Aramco Specific Evaluations for Welding / Mech.

QC candidates
1. Describe the difference between QA/QC?
QA provides the objective needed to give a maximum confidence for quality
while QC is involved with the monitoring of a process and eliminating the
causes of any deficient output with any process, which has effect on quality.
2. What is an essential variable as related to a Weld Procedure Specification
(WPS)?
Essential variables are those in which a change, is considered to affect the
mechanical properties of the weldment and shall require requalification of
the WPS.
3. What is the relationship between Procedure Qualification Record (PQR) and
a WPS?
PQR is a record of the welding data used to weld a test coupon, it contains
the result of the tested specimens, while the WPS is the written form of the
welding procedure for making a specified kind of weld joint using specified
base and filler materials.
4. Heat input (SMAW per ASME SEC IX) is a common of what two electrical
characteristics & travel speed?
Volts and amperes, heat input = volts x amperes / travel speed.
5. Excessive heat input is mainly attributed to what poor welding techniques
during SMAW process?
Incorrect welding technique
6. What are 3 potential sources of Hydrogen encountered during SMAW
process?

Damp electrodes
Moist surface
Improper weather condition.

7. What are several likely causes of porosity in carbon steel welds using the
SMAW process?

Excessive moisture in the flux

Arc length too long
Use of low welding current
Damage electrode flux

8. What dimension is measured to determine the size of a concave fillet weld?

Its height and length

9. What dimension is measured to determine the size of a convex fillet weld?
Its throat thickness
10.
Where would cracking most likely occur from excessive current input
in a single pass weld?
Liquation cracking
11.
Using GTAW process, describe what happens to a root pass applied
without purging/back gauging on SS?
It will produce oxidizing, coking to the weld metal.
12.
Name 3 of the 5 mechanical tests in ASME IX employed for procedure
& performance qualifications?

Tension test
Guided bend test
Filler-weld test
Notch-toughness test
Macro test

Mechanical/NDT, assume SMAW process for all questions.

1. How is Magnetic Particle inspection of a weld using wet continuous test
method performed?

Measure and record the temperature of examination surface,

temperature shall not exceed 135*F (57 *C )
Clean examination surface and adjacent area within 3 inches ( 76.2
mm ) of the examine area
Perform visual inspection of the examination surface for cleanliness
and discontinuities
Check for remnant magnetic fields exceeding + 2 gauss.

2. Indications with Liquid Penetrant Testing are easily seen if the surface has
been prepared by grinding prior to testing? True or False? Why?
False, surface discontinuities of the examine area will not be seen or occur
3. Name an NDT method and techniques that employs a reflected sound beam
that can be used for the volumetric examination of welds?
Ultra sonic test
4. List 3 advantages of RT over other NDT Methods?
Advantages:
Permanent record
Little surface preparation
Defect identification very easy
No material limitation
Not so reliant operator skill
Disadvantages:
Requires bulky and expensive machinery
Expensive consumables
Cannot detect plate laminations, lack of inter-run fusion or cracks
perpendicular to x-ray beam
5. If a product is to be stress relieved, why is it important to use exactly the
same RT procedure before and after stress relieving?
To ensure the weld has no cracks or defects.
6. A dark narrow area 2-3 mm wide appears on a radiograph all along the edge
of the area of the representing the weld. The joint has a 60 Degree double
vee groove. What is the indication most likely to be?
Slag inclusion

7. A localized darker density Radiographic image with fuzzy edges in the

center of the weld image that may or may not be wider than the width of
the root pass images is most likely what ?
Burn through
8. Name 5 common film artifacts that may be cause for rejection of the
Radiographic film?

Film marks
Low density
Poor identification
Fog and processing irregularities
Unacceptable technique and set-up

9. When the radiation source is located inside piping with the film located
outside, single-wall exposure and single-wall view, name this type of
exposure?
Panoramic- single wall exposure, single wall viewing (single wall single
image)
10.

How do gamma rays compare with x-rays when applied to RT of welds?

x-rays generally produces better quality radiograph and safe, while gamma
sources permanently produces radiation and require shielding when not in
used.
11.

Per ASME B31.3, name three of the four Categories of Fluid Service?
Category D Fluid service
Category M Fluid service
Normal Fluid service (NFS)
High Pressure Fluid service

12. Per ASME B31.3 who is responsible for classification of service to a given
category?
Owner
13. Per ASME B31.3 what are the RT requirements for Socket welds in a
severe cycle service?
Random RT
14. Relating to the above question, give 2 reasons why random RT of socket
welds is recommended even though code does not require RT?

Gap verification
4

15. Briefly describe good QC practice relating to the installation & bolting of
flanges?

Bolt holes shall be aligned within 1.8 mm maximum offset

Flange bolts and studs shall be long enough to penetrate completely
through the nuts minimum of 3 threads protrusion
Bolts nuts faces and nut bearings surfaces shall be lubricated before
installation

16. What is an often- overlooked inspection/ NDT requirement on the

installation of the orifice flanges?
Welds root at orifice flanges shall be ground or machined smooth and flush
on the inside of the pipe, and it requires RT.
17. What API documents apply to the replacement of the existing floor for an
Aboveground Oil Storage tank?
API 653
18. Relating to weld fabrication shop evaluation prior to the beginning of pipe
welding for a major project, what are several key items you would look for
as the Inspector before you approved the shop for welding?
The inspector must considered the following: material specification, welders
qualification, WPS
Hint: 5M + E formula = Manpower, Methods, Materials, Machines,
Measurements, Environment
Per SAES W-011
1. What is the maximum size of low hydrogen (E7018) permitted?
5mm for the 1g/1f position, 4mm other positions
For non-hydrogen; 5mm for all positions
2. What are the diameter limitations (per pipe size) for the different welding
processes?
SMAW
3- up

GTAW
to 10

GMAW
3- up

3. What is the requirement (Material, location) for bridges tacks?

It should be same materials, electrodes, minimum preheat and should be
located above the root area
4. For temporary supports and attachments welded to the pipe, what are
requirements related to Materials? NDT?
5

It should be same materials, and PT or MPT

5. What is the minimum amount of time that E-7018 electrodes can be kept
out in the field?
Up to 4 hours
6. What is the minimum drying temperature and drying time?
260C- 430C for 2 hours
7. How many times can electrodes be re-baked?
One time only
8. What is the maximum internal misalignment of butt joints?
1.5 mm max.
9. Piping during preparation before fit-ups shall be cleaned/ground
nternally/externally for what distance from the edge of the prepared
joint?
Ground internally/externally for at least 25 mm, and should be clean
10. Moist surfaces require moisture removal and surface to be preheated
must be preheated to what distance from the joint edge?
75mm from the joint edge