SAUDI ARAMCO QUESTIONS FOR WELDING INSPECTOR: 1) Duties of welding Inspector 2) 3) 4) 5) D] ANS: - There are three stages of duties as follows:- —=+ BEFOREWELDING 1) Joint fit up inspection (Root gap, bevel angle etc). 4) Calibration of welding Machine & ovens. 2) Welder ID card. 5) Base metal, Thickness of base meta & consumable as f 3) WPS application. 6) Pre heat requirement, ===> DURING WELDING 1) Welding Parameters like current, Volt & travel speed. . 4) Gas flow-rate . 2) Welding process must be verified. 5) Consutriable brand. 3) Interpass tempreture measurement. ==) AFTER WELDING 1) Weld Visual Inspection. 2) Any PWHT requirement. 3) NDE requierement. What is WPS Difference between WPS & POR et ANS: - WPS contains the qualification ranges & POR contains the actual value recorded during welding of test coupo Whatis essential Variable ANS: - A Change in a welding condition which will effect on Mechanical properties of weldment & it shall require re- qualification of WPS. Example: - P-Number, PWHT, F-Number & Pre-heat. What is non-essential Variable ANS: - A Change in a welding condition which will not effect on Mechanical properties of weldment & Changes may tx + Insp-PDF-form 2) 3) 4) 5) 6) 7 8) 9%) 1 of Q@ Q 1) Weld Visual Inspection. 2). Any PWHT requirement. 3) NDE requierement. What is WPS ANS: - WPS is stands for Welding Procedure Specification. It is a written document which provides the direction to the person applying the material joining process. What is PQR ANS: - PQR is stands for Procedure Qualification Record. PAR is record of variables recorded during the welding of test coupon & to fulfill the required Mechanical properties. Difference between WPS & POR ANS: - WPS contains the qualification ranges & POR contains the actual value recorded during welding of test Biipin: What is essential Variable dt" wat’ ANS: ~A Change in a welding condition which wil effect on Mechanical properties of weldment & it shall require re~ qualification of WPS. Example: -P-Numbet, PWHT, F-Number & Pre-heat, OF ot Ci pee What is non-essential Variable Se oe ANS: - A Change in a welding condition which will not effect ‘on Mechanical opens of ‘weldment & Changes may be made without re-qualification of WPS. we Example: - Groove design, Root Gap, Electrode diameter. * Whatis supplementary Variable gai AN What is Polarity " i ANS: - Polarity is determined whether the most of the arc energy is concentrated at the electrode surface or surface of the parent material What is straight Polarity ANS: -When the electrode is connected to the negative terminal of the power source.sp-PDF-form 2 oft 10) What is reverse Polarity ANS: - When the electrode is connected to the positive terminal of the power source. 11) Define Low hydrogen Electrode ANS: - Electrodes which contain hydrogen level less than or equal to 8mi/100gm of deposited weld metal Measured accordance with AWS A4.3 12) Explain E-7018 ANS:- E- electrode 70 - Minimum tensile strength (KS!) 70000 - Minimum tensile strength (PS!) 1—Welding position 8 ~Type of coating & current characteristics. 13) Explain E- 705-6 ANS: - ER electrode rod 70 - Minimum tensile strength (KSI) S~Solid bare wire 6 -Chemical composition 14) Define SATIP, SATR, SAES and SAEP. ANS: SATIP - Saudi Aramco typical inspection plan. SATR - Saudi Aramco test report. ‘SAES — Saudi Aramco Engineering Specification. SAEP — Saudi Aramco Engineering Procedure. 15) Thickness Limitation for Procedure qualifica ANS: - , x QW-451 PROCEDURE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS-Insp-PDF-form QW-122.4 Multiple Position 6G. Pipe with its axis in- clined at 45 deg to horizontal. Welding shall be done with- 4 of Q Q => out rotating the pipe. Refer to Figure QW-461.4, illustration (d). APNIC°"""" 19) Difference between 1G & 5G in pipe positions ANS: - As above explained. (1G Pipe Rotated & 5G Pipe Constant). 20) If Welder qualified in 1 %” Pipe diameter then what is his qualifil range ANS:- From 1” to unlimited diameter. 21) What is “P.” Number & why it assigned Table QW-452.3 Groove-Weld Diameter Limits oe ‘Outside Diameter Q Outside Diameter of Test | __—_—__In. (mm) _ Coupon, In. (unm) ‘Min. Less than 1 (25) tae welded 1 (25) to 2% (73) ) Over 2% (73) 2073) | GENERAL NOTES: (a) Type and number of tests required shall be i acco (Qw-452.) (0) 2_ ln. (73 ene) 0.D. ts the equivalent of NPS 2'4 (0 ANS: - “P” Number is assigned for base metals to reduce number of welding procedure. 22) What is “ F “ NumberPDF-form, 5 of Q Q ‘the equivalent of NPS 24, (DN 65) 21) What is“ P” Number & why it assigned ANS: - “P” Number is assigned for base metals to reduce number of welding procedure, 22) What is “F “Number ANS: - “F “Number is grouping of electrodes & welding rods. F number is fundamentally determines the ability of welders to make satisfactory welds with a given filler 23) What is “ SFA” Number & ANS: ~“SFA” Number is an ASME specification. Example: - Steel and steel alloys Aluminum and aluminum alloys etc. 24) What is “A “ Number \ 25) ANS: - “A “Number is identified of weld metal chemical composition or weld metal analysis. 26) For What diameter GTAW process shall be used for all Pass of weld ANS: - The GTAW process shall be used for all passes for butt welds and socket welds in piping & nozzles I outside diameter (1” NPS). This does not apply to weldolets, sockolets, threadolets & welding bosses. 27) If Welder qualified in “3G “then can he qualified to weld on pipe? ANS: - Yes he can able to weld as Flat & Vertical position for pipe over 24” inch diameter. And also able to weld in flat position for pipe less than or equal to 24” inch diameter. 28) What is the time limit for welder expiration? ANS: - No greater than 6 months from the date of qualification. 29) What is the time period for welder renewal & what are the tests are required for renewal ANS: - Welder renewal time period is within 6 months with below requirements:~ A) Welder shall have passed Mechanical & visual examinations. 8) Alternatively welder may be qualified by volumetric NDE. C) Renewal of qualification may be done on production work.30) What type of inspection required during incoming consumable inspection. ANS: - A) Physical inspection any damaged or rusty 8) Comply the heat number of each pack against MTC. C) Tensile test, elongation test, impact test & radiography etc. 31) Why tensile and bend test required for PQR b ANS: - Mechanical test is required to POR qualification the POR gives suitability of weld for required me Tensile test indicates the strength of weld. Bend test indicates the ductility of the weld. 32) What is the application of impact test ANS: - Impact test helps in ensuring that the material is best for an application where it is subjected to s 33) What is heat input ANS: - Heat input is the arc energy; it is the amount of heat generated in the welding arc per unit length 34) Formula of heat input ANS:- Heat input = Current X voltage X 1000 Travel Speed (mm/sec) 35) How much illumination is required for visual inspection ANS: - Minimum 1000 Lux light intensity & surface to be examined at an angle of not less than 30° degree The eye is within (24”) 600mm of the surface to be examined. 36) What are the additional tests are required for ” SS“ consumables ANS: - PMI (Positive Material Identification). 37) For 20mm thickness how much impact test are required ANS: - If POR thickness exceeds 12mm & multiple processes or multiple consumables used, separate impa shall be conducted for each process or each consumables. 38) “ DUCTILITY” where you found in below test A) Tensile testxt \sp-PDF-form 6 oft Q Q [chatty o 9UI Tate Wy UE cAatt ana: = winmnun auuU LUA ng (CU aL a aNBIE UF NUL IE99 LtetT 3U The eye is within (24”) 600mm of the surface to be examined. 36) What are the additional tests are required for “ SS“ consumables ANS: - PMI (Positive Material Identification). 37) For 20mm thickness how much impact test are required ANS: - If PQR thickness exceeds 12mm & multiple processes or multiple consumables used, separ shall be conducted for each process or each consumables. 38) “ DUCTILITY ” where you found in below test \\\ A) Tensile test Wi B) Bend test C) Impact test D) None of the above ANSWER. (A) Tensile test (After elongation) . b 39) E-7018 What specify digit Number 3 & 4 A) Coating Characteristics , Position B) Position , Coating Characteristics C) AboveA&B 1D) None of the above ANSWER. (B) \ \Top Digital Course Online °* Introduction fo Advanced OM Cou mm nica, 40) Which Welding process is less sensitivity related to wind prme Xf Id-Insp-PDF-form 7 oft Qa 40) Which Welding process is less sensitivity related to wind A) SMAW B) GTAW c) GMAW D) None of the Above ANSWER (A) SMAW. 41) Considering material which material get more distortion A) Carbon steel 8) Alloy Steel C) Stainless Steel N D) Allof the above ANSWER (C): Stainless Stee! because of high heat input. 42) Define Plasticity ANS: - The property of the material by virtue of which it tends to retain the altered size and shape on remo’ force. 43) Define Elasticity ANS: -The property of the material by virtue of which it tends to its original shape on removal of deforming 44) Define Ductility ANS: - ductility is the ability to undergo tensile stress without fracture or damage. Example: - ability to draw a material into a wire by pulling at the ends. 45) Define Malleability 46) ANS: - Malleability is the ability to undergo compressive stress without fracture or damage Example: - Hammered or pushed into thin sheets without breaking. 47) Define Hardness ANS:- The hardness of a metal is its resistance of plastic deformation. 48) Define Toughness ANS: - Toughness is the amount of energy per volume that a material can absorb before rupt»sp-PDF-form 7 oft QQ Example: - ability to draw a material into a wire by pulling at the ends. 4S) Define Malleability 46) ANS: - Malleability is the ability to undergo compressive stress without fracture or damage Example: - Hammered or pushed into thin sheets without breaking, 47) Define Hardness ANS:- The hardness of a metal is its resistance of plastic deformation. 48) Define Toughness ANS: - Toughness is the amount of energy per volume that a material can absorb before rupturing. 49) Define Stress AN: Force per unit area. N/M 50) Define Strain ANS: itis the ratio of change in léngt! 51) What is SOUR SERVICE Ae ANS: - Sour service refers to H2S (Hyd 52) What is NON SOUR SERVICE |. « « ANS: - Non sour services are those 3) => wporad : a Eee) Top Digital Course Online | — ax 54) BE For” SOUR SERVICE" PAR Is prepared with hardness 55) What is inert gas & active gasnsp-PDF-form soft Q Q 54) IES For“ SOUR SERVICE" POR is prepared with hardness 55) What is inert gas & active gas ==> INERT GAS: - Inert gas has no effect or no reaction with the welding process. Example: - ARGON GAS. ACTIVE GAS: - Active gas does have an effect on the welding process. ===} Example: - NITROGEN, OXYGEN, CARBON DIOXIDE, HYDROGEN USED FOR GMAW ON FERROUS METALS. 56) Types of consumables A) Basicelectrodes €-7018 (HIGH QUALITY) LOW HYDROGEN ELECTRODE B) CELLOLOSIC E-6010 ROOT PENETRATION C)-RUTILE E-6013 MECHANICAL PROPERTIES 57) Susceptibility of hydrogen cracking ANS:- Hydrogen cracking in the HAZ of a steel occurs when four (4) conditions exist at the same time A) Hydrogen level > 15ml/100gm of weld metal deposited, : ~ = B) Hardness microstructure > 400HV hardness C) Stress >0.5 of the yield stress D) Temperature < 300°C. 58) Delayed cracking ANS: - Cracks may occur sometimes after welding has finished (Possibility up to 72 hours). 59) Weldolet :- ANS: - Weldolet is used for butt weld branch connection where standard TEE is not available due to size restrictions. 60) Sockolet :-x + 1sp-PDF-form 2 oft Q Q C) Stress >0.5 of the yield stress D) Temperature < 300°C. 58) Delayed cracking ANS: - Cracks may occur sometimes after welding has finished (Possibility up to 72 hours). 59) Weldolet :- ANS: - Weldolet is used for butt weld branch connection where standard TEE is not available di restrictions. 60) Sockolet :- ANS: - Sockolet is used for socket welding of branch connection where require reinforcing pad. 61) Difference between pipes and tubes :- ANS:- PIPES 1) Pipes is identified by NB 2) Thickness is identified by schedule 1) Tubes is identified by 2) Thickness is identified by Birminghaix + sp-PDF-form 2 of QQ Pre heat is done to slow down the cooling rate; pre heat temperature for CS above 19mm is 80°C. 63) PWHT (POSTWELD HEAT TREATMENT) PWHT is done to remove residual stress fram the weldment. 64) Post heat To maintain uniform homogenous structure. 65) PWHT for Carbon Steel A) Pre heat temperature above 19mm is 80°C. B) Soaking temperature during stress relieving is 620°C +/- 20°C C) Soaking time during stress relieving is 1 hour. D) Rate of heat / cool is 150°C / hour. 66) PWHT for Alloy Steel 67) Consumables used for different pipes. 68) Current calculation for welding A) Pre heat temperature is 180°C. B) Soaking temperature is 720°C +/- 20°C. C) Soaking time is 2 hours D) Rate of heat / cool is 100° C / hour. E) Post heat is 300°C, PIPES EILLER WIRE 1) A106 Gr.B ER70-S2. © °F 2) A312 TP 304 ER308 3) A312 TP304L ER308L 4) A3127P316 ER316 316 - 5) A312 TP316L ER3161 + E364 6) A335 P11 ER80OS-B2 / ERS15 4 ’ €-8018-B2 7) A335 P91 ER9OS-B2 ' €9018-B2 ANS: - Current = (Diameter of electrode X 40) +/- 20 _For XE Neld-Insp-PDF-form 9 of Q Q 6) A335 P11 ERBUS-B2 / ERS15 E-8018-B2Z 7) A335 P91 ER90S-B2 £9018-B2 68) Current calculation for welding ANS: - Current = (Diameter of electrode X 40) +/- 20 69) Alloying elements & effects A) C-Carbon for strength B) Mn—Magnese for toughness C) $-Silicon for < 0.3% deoxidizer D) Al—Aluminium for Grain refiner E)_Cr- Chromium for corrosion resistance \ \ \ F) Ni-—Nickel for Low temperature application \ 1 G) Mo-Molybdenum 1% creep resistance VN H) V-Vanadium for Strength : 1). $-Sulphur for residual element J) Titanium for grain refiner K)_Nb- Nobium for grain refiner L) Cu- Copper for weathering steel 71) Consumable General Information SMaAW A) SFAS.1 GTAWsp-PDF-form % oft Q Q 70) CEV (Carbon equivalent value )in steel ANS: - Carbon equivalent value ofa steel alloy refers to method of measurin Weldability of the alloy based on its chemical composition, 1g the maximum hardness & the For, good weldability, CEV value must not exceed 0.45, 71) Consumable General Information SMAW GTAW A) SFAS.1 SFAS.18 8) F.No4 F.No6 C) ANot A.No1 D) E7018 ER 705-2 ARAMCO STANDARD QUESTIONS_SAES W-012. 72) Minimum circumferential distance (ARAMCO STATNDARD) > The minimum distance (circumferential offset) between longitudinal welds (including spiral weld seams) of adjacent pipe © Joints shall be 100mm, (es 73) jum distance between parallel girth weld (ARAMCO STATNDARD)>-PDF-form w oft Q Q U yyy 73) Minimum distance between parallel girth weld (ARAMCO STATNDARD) 20mm or 3Tw whichever greater. 74) Interpass temperature Ans :- 1) For P.No 1 —~-———-——-- 315°C 2) For P.No 8 & P.No 4x — 75) Pre heat distance (ARAMCO STATNDARD) 75mm 75mm X_ Visit the Store ' aS Tanishq Jewellery - Guwahati Silpukhuriu oft Q Q 76) Conditioning, storage, and exposure of SMAW Electrodes. Drying Prior to use all clectrodes shall be dried at 260-430°C for 2 hours minimum. The drying step may be deleted if the electrodes are supplied in the dried condition in a hermetically sealed metal can with a positive indication of seal integrity or vacuum sealed package. Electrodes may be re-dried only once, Storage After drying, the electrodes shall be stored continuously in ovens at 120°C minimum. Exposure ‘Upon removal from the drying or storage oven, hermetically sealed containers, or vacuum sealed package. the electrodes may not be exposed to the atmosphere for more than 4 hours. The exposure may be extended to 8 hours if the electrodes are continuously stored in a portable electrode oven hieated to 65°C minimum, Electrodes exposed to the atmosphere for less than the permitted time period may be re-conditioned. Electrodes exposed iti excess’of the = Pemmitted time period must be re-dried. Electrodes that have become wetor moist shall not be used and shall be discarded. = SS eat Re-conditioning gs oe be ete Electrodes exposed to the atmosphere for less than the permitted time period , may be returned to a holding oven maintained at 120°C minimum, after a © minimum holding period of four hours at 120°C minimum the electrode’ may be reissued. * 7 24" s % + * & = * 77) High Frequency Welding Machine :- i w* ei, ‘ * Except for P.No 1 base materials, all manual GTAW shall be used a high frequency start, post purge gas flow for the torch & filler metal shall be added. = i ae, a . é HIGH FREQUANCY MACHINE HAVE BELOW CHARECTERSTICKS 1) Quick arc ignite 2) Automatic pulsed 3) Post purge gas flow for torchform uot QQ may ve retumes ro a nelaing oven mainraince at L2v-C mmunuM; arter a minimum holding period of four hours at 120°C minimum the electrodes may be reissued. 77) High Frequency Welding Machine :- Except for P.No 1 base materials, all manual GTAW shall be used a high frequency start, post purge gas flow for the torch & filler metal shall be added. HIGH FREQUANCY MACHINE HAVE BELOW CHARECTERSTICKS 1) Quick arcignite 2) Automatic pulsed 3) Post purge gas flow for torch & 78) GTAW Process shall be used for all the passes for butt weld Groove weld Nozzles <33.4mm OD or 1” NPS Socket weld “ x ae Denia read nt ero, —* s . ye ae % E e = s ees . one . 79) GTAW Process shall be used for fOOt Pass for butt weld 8% - s -* + Groove weld * + Nozzles 60.3 mm OD or less ae Socket weld 80) When internal coatings are specified on pipe lines , the GTAW process shall be used for the root pass of butt welds ie for below 24” 0.D. A 81) Welding consumable shall be selected based on their mechanical properties.zo Q@ Q 78) GTAW Process shall be used for rOOt pass for butt weld Groove weld Nozzles 60.3 mm OD or less Socket weld 80) When internal coatings are specified on pipe lines , the GTAW process shall be used for the root pass of butt welds ie for below 24” 0.0. 81) Welding consumable shall be selected based on their mechanical properties. 82) Dissimilar metal welds are defined as any weld joint between ferritic steel & austenic steel, duplex stainless steel or nickel base alloy. 83) Joint Preparation:- Oil, moisture, rust, scale, sand, paint or other foreign material shall be rentved from the weld surface & at least 25mm adjacent base metal prior to welding. 84) Butter ~ Buttering or weld build up on the prepared surface shall not exceed the lesser of 1/3 of the base ‘metal thickness or 10mm. Without the approval of CSD. > The buttering operation shall be witnessed by Saudi Aramco inspection. > The buttering shall be inspected by PT or MT after completion the build up but before final welding of the joint. > Buttering of joints between dissimilar metal joints requires prior approval by CSD. 85) Welding Environment: - GTAW, GMAW, FCAW shall not be used for field or yard fabrication unless adequate windshields are used. > Wind velocity in the weld area for GTAW, GMAW or FCAW shall not exceed 8 KPH or 2.2 M / Sec. 86) Line up clamps :- > Aninternal line up clamp shall be used if the pipe diameter is 16” inches or larger. { ‘An external line up clamp may be used for pipe diameter is 16” inches or larger if approved by CSD welding engineer with a condition that 100 % RT is performed to the production welds. Internal line up clamp shall not be removed before the completion of the root bead, External clamps, the root bead must be at least 50% complete prior to removal. a 87) Welding Sequence:- > Pipelines greater than > 16” diameter at least two welders shall be used.xt jisp-PDF-form naa QQ 87) Welding Sequence:- > Pipe lines greater than > 16” diameter at least two welders shall be used, > Welding shall be operating simultaneously & in opposite quadrants. > The second pass or hot pass shall be added as soon as possible after completion of root pass but shall not exceed 5 minute for vertical down welding with cellulosic electrode. Shall not exceed 15 minute for vertical up welding. The hot pass shall be made while pipe is fully supported by the side boom tractor or supports. The Pipe shall not be lifted or moved during welding. The weld joint shall be completed within 24 hours of starting. vy i ¥ 88) Tack Welds :- All tack welds shall be made by qualified welder. > Recommended tack is 3.2mm to 4.8mm, > Length 12.5mm to 25mm. > Pipe 0.0 101.6mm (3.5") or less 3 equally spaced tacks are acceptable. > Pipe 0.0 above 101.6 mm minimum 4 equally spaced tacks. Bridge tacks (located above the root area) are acceptable but such tacks must be made completely within the groove, ‘An inert backing gas shall be used for GTAW or GMAW root passes on single sided groove welds, For ASME P.No 5 & above means alloy steel & stainless steel. > Nitrogen backing gas is prohibited for stainless steel. > Oxygen level for back purge For PS below 19 > Oxygen level For PB (Stainless steel & nickel alloy) below 0.05% 90) Pre heat :- f For carbon steel all ASME P.No 1 materials including AP grades up to & including X70 minimum preheat Shall not be less than 10°C. > Preheat required if the wall thickness exceeds 25mm. 91) Where 100 % radiography required :~form not QQ Pre heat required if the wall thickness exceeds 25mm. 91) Where 100 % radiography required = > First three (3) production groove welds by each new contract welder shall be 100% radiographed. > Allwelds on submarine pipelines require 100 % radiography. Allwelds on offshore pipelines require 100 % radiography. All PA, PS & PG welds require 100 % radiography. All tainless steel (except type 304 & 316 ) and nickel alloy require 100 % radiography. Hydro carbon lines at road crossing (carrier pipe only) requires 100 % radiography. 92) Maximum root reinforcement :- The visual and radiographic acceptance criteria for maximum root reinforcement shall be per the followi 2 table: Maximum Root Reinforcement Service Maximum Reinforcement | Acceptable Length ‘3mm or less ‘Any General 3-6 mm 25 mm maximum Over 6mm None Internally Coated | 25mm or less Any id Over 2.5 mm None MBA aay iselon 93) Production welds hardness testing (For SAES W-012 Pipelines). Hardness testing according to ASTM A833 of production welds is only required if specified by CSD or if PWHT is applied due to service requirement. If specified, the maximum hardness for P-No. 1 materials is 225 BHN for non-sour service and 200 BHN for sour service.F-form 4 oft Q Q@ 93) Production welds hardness testing (For SAES W-012 Pipelines). Hardness testing according to ASTM A833 of production welds is only required if specified by CSD or if PWHT is applicd due to service requirement. If specified, the maximum hardness for P-No. 1 materials is 225 BHN for non-sour service and 200 BHN for sour service. 94) Production welds hardness testing (For SAES W-011 on plot piping). Production hardness testing of welds shall be performed as required by ASME B31.3. Production hardness testing for welds in P-No | material in sour or PWHTed service shall also be performed. 10% of the welds shall be sampled. The maximum allowed hardness is 200 BHN. 95) Define Piping Line Class 3CS2P2 (SAES —L-105) :- Bindicate — —-}Flange rating 300#. CSindicate ©—2Carbonsteel. Zindicate = —3{3mm) Corrosion allowance. Pindicates | —SMain service type, Process or General hydrocarbon, 2 indicates | —Modification suffix for sour service. 3CS1P1 Piast digit 1 indicate as base line class . vVvvvvy 96) PMI (Positive Material Identification ) SAES — A- 206 :- PMI shall be performed to verification that the nominal chemical composition of an alloy material. PMI VERIFICATION COVERAGE:- > Alloy materials > Base metals > Shop & field fabricated welds > Material used for repair & replacement of pressure components. > Incoming stainless steel consumables 97) PMI testing of welding consumables :- > One consumable from each lot shall be tested. > PMI testing of weld metal (e.g. deposited or undiluted weld buttons) is acceptable alte PMI testing of an electrode or wire. —> Immediately before welding.jorm uot QQ 96) PMI (Positive Material Identification ) SAES - A- 206 : PMI shall be performed to verification that the nominal chemical composition of an alloy material. PMI VERIFICATION COVERAGE: > Alloy materials Base metals Shop & field fabricated welds Material used for repair & replacement of pressure components. > Incoming stainless steel consumables a vv 97) PMI testing of welding consumables :- > One consumable from each lot shall be tested. > PMI testing of weld metal (e.g. deposited or undiluted weld buttons) is acceptable alternative to PMI testing of an electrode or wire. —> Immediately before welding. —> During the welding process. b 98) Button test :- Button test is conducted when in case PMI te: due to geometry. > Small fillet weld > Narrow root beads g of the completed weld is not possible ox | EV Charge/Powertrain Test cram see cD 98) Methods of PMI Test :- XRF (X— RAY FLUORESCENCE) :- By this method or technique cannot be used to detect carbon because of inherent limitations of some XRF analyzers. > OPTICAL EMISSION SPECTOGRAPH :- By this method may be used to check for all the required elements, including carbon.rm wo QQ ___Nowat Tanishq Guwahati rs nse Tanishq Jewellery - GuwahatiSilpukhuri 103) Gap Control socket welds according to SAIC-W-2037, Attachment 1. A maximum of (1) one weld repair attempt shall be permitted for socket welds in all cases before replacement of material. “RT “is an option for project inspection here. Reason: - Due to small diameter fittings lose their form & become distorted at the root. 104) Socket Welds (SAES ~ L-110) :- > The maximum size of socket welded joint in hazardous services shall be 1°/*“inch for new construction. > Maximum 2” inch may be used for hazardous service for maintenance. > For sour service, socket welded joints should be avoided. In case they could not be avoided, the maximum size of socket welded joints shall be 1” inch. Socket welded joints are not permitted in location where high vibration can occur Example: - high velocity gas control valves & reciprocating pumps. v 105) Socket weld joints axial gap :- The axial gap between male & female component, as per fig 328.5.2C of ASME 831.3 > Maximum gap 3 mm > Minimum gap 1.5 mm. BEFORE WELDING. 106) _ Seal welding of threaded joints : Seal welds are permitted to be used to prevent leakage of threaded joints. ‘ It shall not be considered as contributing factor to the strength of the threaded joints. : 107) Minimum thread engagements (SAES — 1-110) :- The minimum length of the engaged threads pipe shall meet the requirements of ASME B1.20.1 for taper pipe thread. The minimum number of engaged pipe threads shall meet the requirements of Table 1. Table 1 — Thread Engagement Requirements for Taper Pipe Threads Nom, Pipe Sizeorm pod QQ 108) API SL (SPECIFICATION FOR PILE LINE) :- SCOPE: - The purpose of this specification is to provide standards for pipe suitable for use in as follows Conveying gas, Water & Natural gas industries. This specification covers seamless and welded steel pipe, It include > Plain end > Threaded end > Belled end pipe 109) Product Specification Level (PSL) ‘There are two types of Product specification level > PSLL > PSL2 = Major difference for PSL 2 has mandatory requirements for Carbon equivalent, Notch toughness, Maximum Yield strength, Maximum tensile strength. APPENDIX J—SUMMARY OF DIFFERENCES BETWEEN PSL 1 AND PSL2 {NFORMATTVE) 7 PLL110) 111) 112) 113) 114) 115) ws of Q Q — ee Short summary for welding of on plot piping :- > SATIP.No: W-011-01 + Activity No: 3.6 Pre-Welding & Weld Joint Fit-Up Inspection & Check list SAIC-W-2005, > Activity No: 3.7 In-Process Weld Inspection & Check list SAIC-W-2006. * Activity No: 3.8 Inspect Welds for Socket Joints and Seal Welded Thread Jts. - Gap Control & SAIC-W-2037. > Activity No: 3.9 Post-Welding Visual Inspection & Check list SAIC-W-2006. Short summary for welding of pipe lines SATIP No: W-012-01 Activity No: 3.7 Pre-Welding & Weld Joint Fit-up Inspection & Check list SAIC-W-2048. * Activity No: 3.8 In-Process Weld Inspection Formerly SAIC-W-2049) & Check list SAIC-W-2048, > Activity No: 3.9 Post-Welding Visual Inspection (Formerly SAIC-W-2050) Check list SAIC-W-2048. Inspection Responsibility Assignments :- QA/QC organization to monitor wor! progress without notice from Construction Organization > Witness: QA/QC organization shall be notified of the timing of Inspection or test in advance. However, the inspection or test shall be performed as scheduled if the QA/QC organization representative is not present. > Hold: QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test shall not be carried out without the QA/QC organization representative in attendance. - Review: Review of Documents. Pipe Straightness :- > Pipe smaller than size 4 ¥ “in grades A25, A & B shall be reasonably straight. > Allother pipe shall be randomly checked for straightness , deviation from a straight line shall Not exceed 0.2 % of the length. y Measurement may be made using a taut string or wire from end to end along the side of the pipe. ‘Measuring the greatest deviation. Dents :- Pipe shall not contain no dents greater than 6.4mm deep and length shall not exceed 1/2 diameter of pipe. General notes on consumable :form w oft Q Q rere ws vinnie Not exceed 0.2 % of the lengt! > Measurement may be made using a taut string or wire from end to end along the side of the 5 Measuring the greatest deviation. 114) Dents :- : ! Pipe shall not contain no dents greater than 6.4mm deep and length shall not exceed 1/2 diamet 115) General notes on consumable :- SEANG ELECTRODE ENo WELDING PROCESS 5.1(CS) E-7018 F4 sMAW 5.4 (SS) £316 FS. SMAW 5.5 (CS) £-8018, £-9018 Fa sMaAW 5.18 (CS) ER 70S -2 & ER 70S- 3 GTAW SAUDI ARAMCO QUESTIONS FOR NDTC ORDINATOR 116) _ Difference between destructive & nondestructive test, 7 Destructive test Destructive test includes methods where the material is broken down in order to determine m properties. Example: - Tensile test, bend test. > Nondestructive test Nondestructive testing is a method that does not damage or destroy the material or product beit Example: - Radiographic test, Ultrasonic test, Magnetic particle test, Liquid penetrant test etc. 117) RADIOGRAPHIC TEST (SAEP-1143) :- Radiographic test is a NDT technique that involves the use of either X ray OR gamma rays in orde the internal structure of a component.form w oft Q Q SAUD! ARAMCO QUESTIONS FOR NDT CO-ORDINATOR 116) _ Difference between destructive & nondestructive test :- > Destructive test Destructive test includes methods where the material is broken down in order to determine mecha properties. Example: - Tensile test, bend test. > Nondestructive test Nondestructive testing is a method that does not damage or destroy the material or product being tes Example: - Radiographic test, Ultrasonic test, Magnetic particle test, Liquid penetrant test etc. 117) RADIOGRAPHIC TEST (SAEP-1143) -- Radiographic test is a NDT technique that involves the use of either X ray OR gamma rays in order to vi the internal structure of a component. > Backscatter radiation :- Alletter “8” with minimum 13mm height & 1.5mm thickness shall be attached to the back of each fi holder during each exposure to determine if backscatter radiation is exposing to the film. > Radiation sources :- Xrays Gamma rays (i Cobalt 60 Selenium 75 lium 192) Radiographic fil Industrial radiographic film shall be either Type | or Type Il. Film shall be selected to produce radiographs possessing acceptable sensit Type | film shall be used for radiography of pipe diameters of 8 inch or less NPS. y ity, density & contrast. > Radiographic contrast Radiographic contrast is the degree of density difference between two areas on a radiograph. > Radiographic density :- The overall degree of darkening of an exposed film is referred to as radiographic density.m oft Q Q SAUDI ARAMCO QUESTIONS FOR NDT CO-ORDINATO. 116) __ Difference between destructive & nondestructive test :- > Destructive test Destructive test includes methods where the material is broken down in order to determine mechanical properties. Example: - Tensile test, bend test. Nondestructive test Nondestructive testing is a method that does not damage or destroy the material or product being tested. Example: - Radiographic test, Ultrasonic test, Magnetic particle test, Liquid penetrant test etc. v 117) RADIOGRAPHIC TEST (SAEP-1143) :- Radiographic test is a NDT technique that involves the use of either X ray OR gamma rays in order to view the internal structure of a component. Back scatter radiation :- A letter “B” with minimum 13mm height & 1.5mm thickness shall be attached to the back of each film holder during each exposure to determine if backscatter radiation is exposing to the film. v > Radiation sources :- Xrays Gamma rays {iridium 192) Cobalt 60 Selenium 75 > Radiographic film :- Industrial radiographic film shall be either Type | or Type Il. Film shall be selected to produce radiographs possessing acceptable sensi Type | film shall be used for radiography of pipe diameters of 8 inch or less NPS. ity, density & contrast. > Radiographic contrast :- : Radiographic contrast is the degree of density difference between two areas on a radiograph. > Radiographic den:w oft QQ Radiation sources :- X rays Gamma rays (iridium 192) Cobalt 60 Selenium 75 Radiographic film : Industrial radiographic film shall be either Type | or Type Il. Film shall be selected to produce radiographs possessing acceptable sensi Type | film shall be used for radiography of pipe diameters of 8 inch or less NPS. ity, density & contrast. Radiographic contrast :- Radiographic contrast Is the degree of density difference between two areas on a radiograph. Radiographic density The overall degree of darkening of an exposed film is referred to as radiographic density. Radiographic sensitivity :- ii Radiographic sensitivity is the combination of radiographic contrast and radiographic definition. Sensitivity is judged by 1Q1 also called as penetrameter. } ‘ % Sensitivity = Job thickness “apsty Wow for Our ea Spe Intensifying screens Only lead intensifying screens shall be used. The main function o} radiographic images on the film. Film develop temperature & time :- i Below 18°C and above 24°C developing is not recommended.o 7 a oft Q Q ing screens :~ Only lead intensifying screens shall be used. The main function of intensifying screens it intensifies the radiographic images on the film. Film develop temperature & time :- Below 18°C and above 24°C developing is not recommended. 1QI {image quality indicator) :- IQ) is used to get better sensitivity & IQI shall be selected from either same alloy material group or grade as identified in ASTM SE-747 or from an alloy material group or grade with less radiation absorption than the material being radiographed. 4 Following are the types of IQI: i 1)_DIN Wire type 1a 2) ISO Wire type 1a 3) ASTM Wire type IQ! 4) EN wire type IQ! Densitometer 3 Densitometer shall be used to measure the esas oft fin The densitometer continuous use. Radiographic Technique :- ‘ : AA single wall exposure technique shall be used for radiography ‘whenever practi, When it is not practical to use single wall technique, then 2 double wall technique shall be used” et 1) Single wall technique 2) Double wall technique Single wall technique :- ( Knownas Panoramic). When a radiographic source is centered In the pipe for exposing a butt weld, ‘One exposure Is adequate for the radiographic inspection of the complete weld.u oft QQ or dry method, > Magnetic Particle Test Technique :- A) Prod Technique 8) Yoke Technique C) Direct contact method > Yoke Technique :- There are two types of yokes technique A) ACyoke 8) OC Yoke AC Yoke Technique :- AC yoke method should be.used for surface discontinuities, AC yoke: shall tested prior to use each day with minimum 4.5 kg (20 Ib.) lifting capacity. iv Wv DC Yoke Technique “i DC yoke method should be used for subsurface discontinu day with a minimum 18 kg (40 Ib.) lifting capacity. > Yoke Leg Space :- The yoke leg space shall be between 3 to 8 ines the examination surface for edéqiate evaluation of indications.” Surface Preparation :- . All surfaces to be examined and dry adjacent area wit from rust, scale, slag, sand, grease & paintetc.. * . > Surface Temperature :- eh A) Surface temperatures shall not exceed 316°C when using dry pai B) Surface temperatures shall nat exceed 50°C when using wet particles. Clean the examination surface and adjacent area within 3” inches of the examination area. Se. 7 ¥ vy uo Q Q the examination surface for adequate evaluation of indications. Surface Preparation :~ All surfaces to be examined and dry adjacent area within 1” inch of the examination area shall be free from rust, scale, slag, sand, grease & paint etc. Surface Temperature :~ A) Surface temperatures shall not exceed 316°C when using dry particles. 8) Surface temperatures shall not exceed 50°C when using wet particles. Clean the examination surface and adjacent area within 3” inches of the examination area. Sensitivity Verification :- Pie gauge or burmah Castrol strip may be used to verify adequate magnetization of part. Post examination cleaning :- The part being examined shall be cleaned to remove all residual magnetic particle materials. & ‘Apply Now for Our MBA Program. youl seam wir cur compete eraings. Apply row anasecureyourtuure | ABBY Now!) ° v . Demagnetization :- Demagnetization shall always be performed on parts, which are to be welded after an MT examination has been performed to “prevent arc blow “. The presence or absence of residual magnetism shall be verified & demonstrated using a calibrated gauss meter. Residual magnetism shall not exceed +/- 2 gauss. Prod technique The prod technique should not be used on highly polished or machined surface due to the possibility of arc damage to the surface. Direction of magnetization :- For welds on flat surfaces, the yoke shall be placed across the weld at an angle of 30° to 45° from the long axis of the weld. The second examination shall be perpendicular to the first examination forming an “X” pattern.