""at!on # $%do teat!ng &n!t' D!ffeent &n!ts ae /*+ $!g, Pess&e $%do Des&"-,&!.at!on /*+ Lo0 Pess&e $%do Des&"-,&!.at!on / /*+Na-,t,a *+Na-,t,a $%doteate $ %doteate Un!t 1/1*+ D!st!""at!on and $%do teat!ng $%dogen Un!t 11+ Off Gas PSA Un!t 1+$%dogen stoage &n!t /*+ 2&de D!st!""at!on Un!t/ Vac&&3 D!st!""at!on Un!t
2) What are the duties duties & responsibili responsibilities ties of a welding welding inspector? inspector? • • • • • • • • • • • • • • •
Pefo3 3ate!a" !ns-ect!on' Pefo3 cons&3a4"e !ns-ect!on' A--"!cat!on A--"!cat!on of !ns-ect!on !ns-ect!on ga&ges5 !nst&3ents !nst&3ents and too"s' too"s' 2,eck e6&!-3ent and accesso!es' W!tness -oced&e 6&a"!f!cat!on test' W!tness 0e"de 6&a"!f!cat!on test' Pefo3 7!s&a" !ns-ect!on' Re7!e0 / 0!tness NDT W!tness 3ec,an!ca" test' 8on!to ,eat teat3ent O4se7e -od&ct!on and fa4!cat!on 0e"d!ng' Inte-et and ass&e co3-"!ance to 2ode / Standad / S-ec!f!cat!on' Re7!e0 tec,n!ca" da0!ng' W!tness 0e"d e-a!' Pe-ae and co3-!"e !ns-ect!on ecods'
3) What is the formula formula for heat input? input? a. Heat Input (j/cm)= Voltage Voltage x Amperage x 60 / Travel Travel Speed(cm/min) 4) What are are welder welder qualificati qualification on limits? limits? a!e metal "uali#cation limit!. ($ no. and T%ic&ne!!) • 'iller material "uali#cation limit!.(' o.) • $ipe diameter and po!ition "uali#cation limit!. • eld metal t%ic&ne!! "uali#cation limit!. •
5)What is W!? •
T%e $S i! a *ritten document t%at provide! direction to t%e *elder +or ma&ing production *eld! in accordance *it% ,ode/Standard re"uirement!.
$rocedure -uali#cation ecord ($-) dierent 9) Ho* i! t%e $rocedure +rom t%e $S: $rocedure -uali#cation ecord ecord certi#e! t%at te!t t e!t *eld! • per+ormed in accordance *it% t%e $S meet ,ode re"uirement! and !ummarie! t%e !peci#c te!t te !t re!ult!.
") What What is is #$? #$? •
A ecod of of 0e"d!ng 7a!a4"es 7a!a4"es &sed to to -od&ce -od&ce an acce-ta4"e acce-ta4"e test 0e"d3ent and t,e es&"ts of tests cond&cted on t,e 0e"d3ent to 6&a"!f% a 0e"d!ng -oced&e s-ec!f!cat!on'
%) What What are essenti essential al aria ariable bles? s? Varia2le ($rocedure) a' 1!!ential Varia2le
3 A c%ange in a *elding condition *%ic% *ill aect t%e mec%anical propertie! (ot%er t%an notc% toug%ne!!) o+ t%e *eldment' E'g' ; c,ange !n P N&34e5 0e"d!ng -ocess5 < n&34e5 e"ectode5 -e,eat o -ost0e"d ,eat teat3ent'
2. 1!!ential Varia2le Varia2le ($er+ormance) ($er+ormance) 3 A c%ange in a *elding condition *%ic% *ill aect t%e a2ilit4 o+ a *elder to depo!it depo!it !ound *eld metal. 1.g 5 c%ange in *elding proce!! deletion o+ 2ac&ing electrode ' num2er tec%ni"ue etc.
9) What are supplementary supplementary essential variables? variables? a. T%e c%ange in a *elding *elding conditio condition n *%ic% *ill aect aect t%e notc% toug%ne!! propertie! o+ a *eldment i! &no*n a! !upplementar4 e!!ential varia2le. 1') (an we use two welding process in a W!? =es (E'g'> GTAW ? S8AW) • 11) What is W*? • Post0e"d ,eat teat3ent (PW$T)5def!ned as an% ,eat teat3ent afte
0e"d!ng5 !s often &sed to !3-o7e t,e -o-et!es of a 0e"d3ent' 12)Wh+ we are using W*?
•
To !ncease t,e es!stance to 4!tt"e fact&e and e"a@!ng es!d&a" stesses'
13) Mention the drying temperatures for low hydrogen SMAW electrodes? 7605890:, +or 7 %r! min (A;.<) 905890:, +or 7 %r! min(A;.;) <7057;0:, +or 7 %our! minimum. (SS and on5'errou! electrode!) 1) What do you meant by low hydrogen consumables? >o* %4drogen con!uma2le! are de#ned a! le!! t%an or e"ual to ? ml o+ %4drogen per <00 g o+ depo!ited *eld metal. 1!)
What are dissimilar metal welds? An4 *eld joint (excluding *eld overla4! or !trip lining) 2et*een +erritic !teel and eit%er au!tenitic !tainle!! !teel duplex !tainle!! !teel or nic&el52a!ed allo4! or @!e o+ !tainle!! !teel or nic&el52a!ed #ller metal! on +erritic !teel!.
1,) -xplain about .1/.? T,e -!-!ng 0,!c, !s genea""% fo&nd !n -eto"e&3 ef!ne!es5 c,e3!ca"5 • -,a3ace&t!ca"5 te@t!"e5 -a-e5 se3! cond&cto and c%ogen!c -"ants5 and e"ated -ocess!ng -"ants' T,!s sect!on !nc"&des • a) Acce-ta4"e 3ate!a" s-ec!f!cat!ons and co3-onent standads5 !nc"&d!ng d!3ens!ona" e6&!e3ents # -ess&e te3-eat&e at!ngs' 4) Re6&!e3ents fo des!gn of co3-onents and asse34"!es5 !nc"&d!ng -!-!ng s&--ots' c) Re6&!e3ents and data fo e7a"&at!on and "!3!tat!on of stesses5 eact!ons5 and 3o7e3ents assoc!ated 0!t, -ess&e5 te3-eat&e c,anges5 and ot,e foces' d) G&!dance and "!3!tat!ons on t,e se"ect!on and a--"!cat!on of 3ate!a"s5 co3-onents5 and o!n!ng 3et,ods' e) Re6&!e3ents fo t,e fa4!cat!on5 asse34"%5 and eect!on of -!-!ng' f) Re6&!e3ents fo e@a3!nat!on5 !ns-ect!on5 and test!ng of -!-!ng' 10)What are the t+pes of echanical tests? Tens!on Tests
G&!ded Bend Tests
*) *he term used to describe dela+ in the production schedule to permit inspection !s CCCCCCCCCC $o"d Po!nt •
7<)
1"uation +or Heat Input H = 601I / <000S %ere H 55 Heat Input (BC/mm) • 1 55 Arc Voltage (volt!) • I 3 ,urrent (Amp!) • S 3 Travel Speed (in/min) •
22)What is the rocedure #ualification *hickness imits?
AS8E SE2 I QW ; 1* !)
It !s t,e test co&-on F + S!.e 0e"ded (D!a)
!!)
T,!ckness a"0a%s *T ; T ; T,!ckness of Test 2o&-on
!!!)
8!n!3&3 T,!ckness Q&a"!f!ed ; '133
2.)What are the essential ariables for W*? $eat!ng ate • • Te3-eat&e atta!ned • 2,ok!ng te3-eat&e and 2oo"!ng ate' •
*)
W,at !s t,e ga- of socket 0e"d: •
'1 33 to H 33
25)3ormulae for carbon equialent? •
*9)
,1 = , D (En)/6 D (,rDEoDV)/; D (iD,u)/<;
W,at do %o& 3ean 4% ITP:
•
*)
It !s a 3andato% !te3 !n t,e Q&a"!t% P"an to g&!de and ass&e 6&a"!t% !n a s-ec!f!c t%-e of 0ok !n a s-ec!f!c se6&ence of Q2 act!7!t% ste-s'
W,at !s N2R: •
N2R> (Non 2onfo3!t% e-ot)> A ecod e-ot!ng t,e 7a!at!on fo3 t,e s-ec!f!ed e6&!e3ents'
"#) $ow do you calculate the weld repair percentage? F = (>r/>*) G <00 %ere F 3 $ercent repair rate >r 55 Total lengt% o+ repair in one *ee& >* 55Total lengt% o+ *eld radiograp%ed in one *ee& 20)$* of 6 7ormal and !eer c+clic serice?
D Se7!ce >
a) !f at!ng !s J 1 "45 K RT 4) If 8DT +*M25 1K RT c) $%doca4on se7!ce5 K
8 se7!ce >
a) !f at!ng !s J 9 "45 K RT 4) If 8DT +*M25 *K RT c) $%doca4on se7!ce5 K
$P Se7!ce > K RT S2 Se7!ce > K RT
3%) What should be the distance b&w two parallel welds? 70mm or t%ree time! t%e *all t%ic&ne!! o+ t%e joint *%ic%ever i! greater. H)W,at factos (g!7e at "east fo&) ae taken !nto acco&nt 0,en se"ect!ng and des!gn!ng a o!nt fo a 0e"d!ng a--"!cat!on: Stengt, Access!4!"!t% fo 0e"d!ng 8!n!3!.e d!stot!on 2ost of 0e"d!ng Access!4!"!t% fo !ns-ect!on .2)What is the difference b8w stud bolt and machine bolt? 8ac,!ne 4o"t ,as a ,ead on one s!de and n&t on ot,e s!de 4&t st&d 4o"t ,a7e n&ts on 4ot, s!des'
..)Which standard do +ou refer for the welding equipment calibration? BS 1'
H)W,at ae t,e tests e6&!ed fo 7e!f%!ng s&--"e3enta% essent!a" 7a!a4"es: Notc, to&g,ness tests+ 2,a-% V+ Notc, test Do- 0e!g,t'
3!) What is the chemical composition of a low hydrogen electrode ' (%1#? 10o* ,ar2on. 3) Mention the drying temperatures for low hydrogen SMAW electrodes? 7605890:, +or 7 %r! min (A;.<) 905890:, +or 7 %r! min(A;.;) <7057;0:, +or 7 %our! minimum. (SS and on5'errou! electrode!) 9)
%at are t%e dierent +actor! t%at cau!e HI, A !en!itive micro!tructure A !ucient level o+ %4drogen A %ig% level o+ !tre!!
.%)What is the minimum thickness of pipe that requires stress relieing to be done as per 9.1/.? 33
39)What is the function of shielding gas? Sta2ili!e! t%e arc root! on t%e material !ur+ace!. 1n!ure! !moot% tran!+er o+ t%e molten metal +rom t%e *ire to *eld pool. 'orm! t%e arc pla!ma.
) If 0e"de !s 6&a"!f!ed !n HG -os!t!on !n -!-es5 ,e can 0e"d a"" -os!t!on: HG -os!t!on !n -!-e not 3ent!oned !n AS8E Sec I5 T,e -!-e -os!t!ons ae G5 *G5 1G and 9G as -e AS8E Sec I' )If 8ec,an!ca" da3age occ&ed on 4ase 3eta"s 0,at 0!"" 4e %o& co&se of act!on: If an% 8ec,an!ca" da3age fo&nd on t,e 4ase 3eta"5 cond&ct t,e t,!ckness 3eas&e3ent and 8agnet!c Pat!c"e Test o Penetant Test to 4e cond&cted5 !f !t !s 0!t,!n to"eance acce-t !t ot,e0!se s&43!t t,e e-ot to ,!g,e a&t,o!t% fo f&t,e act!on' *)=o& ,a7e o4se7ed !n t,e s-ec!3en ceta!n defects5 0,% do %o& cons!de !t as !3-otant and do t,e e-ot of !t5 state t0o -"ana defects: W,at ae ca&ses fo t,e occ&ence of !t and ,o0 0!"" %o& a7o!d !t: 6efects: Is a eecta4"e one !'e'5 a d!scont!n&!t% 0,!c, e@ceeds t,e code "!3!ts !s defects' De-end!ng &- on t,e cond!t!ons and se7e!t% !t ,as to 4e e-a!ed' *he two planar defects ae !) ack of side wall fusion !!) ;ndercut/
!) ack of side wall fusion: 2onta3!nated s&face 3a% d&e to o!"5 gease5 and &st etc'5 and too nao0 ga-5 c&ent 7e% "o0 and !3-o-e 3an!-&"at!on of e"ectodes' reention: Be7e" ends s,a"" 4e t,oo&g,"% c"eaned and fee fo3 det!3enta" conta3!nants5 a--o-!ate oot ga-5 0e"d!ng -aa3ete 0!t,!n t,e WPS ange and !g,t 3an!-&"at!on of e"ectodes'
!!) ;ndercut
: D&e to e@cess!7e c&ent5 ta7e" s-eed too ,!g,'
reention : A--o-!ate ta7e" s-eed5 0e"d!ng -aa3etes &nde conto" and s,a"" 4e 0!t,!n t,e WPS ange'
4.)What is the 7o< for (! & !!? 2S+ P • • SS+P
)B&tte!ng o 0e"d 4&!"d &- on t,e -e-aed s&face s,a"" not e@ceed E@ceed t,e "esse of /H d of 4ase 3eta" t,!ckness o 33 0!t,o&t t,e • -!o a--o7a" of t,e co3-an%' 1) Intena" 3!sa"!gn3ent of B&tt o!nts s,a"" not e@ceed '1 33 •
9)
)E@-"a!n E E ; E"ectode ; Tens!"e Stengt, ;fo a"" Pos!t!on ; 2oat!ng )T,e -e,eat s,a"" 4e esta4"!s,ed o7e a 3!n!3&3 d!stance of 133 on eac, s!de of t,e 0e"d' • )E"ectodes5 f!""e 0!es5 f"&@ 0,!c, standads to 4e &sed: AS8E SE2 II 2 • 1)W,at e6&!-3ent 0!"" &se to dete3!ne o@%gen "e7e": O@%gen Sca7enge • 1)W,at !s t,e s&face te3-eat&e of PT: • 1 2 to 1*2 1*)W,at !s t,e < n&34e fo t,e f!""e 0!e ERS: 9 •
5.) What are the duties of a #( =nspector for (onsumable receiing inspection? !'
2,eck t,e Test 2et!f!cates (T'2') of eac, 4atc, of e"ectodes fo t,e confo3ance of -aa3etes 0!t, es-ect to -oect e6&!e3ents' !!' 2,eck t,e a7a!"a4!"!t% of "a4e"s on eac, -ackage &n!ts (Pack o Bo@) and co3-"eteness of t,e !nfo3at!on !n t,e3' !!!' 2,eck t,e cond!t!on of t,e -ackage and e"ectode / f!""e 0!e' If an% da3age fo&nd5 !t !s e-oted fo t,e coect!7e act!on' !7' 2,eck t,e coectness of t,e 4atc, No' E"ectode/
fo t,e &se on 7a!o&s t%-es and gades of 3ate!a" s,a"" 4e c"ea"% segegated 4% t%-e and s!.e to 3!n!3!.e -oss!4!"!t% of eo !n d!st!4&t!on' 54) What is the exposure time for low h+drogen electrode? • T,e e"ectodes 3a% not 4e e@ceeded 3oe t,an fo& ,o&s5 t,e e@-os&e 3a% 4e e@tended to ,o&s !f t,e e"ectodes ae cont!n&o&s"% stoed !n a -ota4"e o7en &-to 912 3!n!3&3' 55)What are the things to be checked in sockolets? A"" f!tt!ng 4oes ae to 4e concent!c 0!t,!n '933 fo a"" s!.es' • To -e7ent cack!ng of a f!""et 0e"d !nsta"" a '1 cad4oad 0as,e o • 0!t,da0 t,e -!-e '1 33 fo3 4otto3 of t,e socket 4efoe 0e"d!ng' 5,)Wh+ post heating is done on some pipe after the welding is oer? To 3a!nta!n &n!fo3 ,o3ogeneo&s st&ct&e' • 5")What are weldolets and sockolets? >nd where the+ are generall+ used? We"do"ets and socko"ets ae se"f e!nfoced f!tt!ngs' • • We"do"ets ae &sed fo 4&tt 0e"ded 4anc, connect!ons 0,ee standad tee !s not a7a!"a4"e d&e to s!.e est!ct!ons and t,e -!-!ng !s at a c!t!ca"/,!g, -ess&e se7!ce' Socko"ets ae &sed to socket 0e"d!ng 4anc, connect!on 0,!c, e6&!es • e!nfoc!ng -ads' 5%)What is the densit+ of steel? '9 kg/3 • 50)=n .1, what is the stands for? • L stands fo "o0 ca4on stee" ,')=f heat input increases what will happen? • =!e"d stengt, deceases Tens!"e stengt, deceases • Pecent !n e"ongat!on !nceases • Notc, to&g,ness s"!g,t"% !nceases and t,en deceases • $adness deceases • • 2oo"!ng ate deceases ( R ∝ / T$) W,ee R !s t,e coo"!ng ate5 T !s t,e -e,eat te3-eat&e5 $ !s t,e ,eat !n-&t' ,1) What is the cause of porosit+? T,e -esence of gas -oes !n a 0e"d ca&sed 4% enta-3ent of gas d&!ng • so"!d!f!cat!on !s te3ed as -oos!t%' T,e -oes ae !n t,e fo3 of s3a""
s-,e!ca" ca7!t!es e!t,e c"&steed "oca""% o scatteed t,o&g,o&t t,e 0e"d de-os!t' So3et!3es enta--ed gas g!7e !se to a s!ng"e "age ca7!t% ca""ed B"o0,o"es' (ause: A' 2,e3!ca""% !3-efect 0e"d!ng cons&3a4"es5 fo e@a3-"e5 def!c!ent !n deo@!d!se' B'
,2)
• •
ow do +ou calculate concae fillet weld?
2a"c&"ated 4% t,oat
,.)ow do +ou calculate the conex fillet weld?
•
•
•
•
•
• • • •
2a"c&"ated 4% Leg s!.e 2on7e@!t% !s t,e 3a@!3&3 d!stance fo3 t,e face of con7e@ f!""et 0e"d -e-end!c&"a to "!ne o!n!ng t,e 0e"d toes' ,4)What is annealing and normali@ing process? Annea"!ng -ocess !s a ,eat teat3ent !n 0,!c, a so"d state !s ,eated and t,en coo"ed at a s"o0 ate' T,e annea"!ng te3-eat&e and t,e ate of coo"!ng de-end on t,e 3ate!a" and t,e -&-ose of t,e teat3ent' Annea"!ng !s &sed to effect an% of t,e fo""o0!ng c,anges !n 3eta"> To e"!e7e stess Ind&ce softness A"te 3ec,an!ca" -o-et!es5 e"ect!ca"5 3agnet!c o -,%s!ca" -o-et!es' Ref!ne c%sta""!ne st&ct&e Re3o7e gases Pod&ce a def!n!te 3!cost&ct&e' No3a"!.!ng -ocess !s a -ocess !n 0,!c, a feo&s 3eta" !s ,eated to a s&!ta4"e te3-eat&e a4o7e t,e tansfo3at!on ange and !s s&4se6&ent"% coo"ed !n st!"" a! at oo3 te3-eat&e' ,5)What are the characteristics of good welding cable? Wea and a4as!on es!stant $!g, e"ect!ca" es!stance Good ,eat es!stance T,e s!.e of t,e ca4"e e6&!ed fo a -at!c&"a a--"!cat!on de-ends on t,e 3a@!3&3 a3-eage to 4e &sed fo 0e"d!ng5 t,e "engt, of t,e 0e"d!ng c!c&!t (0e"d!ng and 0ok ca4"es co34!ned)5 and t,e d&t% c%c"e of t,e 0e"d!ng 3ac,!ne'
•
,,)What are the tests required for anal+sis of consumables? 2,e3!ca" Ana"%s!s ( AS8E SE2 II 2 ) P8I (ERES+A+*9)
•
9)W,at ae t,e tests e6&!ed fo 7e!f%!ng s&--"e3enta% essent!a" 7a!a4"es: Notc, to&g,ness
•
•
•
•
9)W,at !s an !soto-e: D!ffeent t%-es of !soto-e: E@-"a!n t,e c,aacte!st!cs of !soto-e: Ato3s of t,e sa3e e"e3ent 0,!c, ae !dent!ca" !n t,e! c,e3!ca" 4e,a7!o 4&t d!ffeent fo3 one anot,e !n t,e n&34e of ne&tons conta!ned !n t,e! n&c"e!5 and t,&s ,a7e d!ffeent ato3!c 0e!g,ts' Isoto-es a"so act as f"o0 taces fo detect!ng "eaks !n 4&!ed o !naccess!4"e e6&!-3ent' Isoto-es s&c, as co4a"t+95 ces!&3+H5 and !!d!&3+*
9)
Na3e t,e !nst&3ent &sed fo 3eas&!ng dens!t% of -,otoga-,!c o ad!oga-,!c f!"3:
•
Dens!to3ete
)
W,at ae t,e factos on 0,!c, t,e dens!t% of ad!oga-,!c f!"3 de-ends:
T,e dens!t% of ad!oga-,!c f!"3s de-ends &-on t,e fo""o0!ng> + A' Tota" a3o&nt of ad!at!on e3!tted 4% +a% o ga33a a%' B' A3o&nt of ad!at!on eac,!ng t,e s-ec!3en' 2' T,e a3o&nt of ad!at!on -ass!ng t,o&g, t,e s-ec!3en' D' Intens!f%!ng act!on of t,e sceen !f &sed' )$o0 0!"" %o& ca"c&"ate t,e geo3et!c &ns,a-ness !n ad!oga-,!c f!"3: Geo3et!c &ns,a-ness of t,e ad!oga-, s,a"" 4e dete3!ned !n accodance 0!t,> Ug Fd/D 0,ee Ug geo3et!c &ns,a-ness F so&ce s!.e> t,e 3a@!3&3 -oected d!3ens!on of t,e ad!at!ng so&ce (o effect!7e foca" s-ot) !n t,e -"ane -e-end!c&"a to t,e d!stance D fo3 t,e 0e"d o o4ect 4e!ng ad!oga-,ed5 !n' D d!stance fo3 so&ce of ad!at!on to 0e"d o o4ect 4e!ng ad!oga-,ed5 !n' d d!stance fo3 so&ce s!de of 0e"d o o4ect 4e!ng ad!ga-,ed to f!"3'
"2)What is the welder qualification based on f number?
".)Which markers are used on !! materials? Lo0 ,a"ogens and Lo0 s&"f& "ess t,an * --3 • "4)6efine >rc blow? T,e def"ect!on of an ac fo3 !ts no3a" -at, 4eca&se of 3agnet!c • foces' "5)What are the standards for welding as A-$ !tandard? ERES+W++We"d!ng Re6&!e3ents fo On+P"ot P!-!ng • ERES+W++We"d!ng Re6&!e3ents fo Pess&e Vesse"s • • ERES+W+*+We"d!ng Re6&!e3ents fo P!-e"!nes • ERES+W++We"d O7e"a%s and We"d!ng of 2"ad 8ate!a"s ERES+W+9+We"d!ng of S-ec!a" 2oos!on+Res!stant 8ate!a"s • ",)Write the weld la+ers?
I' II' III' IV'
Root $ot Pass
"")What are the Weldment *erms?
!' !!' !!!' !7' 7' 7!' 7!!'
We"d
)W!te S3a"" Boe
We"do"et Socko"et T,eado"et E"4o"et N!--o"et
)D% de7e"o-es: • 2an 4e a--"!ed 4% s-a%!ng5 f"o0!ng -!c% so"7ent can 4e a--"!ed 4% e"ectostat!c s-a% -at!c"e s,o&"d 4e (+) and ,!g, 7o"tage s,ock a"" to 4e done !n a "og c,a34e so 0e can sa&ce t,e K of t,e 3ate!a" )P!nc!-"e of UT' Ref"ect!on of So&nd • %1)What is the use of (ouplant? • To e3o7e t,e a! ga- 4et0een t,e tansd&ce and o4ect' %2)What is the Welding rocess?
a) 4) c) d) e) f)
GTAW S8AW SAW <2AW G8AW PAW
(Gas T&ngsten Ac We"d!ng) (S,!e"ded 8eta" Ac We"d!ng) (S&43eged Ac We"d!ng) (<"&@ 2oated Ac We"d!ng) (Gas 8eta" Ac We"d!ng) (P"as3a Ac We"d!ng)
%.)Welding osition P!-e ; GR5 *G5 1G5 9G5 P"ate ; G5 *G5 HG5 G PIPE>+
G> + A P!-e !s $o!.onta" Pos!t!on and 0e"d 4eed !s a 7et!ca" -os!t!on' T,e
)
P!-e 0!"" 4e otated' *G> + A P!-e !s Vet!ca" Pos!t!on and 0e"d 4eed !s $o!.onta" Pos!t!on 1G> + A P!-e !s $o!.onta" Pos!t!on and 0e"d 4eed !s Vet!ca" Pos!t!on 9G> + A P!-e !s a 1 Pos!t!on PLATE>+ G> + P"ate !s $o!.onta" and 0e"d !s $o!.onta" *G> + P"ate !s Vet!ca" and 0e"d !s $o!.onta" HG> + P"ate !s Vet!ca" and 0e"d !s Vet!ca" G> + A P"ate !s !n O7e,ead Pos!t!on 0e"d !s $o!.onta" Pos!t!on
W,at ae t,e -e,eat e6&!e3ents as -e ERES: $-->* $-#;=$--7*! 8ATERIAL WALL T$I2NESS 8IN PRE$EAT U-to H33 * 2S/LT2S H+1 33 * 1 33 P ( P) ALL 1 P1B( P15 P) ALL *1 SS ALL If a34!ent te3-' !s 4e"o0 125 -e,eat to 2 !s 3andato%' 2 3!n5 !f s-ec!f!ed UTSJ 8-a # ,eat !/- F * 8a@ !nte-ass te3-' fo SS( P) > 2 8a@ !nte-ass te3-' fo 2S5 a""o% (P15P5P) >H12
1)W,% 0e 3a!nta!n t,e !nte-ass te3-eat&e: T,e %!e"d and &"t!3ate tens!"e stengt,s of t,e 0e"d 3eta" ae 4ot, a • f&nct!on of t,e !nte-ass te3-eat&e' $!g, 7a"&es of !nte-ass te3-eat&e tend to ed&ce t,e 0e"d 3eta" • stengt,' Add!t!ona""%5 ,!g,e !nte-ass te3-eat&es 0!"" genea""% -o7!de a f!ne ga!n st&ct&e and !3-o7ed 2,a-% V notc, to&g,ness tans!t!on te3-eat&es' %,)What is the difference b8w tensile test & +ield test? A tens!"e test !s a test to o4ta!n an acc&ate assess3ent of t,e stengt, and • d&ct!"!t% of a 3ate!a" o a 0e"d5 o !n an a""+0e"d+3eta" test5 to dete3!ne 3ec,an!ca" -o-et!es s&c, as tens!"e stengt,5 %!e"d stengt,5 e"ongat!on5 and ed&ct!on !n aea' A %!e"d test !s to o4ta!n t,e stengt, at so3e a4!ta% a3o&nt of e@tens!on • &nde "oad o a -e3anent -"ast!c sta!n (offset)'
%")ow h+drogen electrode handling and oens? •
•
•
W,en conta!nes of "o0 ,%dogen e"ectodes ae o-ened5 t,e% 0!"" 4e !33ed!ate"% -"aced !n an e"ectode 4ak!ng o7en' T,e 0e"d!ng 3ate!a" stoe s,a"" 4e a conto""ed access aea' Una&t,o!.ed -esona" !nc"&d!ng 0e"de # 0e"d!ng o-eated s,a"" 4e -o,!4!ted cons&3a4"es fo3 o&t !t' T,e 3a@!3&3 e"ectodes !ss&ed s,a"" 4e fo a4o&t 1 ,o&s' <o3 ,eat!ng o7en5 as a good -act!ce5 e"ectodes to 4e -"aced 4e"o0 t,e e"ectode st!"" !nto t,e ,o"d!ng o7en' Bak!ng 0!"" 4e done fo "o0 ,%dogen e"ectodes e'g' at te3-eat&e H1 O 2 !n accodance 0!t, t,e 3an&fact&e eco33endat!on'
)W,!"e 0e"d!ng of -!-e t&n!on to -!-e/e!nfoce3ent -ad %o& ,a7e to -&t a ,o"e o "ea7e so3e -ot!on of 0e"d!ng 0,%:
•
%0)
What is the affect if the quantit+ of h+drogen induced in weld metal is more? W,en ,%dogen !s 3oe !n 0e"d 3eta"5 !t tends to 3ake t,e 3ate!a" • 4!tt"e # s&4se6&ent"% "eads to cack!ng' T,ese cacks ae ca""ed ,%dogen !nd&ced cack!ng o de"a%ed cack' To a7o!d t,!s t,e e"ectode 4efoe &s!ng !s 4acked at *12 to H2 fo one ,o& !n 3ot,e o7en # t,en coo"ed do0n to 2 !n t,e sa3e o7en # f!na""% tansfeed to -ota4"e o7en fo &se 0,ee te3-eat&e !s 3a!nta!ned at 9to 2
)
L!st H d!sad7antages of RT o7e ot,e NDT 8et,ods' Rad!at!on Safet% Peca&t!ons5 P"ana defects not ead!"% detecta4"e5 • ,ea7% e6&!-3ent'
)W,% donXt 0e take a 4anc, fo 2%ogen!c Se7!ce fo3 4otto3 s!de t,o&g, t,e f"&!d !s !n "!6&!d state: T,ee !s t,e c,ance of Ice fo3at!on d&!ng no3a" o-eat!on and s!nce • !ce f"o0s fo3 t,e 4otto3 of t,e -!-e !t 0!"" 4"ock t,e 4anc, -!-e connect!on' 02)3rom which side of pipe will +ou take a branch connection? W,en <"&!d !s Gas5 A! o Stea3 and 2%ogen!c Se7!ce ; To-s!de' • W,en <"&!d !s L!6&!d ; Botto3 S!de'
0.)
04)
What are the different t+pes of hardness tests carried out? B!ne"" ,adness Test' • Rock0e"" $adness Test' V!cke $adness Test' What is a theoretical throat? T,e d!stance fo3 t,e 4eg!nn!ng of t,e o!nt oot -e-end!c&"a to t,e • ,%-oten&se of t,e "agest !g,t t!ang"e t,at can 4e !nsc!4ed 0!t,!n t,e coss sect!on of a f!""et 0e"d' T,!s d!3ens!on !s 4ased on t,e
ass&3-t!on t,at t,e oot o-en!ng !s e6&a" to .eo' 05) What is the procedure for application of wrapping and coating? •
Poced&e fo a--"!cat!on of 2oat!ng and 0a--!ng> +
>/ P!o to a--"!cat!on of 0a--!ng # coat!ng5 t,e s&face of -!-e s,o&"d 4e 3ade fee fo3 a"" "oose 8!"" sca"e5 d!t5 &st5 gease5 3o!st&e and ot,e foe!gn 3ate!a"' T,!s !s ac,!e7ed 4% 4"ast c"ean!ng to gade Sa * Y' 9/ T,e -!-e e@te!o s&face o 4"ast s&face s,a"" 4e coated 0!t, -!3e 0!t,!n fo& ,o&s of s,ot 4"ast!ng' T,e -!3e s,a"" not 4e a--"!ed 0,en t,e -!-e s&face te3-eat&e !s 4e"o0 2 and a4o7e 2' W,en 3o!st&e !s -esent on t,e s&face5 t,e sa3e !s ,eated fo s&ff!c!ent t!3e to d% t,e s&face' (/ T,e -!-e afte -!3!ng s,a"" 4e coated 0!t, t0o+f"ood coat of ,ot ena3e" !nco-oat!ng t,e s!3&"taneo&s a--"!cat!on of !nne # o&te 0a--!ng'
9) $o0 %o& 0!"" 3eas&e "!nea !nd!cat!ons and acce-tance: 8ate!a" t,!ckness s!.e t,k933 '933 933 J t,k F 133 H'*33 t,kJ 133 133 )W,at !s a d&-"e@ sta!n"ess stee": T,e te3 d&-"e@ sta!n"ess stee" desc!4es stee" 0!t, 3!cost&ct&e • conta!n!ng a&sten!te and fe!te !n 0,!c, t,e "esse -,ase !s at "east HK 4% 7o"&3e'
W,at ae t,e t%-es of gasket: •
Based on const&ct!on A' <&"" face' B' S-!a" 0o&nd 3eta""!c' 2' R!ng t%-e' D' 8eta" acketed' E' Ins!de 4o"t c!c"e'
•
Based on 3ate!a" A' S%nt,et!c &44e
B' So"!d Tef"on 2' 2o3-essed As4estos D'2S ($!g, -ess&e f"&!d) E' SS ($!g, f"&!d coos!7e) <' S-!a" Wo&nd a) Tef"on 4) 2S c) SS ) W,at ae t,e t%-es of f"anges: • Based on -!-e attac,3ent S"!- ; on' + T,e S"!-+on t%-e f"anges ae attac,ed 4% 0e"d!ng !ns!de as 0e"" as o&ts!de' T,ese f"anges ae of foged const&ct!on' Socket We"d' > + T,e Socket We"d f"anges ae 0e"ded on one s!de on"%' T,ese ae &sed fo s3a"" 4oe "!nes on"%' Sce0ed> + T,e Sce0ed+on f"anges ae &sed on -!-e "!nes 0,ee 0e"d!ng cannot 4e ca!ed o&t' La- o!nt' > + T,e La- o!nt f"anges ae &sed 0!t, st&4 ends' T,e st&4 ends ae 0e"ded 0!t, -!-es # f"anges ae ke-t "oose o7e t,e sa3e' We"d!ng Neck' > + T,e We"d!ng neck f"anges ae attac,ed 4% 4&tt 0e"d!ng to t,e -!-e' T,ese ae &sed 3a!n"% fo c!t!ca" se7!ces 0,ee t,e 0e"d o!nts need ad!oga-,!c !ns-ect!on' B"!nd' > + T,e B"!nd f"anges ae &sed to c"ose t,e ends 0,!c, need to 4e eo-ened' Red&c!ng' > + T,e ed&c!ng f"anges ae &sed to connect 4et0een "age and s3a""e s!.es 0!t,o&t &s!ng a ed&ce' In case of ed&c!ng f"anges5 t,e t,!ckness of f"ange s,o&"d 4e t,at of t,e ,!g,e d!a3ete' Intega"' > + Intega" f"anges ae t,ose5 0,!c, ae cast a"ong 0!t, t,e -!-!ng co3-onent o e6&!-3ent' •
•
<"anges ae c"ass!f!ed 4ased on -ess&e te3-eat&e at!ngs as> + A' 1 Z B' H Z 2' Z D' 9 Z E' Z <' 1 Z G' *1Z <"anges ae c"ass!f!ed 4ased on fac!ng as> + A' <"at face' (<<) B' Ra!sed face' (R/<) 2' Tong&e and goo7e' (T/G) D' 8a"e and fe3a"e' (8/<) E' R!ng t%-e o!nt' (RT)
•
4ased on face f!n!s, as> + A' S3oot, f!n!s,' B' Seated f!n!s,'
*) W,at !s tack 0e"d: Tack 0e"d !s t,e te3-oa% 0e"d to 3a!nta!n o!nt a"!gn3ent' A"" tack 0e"ds • s,a"" 4e 3ade 4% 6&a"!f!ed 0e"des' Reco33ended tack t,!ckness !s H'* ; '33 # "engt, !s *'1 + *1' 33' t,e 3!n!3&3 n&34e of tack 0e"ds fo H'1 !nc, and 4e"o0 ae H e6&a""% s-aced tacks' A4o7e H'1 !nc, e6&a""% s-aced tacks'
•
H) W,at !s Sc,ed&"e [QX: Sc,ed&"e Q stands fo O0neXs 3!n!3&3 6&a"!t% e6&!e3ents fo 2ontacto/S&4contacto 6&a"!t% s%ste3' ) W,at t%-e of c&tt!ng &sed !s SS: T%-es of G!nd!ng 0,ee" and ,o0 to !dent!f% t,e3: P"as3a ac c&tt!ng and g!nd!ng 0,ee" • T%-es fo g!nd!ng 0,ee" ae> Ion o@!de5 .!con!&35 A"&3!n&3 o@!de' • Ident!f!cat!on 4% co"o cod!ng'( 4"&e) • 1) W,at ae t,e co33on 0e"d!ng defects: A' Lack of -enetat!on' B' Lack of f&s!on' 2' Undec&t' D' S"ag !nc"&s!on' E' Poos!t%' <' 2ack' G'
7!!) 2ate P!-e 7!!!) E@cess Penetat!on !@) B&n T,o&g, ) W,at does sens!t!7!t% de-ends on: Def!n!t!on and 2onto" ) T%-es of Po4e !n UT: No3a" -o4e5 Ang&"a -o4e5 t!ang&"a -o4e (1\5 9\5 \)'
) $%do-,!"!c e3&"s!f!es ae: Wate 3!sc!4"e "!6&!ds &sed to e3&"s!f% t,e e@cess o!" f"&oescent -enetant'
) T,e d!scont!n&!t!es 0o&"d 4e !3-oss!4"e to detect &s!ng PT: Intena" !nc"&s!ons *) W,at !s an a""o% stee": Ion 4ased a""o%+ c F *K5 8n '*1 K5 3!n 6&a"t!t!es of one o 3oe a""o%!ng e"e3ents ot,e t,an 8n5 s!"!con and 2&5 t,at does not s-ec!f% 2 content J K
