WELDING QUESTIONAIRE

Duties and Responsibilities of Welding Inspector.

Perform material inspection.
Perform consumable inspection.
Application of inspection gauges, instruments and tools.
Check equipment and accessories.
Witness procedure qualification test.
Witness welder qualification test.
Perform visual inspection.
Review / witness NDT
Witness mechanical test.
Monitor heat treatment
Observe production and fabrication welding.
Interpret and assure compliance to Code / Standard /
Specification.
Review technical drawing.
Witness weld repair.
Prepare and compile inspection records.

1) What is the formula for heat input?

Heat Input (j/cm)= Voltage x Amperage x 60 / Travel Speed(cm/min)
2) How do you calculate the weld repair percentage?
% RR = (Lr/Lw) X 100
Where, % RR Percent repair rate
Lr -- Total length of repair in one week
Lw --Total length of weld radiographed in one week

3) What should be the distance b/w two parallel welds?

20mm or three times the wall thickness of the joint, whichever is
greater.
4) What are the types of thermocouples in PWHT?
Type K (Chromel-Alumel)
Type J (Iron-Constantan.
5) What is HIC?
HIC Hydrogen Induced Crack
6) Different categories of fluid services in ASME B 31.3?
Category D
Category M
High pressure fluid service.
Normal fluid service
7) What is ocv and ccv?
OCV - open circuit voltage
CCV closed circuit voltage
8) What are the types of olets?
Weldolet
Sockolet
Threadolet
Nippolet
9) 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

10) What is the P no for SS & CS?

SS P No. 1
CS P No, 8
11) What are supplementary essential variables?
The change in a welding condition which will affect the notch
toughness properties of a weldment is known as supplementary
essential variable.
12) What are essential variables?
Essential Variable (Procedure) A change in a welding condition
which will affect the mechanical properties (other than notch
toughness) of the weldment.
Essential Variable (Performance) A change in a welding condition
which will affect the ability of a welder to deposit sound weld metal.
13) Which standard do you refer for the welding equipment calibration?
 BS 7570.
14) What are the tests required for verifying supplementary essential
variables?
Notch toughness tests-
Charpy V- Notch test
Drop weight.
15) What is a welding procedure specification (WPS)?
The WPS is a written document that provides direction to the welder
for making production welds in accordance with Code/Standard
requirements.
16) How is the Procedure Qualification Record (PQR) different from the WPS
(Welding Procedure Specification)?
Procedure Qualification Record certifies that test welds performed in
accordance with the WPS meet Code requirements and summarizes
the specific test results.
17) What is a Weld Map and how is it used?
It is an isometric drawing showing the location and numerical
identification of each weld used in the construction of a process
piping system. Each weld when completed is labeled with the weld
number indicated on the weld map, the date completed, and the
welder/welding operator identification number or code.
18) What are the welder qualification limits?
Base metal qualification limits. (P no. and Thickness)
Filler material qualification limits.(F No.)
Pipe diameter and position qualification limits.
Weld metal thickness qualification limits.
19) What is the chemical composition of a low hydrogen electrode E7018?
E7018 C 0.15, Mn 1.60, Si 0.75, P 0.035, S 0.035, Ni 0.30, Cr 0.20,
Mo 0.3, V 0.08.
20) How can you verify that the received electrode has the chemical
composition as per MTC?
By verification of chemical composition of filler materials through
chemical analysis method.
By verifying the heat no. and Lot no. of welding consumables.
21) What are the tests required for analysis of consumables and the standard
for this analysis?
Tests-
Chemical analysis method
Positive Material Identification (PMI)
Standard-
ASME Sec IIC
22) How do you calculate the weld repair percentage?
% RR = (Lr/Lw) X 100
Where, % RR - Percent repair rate
Lr - Total length of repair in one week
Lw - Total length of weld radiographed in one week

23) JERES standard for consumable storage & handling procedure for low
hydrogen electrode?
JERES-W-011. Appendix A

24) What does L stands for 316L and the composition?

Low Carbon.

26) What are the criteria for selecting welding consumables?

Welding consumables shall be selected based on their mechanical

properties, compatibility with the materials to be joined, their
suitability for the intended service, and consideration of polarity,
position, and direction of welding.
27) What do you meant by low hydrogen consumables?
Low hydrogen consumables are defined as less than or equal to 8 ml
of hydrogen per 100 g of deposited weld metal.

28) What are dissimilar metal welds?

Any weld joint (excluding weld overlays or strip lining)
between ferritic steel and either austenitic stainless
steel, duplex stainless steel, or nickel-based alloys, or
Use of stainless steel or nickel-based filler metals on
ferritic steels.
29) Give the names of two aluminium flake weldable primers? And
the maximum coating thickness?
Bloxide and Deoxaluminate.
The max coating thickness shall not exceed 0.050mm
(0.002 inches).
30)What is the heating and cooling rate for PWHT?
The PWHT heating and cooling rates above 316C shall not exceed
222C/hr divided by the weld thickness in inches, but in no case shall it
be more than 222C/hr.

31) On what condition remote current controls are used in field welding?
For field welding, remote Current controls shall be used if the welding
is more than 30 m from the welding power source or when the
welders are working in remote locations (eg. on an elevated pipe rack).

32) Mention the drying temperatures for low hydrogen SMAW electrodes?
260-430C for 2 hrs min (A5.1)
370-430C for 2 hrs min(A5.5)
120-250C for 2 hours minimum. (SS and Non-Ferrous
electrodes)

33) Test Positions for Groove Welds

Plate Positions:
1G Flat Position
2G Horizontal Position
3G Vertical Position
4G Overhead Position
Pipe Positions:
1G Flat Position. (Pipe axis horizontal and rolled during welding so
that weld metal is deposited from above)
2G Horizontal Position. (Pipe axis vertical and weld axis in horizontal
plane, pipe is fixed)
5G Multiple Positions. (Pipe axis horizontal and weld
groove in vertical plane, pipe is fixed)
 6G Multiple Position. (Pipe with its axis inclined at 45 deg to
horizontal, Pipe is fixed))
34) Test Positions for Fillet Welds

Plate Positions:

1F Flat Position
2F Horizontal Position
3F Vertical Position
4F Overhead Position
Pipe Positions:
1F Flat Position
2F and 2FR Horizontal Position
4F Overhead Position
5F Multiple Position

35)What are the types of Mechanical tests?

Tension Tests
Guided Bend Tests
Fillet Weld Tests
Notch Toughness Test
Stud Weld Test

36) What is the equation for carbon equivalent?

CE = C + (Mn)/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15

37) Equation for Heat Input?

H = 60EI / 1000S
Where,
H -- Heat Input (KJ/mm)
E -- Arc Voltage (volts)
I Current (Amps)
S Travel Speed (in/min)
38) What are the different factors that cause HIC?
A sensitive microstructure
A sufficient level of hydrogen
A high level of stress
39) Advantages of Argon Vs Helium as shielding gas?
Argon
Good arc starting.
Good cleaning action.
Good arc stability.
Focused arc cone.
Lower arc voltage.
10 30 cfh (cubic feet per hour) flow rate.
Helium
Faster travel speeds
Increased penetration.
Difficult arc starting.
Less cleaning action.
Less low amp stability.
Flared arc cone.
Higher arc voltages.
Higher flow rates (2x).
Higher cost than argon.

Argon / Helium mix

Improved travel speed over 100% argon.
Improved penetration over 100% argon.
Cleaning properties closer to argon.
Improved arc starting over 100% helium.
Improved arc stability over 100% helium.
Arc cone shape more focused than helium.
Higher flow rate than argon.
Cost higher than argon.

40) What are the general types of welding and joining processes?
Fusion
Arc
Gas
Power beam
 Resistance.
Thermomechanical
Friction
Flash
Mechanical
Fasteners
Solid state
Adhesive
Soldering
Brazing

41) Different types of electrodes?

Cellulosic
Deep penetration in all positions.
Suitability for vertical down welding.
Reasonably good mechanical properties.
High level of hydrogen generated Risk of cracking in the HAZ.

Rutile
Moderate weld metal mechanical properties.
Good bead profile produced through the viscous slag.
Easily removable slag.

Basic
Low hydrogen weld metal.
Requires high welding current/speeds.
Poor bead profile (convex and coarse surface profile)
Slag remove difficult.

42) What are the main metal transfer modes in welding?

Short circuiting
Droplet/spray
Pulsed
43) What is the function of shielding gas?
Stabilises the arc roots on the material surfaces.
Ensures smooth transfer of the molten metal from the wire to weld
pool.
Forms the arc plasma.
44) Commonly used shielding gases in GTAW?
Argon
Argon + 2-5% hydrogen
Helium/Helium Argon mixtures
45) What is CTOD?
CTOD is Crack Tip Opening Displacement test. The test piece contains
a machined notch or a genuine crack and will be loaded at a rate more
representative of service conditions.