1. What is WPS? WPS is Welding Procedure Specification, It is a written document that provides direction to the welder or welding operator for making production welds. 2. What is the Welding Process? a) GTAW
(Gas Tungeston Arc Welding)
b) SMAW
(Shielded Metal Arc Welding)
c) SAW
(Submerged Arc Welding)
d) FCAW
(Flux Coated Arc Welding)
e) GMAW
(Gas Metal Arc Welding)
f) PAW
(Plasma Arc Welding)
3. ASME SECTIONS a) SECTION I Rules for Construction of Power Boilers b) SECTION II Materials Part A - Ferrous Material Specifications Part B - Nonferrous Material Specifications Part C
- Specifications for Welding Rods, Electrodes, and
Filler Metals Part D - Properties (Customary) Part E - Properties (Metric) c) SECTION III Subsection NCA Division 2
---- General Requirements for Division 1 and
Division 1 Subsection NB-Class 1 Components Subsection NC-Class 2 Components Subsection ND - Class 3 Components Subsection NE - Class MC Components
1
Subsection NF – Supports Subsection NG - Core Support Structures Subsection NH - Class 1 Component in Elevated Temperature ServiceAppendices Division 2 - Code for Concrete Containments Division 3 - Containments for Transport and Storage of Spent Nuclear Fuel and High Level Radioactive Material and Waste d) SECTION IV Rules for Construction of Heating Boilers e) SECTION V Non Destructive Examination f) SECTION VI Recommended Rules for the Care and Operation of Heating Boilers g) SECTION VII Recommended Guidelines for the Care of Power Boilers h) SECTION VIII Rules for Construction of Pressure Vessels Division 1 Division 2 – Alternative Rules Division 3 – Alternative Rules for Construction of High Pressure Vessels i) SECTION IX Welding and Brazing Qualifications j) SECTION X Fiber – Reinforced Plastic Pressure Vessels k) SECTION XI Rules for In Service Inspection of Nuclear Power Plant Components l) SECTION XII Rules for Construction and Continued Service of Transport Tanks.
ASME - American Society of Mechanical Engineers ASME B 31.3 – Process Piping 2
ASME B 31.1 - Power Piping ASTM – American Society of Testing Materials API - American Petroleum Institute AISC – American Institute of Structural Concrete AWS D1.1 – American Welding Society (Structural Welding) AWS D1.6 – American Welding Society (Structure SS Welding) 4. What are the different types of Groove? a) V – Groove b) U – Groove c) Double V Groove 5. What are the different types of Base Material with Grade?
CS i) A 106 Gr B ii) A 53 Gr B iii) API 5L Gr B
SS i) A 304 ii) A 304L iii) A 316 iv) A 316L v) A 321 vi) A 322 vii) A 347 viii) A 348
ALLOY A 335 - P11 A 335 - P22
MONEL ASTM B 165 No: 4400
ALUMINIUM SB 241 Grade 5083
6. What is the Procedure Qualification Thickness Limits? 3
QW – 452 i)
It is the test coupon < 1¨ - Size welded (Dia)
ii)
Thickness always 2T – T – Thickness of Test Coupon
iii)
Minimum Thickness Qualified – 1.5mm
7. Materials (F Nos)
GTAW
SMAW
CS
6
4
ALLOY
6
4
SS
6
5
MONEL
42
42
8. Material Consumables:GTAW
SMAW
CS
ER 70S – 2/3/4
7016, 7018 – 1
SS
ER 308, ER 308L
E 308, E 308L
ER 316, ER 316L
E 316, E316L
9. Specify Electrode Trade Name ESAB, LINCON, ADOR, GEKA, METRODE 10. Welding Position Pipe – 1GR, 2G, 5G, 6G, Plate – 1G, 2G, 3G, 4G PIPE:1G: - A Pipe is Horizontal Position and weld beed is a vertical position. The Pipe Will be rotated. 2G: - A Pipe is Vertical Position and weld beed is Horizontal Position 5G: - A Pipe is Horizontal Position and weld beed is Vertical Position 6G: - A Pipe is a 450 Position PLATE:1G: - Plate is Horizontal and weld is Horizontal 2G: - Plate is Vertical and weld is Horizontal 3G: - Plate is Vertical and weld is Vertical 4G: - A Plate is in Overhead Position weld is Horizontal Position 4
11. What is pre-heat temperature for CS, SS, ALLOY, and MONEL? CS =Less 25 mm 100C Min , Above 25mm 800 C SS = Max 100C ALLOY = P 11 = 1500C, P 22 = 1490C MONEL = Max 100C 12. Interpass Temperature CS = 2500C SS = 1500C ALLOY P11 = 3000C ALLOY P22 = 3000C MONEL = 2000C 13. Types of Welding Position? Uphill Position and Down Position. 14. What is PWHT? Post Welded Heat Treatment, To Remove Residual Stress. CS - Above 19 mm – 5930C to 6490 Alloy – Above 13 mm – 7040C to 7460 / High Alloy – 7040C to 7600C 15. Gas Backing When we are using SS material must use Purge Gas May be – Argon / Nitrogen 16. What is Pipe? It is a tubular item made of Metal, Plastic, and Glass etc. 17. What is the width of Weave Bead? Max. Weave width = 3x Electrode dia. 18. Write the weld layers? I. Root II. Hot Pass III. Fill IV. Cap 19. PWHT for Ni – Alloy? > 13mm →5500C to 5850C 20. What are the main Responsibilities of Welding Inspector? To Observe, To Record, To Compare (Acceptance Levels) 5
21. Type of Common Welds? Groove Welds Fillet Welds Spot / Seam Welds Plug / Slot Welds Edge Welds 22. Type of Common Joints? Butt Joints T
Joints
Lap Joints Open Corner Joints Closed Corner Joints 23. Types of Joint Preparation? Bevel, V, J, S (Single & Double Sided) 24. What are the Weldment Terms? i. Weld Face ii. Weld Root iii. Fusion Zone iv. Fusion Boundary v. Heat Affected Zone (HAZ) vi. Weld Toes vii. Weld Width 25. What are the Welding Imperfections? I. Cracks II. Gas Pores and Carities III. Sold inclusions IV. Lack of Fusion V. Surface and Profile VI. Mechanical / Surface damage VII. Misalignment. 26. What is the Major Inspection of Material Receiving? a) Size b) Condition c) Type / Specification / Schedule 6
d) Storage e) Heat Number 27. Pipe Inspection (Material)? i)
Welded Seam
ii)
Inside ø
iii)
Out side ø
iv)
Length
v)
Wall Thickness
28. What is Steel? An Alloy of the Iron with the Non – Material Carbon (0.01 -1.4% C) 29. What is Plain Carbon Steel? Steel that contain only Iron & Carbon are main elements,Traces of Mn,Si,Al,P&S may be also present from refining. 30. Low Carbon Steel? 0.01 – 0.3%C
31. Medium Carbon Steel? 0.3 – 0.6%C 32. High Carbon Steel? 6.6 – 1.4 %C 33. Low Alloy Steel? Steel Containing Iron and Carbon and other Alloying elements. i.e.:- Mn, Co, Ni, Mo < 7% Total 34. Which of the following is a function of a Flux Coating of a SMAW electrode? All, Insulation, Alloying, De Oxidation Shielding. 35. Write Pipe Specification? Material Pipe, Size, Length of Pipe, Size of Bore 36. Types of Gasket? F.F = Float Face
- Metallic Gasket
R.F = Raiced Face
- Non Metallic Gasket
37. Types of Metallic, Non Metallic Gasket? Metallic 7
Non Metallic
Spiral Wound Gasket
Rubber Gasket
Octagonal Ring Gasket
Asbestos Gasket
Plat Ring Gasket
Tufflon Gasket Oil Paper Gasket
38. Write Small Bore Fittings? Weldolet Sockolet Threadolet Elbolet Neppolet 39. Types of Flanges? Weld Neck Flange Slip On Flange Socket Flange Screwed Flange and Blind Flange 40. Types of Nipples? Plain Threaded Swage 41. Types of Caps? But weld Caps Threaded Caps End Cap 42. Types of Coupling? Full Coupling, Half Coupling, Threaded Coupling, Reducer Coupling. 43. Types of Boss? Weld Boss, Socket Weld Boss 44. Types of Orifice Plates Concentric Orifice Electric Orifice Segmetal Orifice 45. Types of Electrodes? Coated Electrode Bare Electrode (Non Coated Electrode) 8
46. Size of Electrode? 1.6 mm 2.5 mm 3.15 mm 4 mm 5 mm 6 mm 47. Duties of Welding Inspector? I. Pre Heating (Method & Control) II. In Process Distortion Control III. Consumable Control IV. Welding Process V. Welding Run Sequence and Interpass Temperatures VI. Min / Max Interpass Temperatures VII. Full Compliance with all Elements given on the WPS 48. Duties of Welding Inspector after Welding? i) Visual Inspection ii) N D T iii) Repairs iv) Repair Procedure (NDT / Welding) 49. Tool Box a) A Welding Gauges b) Tap c) Torch d) Mirror e) Pen Report 50. Fillet Weld Profiles Convex, Concave, Mitre 51. What is the Profile Imperfection? i) Spatter ii) In Completely filled Groove iii) Lack of Root Fusion iv) Incomplete Root Penetration v) Shrinkage Grooves 9
vi) Root Concaring vii) Crater Pipe viii) Excess Penetration ix) Burn Through 52. Accepted Mis Alignment? 1.5 mm as per ASME 31.3 53. What is Mechanical Testing? Hardness, Toughness, Tensile Strength, Ductility.
54. Major things of Welding Procedure? a. Pipe Dia & Thickness b. Welding Position c. Process d. Material Group e. Consumable f. Heat Input Range (Kg / mm) g. Pre Heat & PWHT 55. Explain E 8018 E – Electrode 80 – Tensile Strength 1 –for all Position 8 – Coating 56. Inspection of Before Welding? 1. Application Std 2. WPS 3. Welder Qualification 4. Material Composition 5. Condition of Material 6. Types of Edge Preparation 7. Consumables 8. Welding Process. 57. Inspection of after Assembly Clearance Dimensions 58. What is Soluble Dam? 10
Soluble Dam is Water – Solute Material used for Refracting the Purging Gaswith in the Pipe. 59. What should be the Radius of Long Radius Elbow? 1.5D (D – is Diameter of the Pipe) 60. What is the True Welding Inspector Certifications Covered in AWS QC -1? CWI, CAWI, SCWI 61. What are generally considered to be the most important quality of a Welding Inspector? Professional Attitude 62. The Vision Requirements for a CWI are near Vision Acuity on: Jaeger J2 at 12 inches, with or with out corrective lenses. 63. The Welding Inspector should have a basic understanding of Welding Process Non Destructive Testing Methods Code and Standards 64. The term used to describe delay in the production schedule to permit inspection is Hold Point 65. Inspection report correction should be made by: Single – line out the error correct the error, date end initial 66. A definition of Ethics is: 1. Using common sense and honesty 2. Living by the rules 3. Being faire and impartial 4. Basing decisions on facts 67. For communication to be effective it should form a “continuous loop” 1. True 68. Proper usage and handling of compressed Gas Cylinders include.
Not welding on Cylinders
Not including the Cylinders in the ground or Electrical circuit
Securing them properly.
Identifying the gas prior to use.
69. Acetylene becomes unstable above what pressure? 15 psi 11
70. Oxygen is a Flammable Gas False 71. Electric currents above approximately 6 milliamperes are considered Primary currents, Harmful 72. When operating gas cylinders the primary value should be opened One turn or less onan acetylene cylinder. All the way onan oxygen cylinder to backseat the value 73. Why is there an increasing need for weld quality? Safety Economics Less conservatives design Government regulations 74. What AWS documents describe the rules for the CWI certification program? AWS QC -1 75. Weld quality control should begin after welding has been initiated False 76. The a acronym KASH stands for Knowledge, Attitude, Skills and Habits. 77. A metal that is difficult to magnetize is said to have? Low Permeability 78. Ferromagnetic Material is? Strongly attracted by a magnet. Capable of being magnetizer 79. A circular field may be induced in to a specimen by which of the following methods? a) Direct Induction (Head Shot) b) Direct Inductions (Prods) c) Central Conductor 80. The permeability of a material describes? The easy with which it can be magnetized. 81. In which material can be magnetized? Iron, Nickel, Cobalt 82. The magnetic Field is Stronger when? The magnetizing current is flowing 12
83. The unit usually used to denote flux density is the? Gauss 84. Materials which are repelled magnetically are called? Dia magnetic 85. Materials which are attracted magnetically are called? Ferromagnetic 86. The interpretation of magnetic particle indications may be aided by? Observing the indications as they are formed 87. Materials which are strongly attracted to a magnet are called? Magnetic Materials 88. During magnetic Particle testing generally leakage field caused by discontinuities which are? Transverse to magnetic Field 89. Method of magnetization is the? Type of magnetizing Current 90. To detect very fine Cracks on contour surface the method is? Wet particle suspension with A.C. 91. The ability of the magnet to attract or repel iron is? Concentrated at local areas called poles 92. When testing for fine shallow surface cracks, the preferred MT method should be? Wet A.C. 93. Commonly used technique for preserving MT powder patterns? Clear lacgues, transparent tape, and photography 94. The defect commonly associated with the welding process? Lack of Penetration 95. The unit of measure of one line of flux per square centimeter of area is one? Gauss 96. Materials which are weakly attracted magnetically are called? Paramagnetic 97. The end of a magnet at which the lines of flux are thought of a entering the bar is? The South Pole 98. The general term used to refer to a break in the metallic continuity of the 13
Past being tested is? Discontinuity 99. If like poles are closest the magnets will? Repel one another 100. Surrounding an electro-magnet the magnetic field is strongest? While the current is flowing 101. A solenoid is a coiled conductor? Containing a number of loops
102. Longitudinal magnetization can be established in an article by? Placing the past inside a coil through which current is flowing. 103. The strength of the magnetic fields or a coil is determined by? The Current on the Coil, The Number of turns in the Coil 104. Which type of current is best for detection of surface discontinuities? Alternating current 105. Half wane DC is? Pulsed DC, Used with dry power, used for Inspection of welder 106. When using a coil what is the effective distance on magnetic field? 6 to 9 inches on each side of the coil 107. When a yoke is used the resulting magnetic field will be? Longitudinal 108. Disadvantage of using a permanent yoke is? They provide relatively low magnetic flux field 109. A Residual magnetic field is always? Weakes that the magnetizing field producing it.
110. Dry particle examination shall not be performed if the surface temperature Of the part is? Exceeds 10220F 111. In wet particle examination shall not be performed if the surface Temperature of the part is? Exceeds 1850 F 112. In black light, light used is? 14
White light 113. The Examines in black light dark adaptation is? At least 5 minutes 114. The ammeter shall be calibrated at least? Once a year 115. In A/C yoke the lifting power is? 10 Lb at the maximum pole spacing 116. In DC or permanent yoke the lifting power is? 40 Lb at the maximum pole spacing 117. The magnetic force of yoke shall be checked? Once a Year 118. MAGNETIES There are two types of magnetic i)
Longitudinal Magnetic (or) Axlem Magnetic
ii)
Circular Magnetic (or) Radial Magnetic
119. FLEMING RULE Circular: - Current flow in the Thumb direction The magnetic field is the finger direction Longitudinal: - The Current flow in the finger direction The magnetic field in the Thumb direction 120. Gauss meter? That will measure that what amount of magnetism field retained on the surface.
121. Permeability? Easy to magnetism
122. Reflecturns:Opposition of magnetic field 123. Continuous magnetism? Apply current magnetism object simently testing using iron particles 124. Residual magnetism? Apply current after shut- off the current using the retained magnetic field testing the object. 15
125. Steel melting point? 15400C 126. Prod Equipment? i) For job thickness up to 18mm 90 Amphere per inch of prod spacing ii) For job thickness greater than 18 mm 110 Amphere per inch of prod spacing. iii) The prod spacing is not less 2 inch note more. Then 8 inch iv) Effective prod spacing is 3 to 5 inch v) The same area is tested for 2 times one is perpendicular to other for complete coverage. 127. The tendency at a liquid penetrant to enter a discontinuity is primarily related to? Capillary action
128. In penetrant testing the time period from developer application to inspection after refereed to as? Development time
129. The method used to remove excess visible dye penetrant from a test part is primarily deferment by the? Surface roughness of the part under test
130. A discontinuity that must be found in welding? Crack, lack of penetration
131. The discontinuity found I forging is? Hydrogen flake
132. For applying non –aqueous developer is normally considered most effective? Spraying
133. Developer assists in the defection of the visible dye penetrant lot indication by? Providing a contracting back ground
134. The discontinuities would be impossible to defect using PT? 16
Internal inclusions
135. The penetrant system is generally considered least sensitive? Water washable – visible dye
136. In which conditions will decrease the life of a black light bulb? Line voltage fluctuations
137. Developers improperly used? May obscure indication
138. When using the dry developer, the drying operation is performed? After application of the developer and before inspection
139. An Excessive concentration of developer powder in a wet developer can cause? Creaking of the developer capacity during / after the drying 140. In penetrant system is generally considered highest sensitive? Solvent removable – fluorescent dye. 141. In a post emulsifiable dye – penetrant the emulsifies time? Is the faire needed to rise the emulsifies and excuses penetrant from the surface
142. The instruments used in PT to measure specific gravity of wet developers? Hydrometers
143. In which method is not generally accepted? Wire blushing 144. What is the most universally used black lift source? Enclosed mercury vapors are lamps
145. Lines indication is? One heaving a length greater then three times the width
146. Relevant indications? 17
Major dimension greater than 1/16.inch Major dimension greater than 1.6 mm
147. Lipophhilic ecrulsities are? Oil miscible liquids used to emulsify
148. Hydrophilic emulsifies are? Water miscible liquids used to emulsify the excess oil fluorescent penetrant
149. The maximum intensity of visible light examination is? 100 FC 1000LX 150. In fluorescent light examination visible ambient light? Should not excel 2 FC Should not excel 20LX 151. Water wasable? Apply penetrant if self contain emulsifies
152. Emulsifies? Is a liquid act with surface penetrant to make water wasable after penetration time the surface penetrant is clean with water so the surface to be drayed by hot air than apply developer than evaluations
153. Solvent removable method? Apply penetrant after penetration time the surface penetration is cleaned by solvent than apply developer and evaluation
154. Dry developers? Can be applied by spraying, flowing pricy solvent can be applied by electrostatic spray particle should be (-) and high voltage shock all to be done in a log chamber so we can sauce the 80% of the material
155. Non - aqueous developers? 18
This is only applied on dry surface this mixed with sol solvent and chock power applied by spraying duping not allowed because the pentrant will be cleaned so we can’t find the defect
156. By Spraying? Is advantages because the solvent enter to the discontinuity and Cary out the penetrate and solvent can be evaporate the penatrant will form the cane indication very well and we can’t early see the defect Solvent
157. Wet developer (or) Aqueous developer? (i)
Solvent = Particle size 0.15micron – This one best
(ii)
Suspended = II Quality
158. Soliable Particle diluted with water this developer will term fungus but ready to use
159. Suspended: Water is only the curies this will slot form fungus but an every way we have to Shake. 160. Filter: Will charge the while light to UV light 365 NM of wave length 161. Lipophilic emulsifies: Is act with surface penatrant by diffusion process
162 What is the NDT Method? RT, UT, PT, MT VT = Visual Testing AET = Acoustic Emission Testing TIR = Thermal Infrased Real Testing NRT = Neutron Radiographic Testing ET= Eddy Current Testing LT = Leak Testing 19
V.A.T. = Vibration Analysis Testing RT = Radiographic Testing UT = Ultrasonic Testing PT = Penetrant Testing MT = Magnetic Particle Testing
163 Wave lengths of x-ray and gamma ray a.) 10-9 to 10-13m 164. SNTC – TC -1A Guide line for. Society of National Technical Council 1st document.
165. RSO, RT, RTFI RSO = Radiation Safety offices, RT = Radiographic Testing, RTFI = Radiographic Film Interpretation. 166. D4, D7 D4 - Extra fine grain film with very high contrast D7 - Fine grain film with high contrast and high speed 167. Does level I can do interpretation? No 168. Does level II can do procedure writing? Yes 169. Types of Penetrameter b.) Hole type – DIN c.) Wire type – ASTM 170. Types of Curie? In gamma ray sources? Cobalt 60 – 5.3 years Iridium 192 – 74 days Cesium 137 – 30 years Thulium 178 – 127 days Ytterbium 169 – 31 days 171. Special purposes of curie? Xenon 133 – 5.3 years Europium 152 – 13 years 20
Gadelium 154 – 9.3 years Sodium 24 – 15 hours Selenium 75 – 121 days Iodine 125 – 57.4 days
172. Who invented the iridium? Iridium was identified and named by Tennant (England)
173. Wire type 62-years of design Fe – iron 10 & 16 Designation Number ISO – International Organization for Standardization DIN – Deusche Industry Norm
174. Hole Type 1 ½”
Designation number represent thickness of the penetrameter ½” X Contrast
X
4T
1T
2T
Level
Sensitivity level
1T = thickness = 0.05 inch 2T = thickness = 0.05 x 2 4T = thickness = 0.05 x 4
175. IQI - Image Quality Indicator 21
176. Wire type materials. Aluminum, Copper, Iron
177. Half life period formula No = Present Curie Strength N = Curie strength after‘t’ days t = no. of days of time elapsed T = half life period y = decay constant is 0.693 No = e –yt/T
For example: 20 curie No = e –yt/T No = e -0.693 x 5 / 75
= e-0.462 = 0.95
178. Types of Radiographic Technique a.) SWSI 1.) Unidirectional 2.) Penarmic b.) DWSI c.) DWDI
179. Developing Process Developing 5mts Accelerator (sodium carbonate) – is an alkali Preservative (sodium sulphate) – preventing oxidation Restrainer (potassium bromide) – exposed region of silver bromide Developing agent (hydrogenous) – prevent development of unexposed Crystals. Stop bath for few seconds
22
Arrest the function of the developer, stop bath may contain Glacial Acidic Acid (GAA).
Fixes is used to remove the developed silver bromide 1mts. Fixing has a solvable compound with silver bromide Fixes is a sodium thiosulphate a cleaning agent.
Running water after fixes thoroughly washed to remove all processing material
Wetting agent is to drain water uniformly
Dryer
180. Types of comer Tech-ops – 24 kg Spec2t
– 24 kg
Gamma grid – 18 kg Rollicamera – 35 kg
181. Screen cover material Lead screen Top screen 0.005mm Bottom screen 0.010mm
182. Stages Avoid guide to be bend Use minimum guide tube length Use collimeter Survey meter Area of cordon Bate return of source Emergency requires proper procedure Camera back to storage room 23
Camera maintenance at least once in three month Collimeter – tungsten material
Calibration and Maintenance Survey meter – 3 month Pocket dosimeter – 1 year Proper check daily,- battery check Densitometer – 90 days
Porosity due dirty electrode wire, dirty base metal, improper technique Undercut current too high, welding speed too high, arc length too long Incomplete fusion due to faulty joint, improper weld rod diameter, improper weld polarity Incomplete penetration faulty joint design, welding speed too rapid, weld current too low, arc length too long.
183. What does sensitivity depends on? Definition and Control 184. Acceptable density limit for viewing a weld image. 2 to 4 Densities 185. The density variation through the Penetrameter to area of invest -15% to +30% 186. Filter is used? To Reduce Scatter Radiation To Absorb Secondary Radiation To Produce Only Hard Radiation
187. Panoramic exposure, minimum number of IQI is? 3 penetrameter, 120° of part. 188. Lamination is a? Process Defect
189. Principle of UT. Reflection of Sound 24
190. Sound
Sonic
Subsonic
Ultrasonic
191. Human Range. 20 Hz to 20,000 Hz Below 20 Hz 5 MHz to 15 MHz Ultrasonic Range 2 MHz to 4 MHz Industrial Purpose Above 204 Hz Ultrasonic Waves
Above 20,000 Hz, it will not travel through air; it will only travel in the solid material. 192. Major uses for UT. a.) Flow Detection b.) Thickness Measurement c.) Distance Measurement d.) Material Characterization
193. Advantages of UT. e.) Depth Information f.) Immediate Result g.) Not Hazardous h.) High Sensitivity i.) Portable j.) Low Cost 25
194. Disadvantages of UT. k.) Operator skill is required l.) Indirect indication it is in the “Echo” form m.) Couplant is required n.) Non Homogenous material testing is not possible 195. I.I.W. Block? International Institute of Welding 196. Types of Block? V1, V2 block
197. UT Machine
Flow Detector
Analog machine
Digital machine
1.) Mod Sonic 2.) Sonatest a.) Site Scan 140 b.) Site Scan 240 c.) Site Scan 444 d.) Site Scan 346 3.) Kraut Grammes 4.) Panameterix 5.) P x 10 6.) P x 20 198. What is the use of Couplant? To remove the air gap between the transducer and object. 199. Types of Couplant Water, Oil, Grease (Silicon Grease or Petroleum Grease), Gel, Wall Paper Paste, Soft Rubber.
26
200. Types of reference Block Side drill hole type a.) 0 to 25 mm = 19 mm
2.4
b.) 25 to 50 mm = 38 mm
3.6
c.) 50 to 100 mm = 76 mm
4.8
d.) 100 to 150 mm = 114 mm
6
e.) 150 to 200 mm = 152 mm
7.2
201. Types of Echo pattern for scanning. A Scan it is used in Industrial B Scan it is used in Medical C Scan it is used in Immersive Testing and Atomic
202. Calibration method o.) Resolution p.) Penetration q.) Sensitivity r.) Sweep linearity s.) Screen high linearity t.) Amptitude control linearity
203. Resolution Place the normal probe at a focal point in V1, block for a 100mm range. The echo will comes at 85, 91, 100 mm separately
204. Penetration Place the normal on perspex, the echo will come out 50mm based upon velocity station perspex & steel [2730:5920] 23.5 mm Perspex is equal to 50mm of steel. 205. Sensitivity Place the probe towards 1.6mm hole the echo will come at 15 (01)35. 206. Sweep linearity
27
Place the probe on thickness 25, 50, 75, 100 mm. The echo will produce in a descending order. 207. Screen high linearity Place the probe towards ½t and ¾t to 80% and 40% reduce 2db up to 6db. The value in table is 25.6 tolerances ± 5% of the value. 208. Amptitude Control linearity Place the probe towards the artificial defect to 80% reduce to 6db 12db measure the value make to 40% of height increase +6db measure the value make 20% increase +12db measure the value, as per tolerance 20% of the value. 209. DAC Distance Amplitude Correction Curve A scan 1605 MHz 210. Types of Probe. Normal probe, Angular probe, triangular probe (45°, 60°, 70°). 211. Normal probe, Triangular probe. Normally used for thickness check-up only. 212. Angular Probe Used to find the weld defect. 213. Size of the probe. 8 x 9, 20 x 22 214. Formula ½ beam path = t /cos θ Full beam path = 2t/cos θ 1½ beam path = 3t/cos θ 2 beam path = 4t/cos θ 215. Skip distance ½ skip distance = t x tan θ Full skip distance = 2t x tan θ 1 ½ skip distance =3t x tan θ 2 skip distance = 4t x tan θ 215. Depth ½ depth = beam path x cos θ Full depth = 2t-beam path x cos θ 28
1½ depth = beam path x cos θ-2t 2 depth = 3t-beam path x cos θ
216. Location Beam path x sin θ
217.
θ
sinθ
cosθ
tanθ
secθ
45°
0.7
0.7
1
1.4
60°
0.86
0.5
1.732
2
70°
0.93
0.34
2.74
2.9
218. Thumb rule 90- Thickness. For example 24mm thickness 90-24=66mm Nearest probe is 70°, so we have to select 70° probe
219. Below 38mm we use 4mHz probe, above 38mm we use 2mHz probe.
220. V2 Block Notes: Based upon V2 block, echo pattern facing the angle probe towards 25mm radius the 1st echo will come at 25mm make the echo to 2.5 divisions. The next echo will come in an increment of 75mm to 100mm automatically at 10th division. A 100mm range facing the probe towards 50mm radius the 1st echo will come at 50mm make this echo at 4th division, the next echo will increment at 75 to 125mm at the 10th division.
221. V1 Block Notes: 29
Based upon V1 block echo pattern face that angle probe towards 100mm radius at focal point 1st echo will come at 100mm make this echo at 4th division. The 2nd echo travel 125 mm of increment come at 225mm on the 9th division automatically each division 25mm 50 division 250mm.
23mm thickness Probe selection 90-t 90-23=67 Frequency: below 38mm – 4mHz Above 38mm – 2mHz Probe size 8 x 9, 20 x 22 Couplant: water, grease, oil
Set the Range (70°)
½ beam path = t/cosθ = 23/0.5 = 46 mm Full beam path = 2t/cosθ = 46/0.5 = 92mm
222. A “Hot Work Permit” is required for: Areas where a fire Hazard May occur during a Welding, Cutting, Preheating-
Operation.
223. Eye Hazard Found in Welding Operations Include: (i) Flying Particles (ii) Radiation (iii) Smoke and Fumes 224. Protective Equipment not suitable for Eye Protection from Welding Radiation includes: Clear Safety Goggles. 225. Suitable Clothing Materials for Welding and Cutting are: Wool Chemically Treated Cotton 226. Before working on Equipment Where Machinery Guards have been removed a Lock, Tag, and Try Procedure should be Completed. True 30
227. In avoiding Jumes during welding the most important factors is The Position of the Welders Head 228. It is not important to consider Ventilation during welding and cutting operations False 229. When entering contained Space a “Standby” is not required: False 230. Some of the Toxic Material the welder may be exposed to be: Cadmium, Chromium, Nickel, Lead 231. The Welding Inspector is exposed to which of the following Safety Hazards: (i) Radiation, (ii) Jalling Objects (iii) Electrical Shock, (iv) Eye Hazards 232. A document which covers safety in welding and cutting is: ANSI / ASCZ49.1 233. The Most Important Component of an Effective Safety and Health Program is: Management Support 234. Safety Tran king is mandated under prorisions of OSHA
235. The Abbreviation “MSDS” means: Material Safety Data Sheet
236. The Abbreviation “TLV” means: Threshold Limit Value 237. Employs must make all applicable “MSDS” data available to their employs True 238. Personal must be trained to recognize Safety Hazards. True 239. The Welding Inspector must offer communicated with (i) Welder, (ii) Supervisor, (iii) Welding of Management 240. NDE Personnel (other than CWI) should be certified to what document: ASNT-SNT-TC-IA 241. You must have a high school diploma to become a CWI False 242. The CWI Exam has several parts; these are fundamentals practical, code True 31
243. The CWI Exam requires that the D1.1 code be used for the open book code test False 244. The little of the AWS. Standard, A3.0 is: Standard Welding Terms and Definitions 245. API Standard 1104 Cores the fabrication of Gross Counter Bridges False 246. Some of the Approval Codes / Standard for the Open Book, Portion of the CWI Exam are AWS D1.1, API 1104, AWS D 1.5, and AWSD 15.1 247. Prior to Staring a Job Assignment, the Welding Inspector should determine: (i) What code standard, or Specification applies? (ii) What Inspections should be conducted? (iii) When Inspection should be (iv) Where Records are maintained
248. When we are using Eccentric Reduces Concentric: (i) Eccentric-Pump Suction to Avoid (ii) Pump
249. What is the Thumb Ruche to Calculate Spanner? Size of given Bolt? 1.5 Dia of Bolt 250. What is the Thumb the calculate current required for welding? Current (AMP) = Diameter elevation (mm)* 40 251. What are Items we are remitting before the Hydro test in the line? (i) Control Value (ii) Organic Plate (iii) Rote Mat (iv) Safety Values (v) Thermo wells 252. What is the use of Reduces? To joint different Diameter of Pipes Different Bolt It has head one end and has threading other end it is tightened with a nut
253. What is the use of Gas cut? 32
Stud Bolt It is thread bolt end
Gas cut is a Certain Material used to fix between the flanges. 254. What is the use of Elbow? Tie Joint the two Pipe, Pipe cut an angle of 450 or 900 255. What is the use of Tee? Used to make a branch line at right angle to the main line. 256. Which one we are not considered a type of joint? Fillet 257. What is the ANSI/ASME Dimensional STD for Steel Flange & Filling? (i) B 16.3 (ii) B 16.5 (iii) B 16.9 (IV) B 16.10
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