1.

What is the difference between On-Plot & Off- Plot Piping & mention the
standards referred for the same.

On Plot Off Plot

SP 1173- Specification for welding on plot SP 1174- Specification for welding of
pipe work Class 2 & Class 3 Pipelines

SP 1177- Specification for welding of

Class 1 Pipelines

SP 1096- Specification for welding of SP 1097- Specification for welding of

Duplex Stainless Steel Piping (normally Duplex Stainless Steel Pipelines.
On plot locations) Applicable to Class 1 (pipelines) & Class 2
(flowlines)

Applicable code is ASME B 31.3 Applicable code is ASME B 31.4, ASME

B 31.8, and API 1104

On-plot is the Piping within the process Off-plot is the Pipeline / Flowline for
area of Chemical plant and Petroleum transportation, transmission &
Company Piping distribution systems

2. What is the main difference between A333 Gr.6 & ASTM A 106 GrB pipes and at
what conditions the above materials are used.

A 106 Gr.B A 333 Gr.6

A 106 is specification for seamless CS A333 is specification for seamless &
pipe for high temperature service welded steel pipe for low temperature
service
Impact Test not mandatory Impact test at -45C is mandatory

3. In GTAW, SMAW welding process, what are the current polarities of the welding electrodes?

GTAW SMAW
DCEN DCEP
4. For the manufacturing & Testing of Valves generally which International Standards
or codes are referred?
API 598; API 6D
5. For the manufacturing & testing of Pumps generally which International
Standards or codes are referred?
API
6. What is the different Radiography techniques generally used in the fabrication
industry?
SWSI- Single Wall Single Image
DWSI- Double Wall Single Image
DWDI- Double Wall Double Image
Panoramic
7. By which methodology of radiography, you can archive the radiographs for its 20
Years of life?
DR3000 Radiograph Film Digitisation System
8. How do you calculate the sensitivity of the Radiograph?
Image Quality Indicators, also known as penetrameters.
Penetrameter types are:-
DIN Type- 54109, also known as wire type
ASTM type- E1025, also known as strip hole type
BSS / AFNOR type also known as step hole type
Percentage Sensitivity = Thickness of the least wire visible / Job thickness in mm x
100
9. How will you calculate the Heat Input during welding and kindly mention the
Importance of the same in Carbon & Alloy Steels?
Heat Input = (Voltage x Ampere x 60) / (Travel Speed in mm per min x 1000)
kJ/mm
Is a supplementary essential variable as per ASME BPV Sec IX
Decrease in Heat input per pass not more than 10% for sour service and not more
than 20% for non-sour service

10. What are Essential & non-essential variables in a welding procedure specifications?

Essential Variables Non-essential variables

Essential variables are those in which a
change, as described in the specific
variables, is considered to affect the
mechanical properties of the weldment,
and shall require requalification of the
WPS.
Examples:-
1. Change in Thickness qualified &
P No. qualified for a base metal
2. Change in F-number, A-number, &
deposited weld metal thickness in
Filler metals
3. Decrease in preheat >56C
4. Change in PWHT
Non-essential variables are those in
which a change, as described in the
specific variables, may be made in the
WPS without requalification
1. Change in groove design, deletion
of backing, change in root spacing,
and Addition or deletion of
retainers for Joints
2. Change in diameter & AWS
classification of filler metals
3. Addition of position, and change
in uphill downhill vertical welding
4. Change of Current or Voltage
range in electrical characteristics
5. Change in technique

11. In GTAW welding the addition or deletion of gas backing, a change in backing gas
composition, or a change in the specified flow rate range of the backing gas is a
Essential or Non-essential variable?
Non-essential Variable
12. In GTAW welding change from a single shielding gas to any other single shielding
gas is an Essential or Non-essential variable?
Essential Variable
13. What all things you will check before, during & after welding?

Before During After

 1. Original copy of 1.Calibrated Portable Arc 1. As built drawings
approved WPS Monitoring System with a with unique weld
2. Reviewed copies of print out (if applicable) numbers
material test 2. Review of the various 2. Weld history sheet,
certificates test requirements with weld maps
3. Reviewed copies of arrangements 3. All inspection
batch test 3. Cleaning, End reports
certificates for the preparation, Alignment 4. NDT reports
welding 4. Weather conditions 5. PWHT charts
consumables 5. Arc strikes 6. Radiographs
4. Original copy of 6. Arrangements for 7. Non-conformance
Welders interpass cleaning, and reports
Performance perheating if any 8. Corrective Action
Qualification test 7. Verification of welders Requests
certificates qualification cards 9. Certificate of
5. Approved Compliance
consumable
handling procedure
6. Review of
Isometrics and PEFS
7. Stage inspection
reports

14. How do you check the correctness of Nozzle orientation angle in the pressure
Vessels?
Through PEFS / P&IDs and other related equipment drawings
15. What are the essential checks to be carried by a inspector prior to witnessing the
hydrotest of a Vessel or Pipeline
Company approved Mechanical Completion
Test pack readiness except Hydro test
Water test certificate
Duration of water inside vessel / pipeline, after draining
Completeness of NDT and its approval by company for all the weld joints
Finalised weld map, weld history
Calibration certificate for Pressure gauges
 Ensuring the availability of company representative through prior
intimation / notification of the test
16. What is the quality checks required for the Water to be used in Hydrotest of a
Pressure Vessel or pipeline etc.?
Presence of any harmful Alkaline content
PH value
Proper mix of chemical agents / adhesives for requirement due to
prolonged logging of water into the pipeline / vessel
17. If a complete piping or a pipeline is completely finished & hydrotested
suceessfully & then you find that some 10 weld joints in that line has ben welded
by non-qulified welder, then what is site inspectors action for way forward?
Immediately report to companys site quality representative,
18. What is the equivalent of Blast Finish SA 2 in brush finish?
In brush finish, loose mill scale, loose rust and foreign particles are removed
In Blast finish SA 2 , a near white metal state is attained with as above condition,
and the blasted surface will show varying shades of Grey colour.
Hence both finishes are different.
Wrong
Correct answer is SA 2 equivalent is ST3 in brush finish.
19. How the pressure gauge shall be selected for hydrotest & what is the range of
Pressure gauge should be used for hydrotest?
Pressure gauges with as much as minimum least count with as much as bigger
dial indicator is much preferrable
20. In general for what thickness of Pipe or Plate the Post Weld Heat Treatment is
required & what will be the Cycle range and temperature according to ASME B
31.3?
20mm and above
593-649C with holding time of 2.4 min / mm, but 1Hr minimum required.
21. How do you calculate the dew point of steel surface?
Dew point Td = T - (100 - RH) / 5,
Where, T is the dry bulb temperature, and RH is the relative humidity.
22. How do you calibrate Pressure gauges?
By comparing the values of several readings with a master gauge, which should
have a different range.
23. What is the post weld heat temperature for alloy steel material?
 Complete thickness, 13 mm & above, and 20 mm & above depending upon the P-
Number classification.
24. What is a four or five digit coding for electrode as per AWS classification SFA 5.1?
EXXXX
E - Electrode
First & Second X - Minimum tensile strength of the deposited weld
metal, eg:- 70 means at least 70000 psi
Third X - Refers to weld position
1 means electrode is suitable to use in any position
2 means electrode can be used in flat position only
4 means electrode is suitable for downhill progression
Fourth X - Represents composition of coating present in
electrode, 5, 6, or, 8 are classified as Low Hydrogen
electrodes

25. Where the use of electrode E7018 is recommended?

Joints involving high-strength, high carbon, or low alloy steels requiring high
travel speeds
26. Why the electrode E7018 is called low hydrogen electrode?
The electrode E7018 is made with inorganic coverings that contain minimum
moisture. The maximum allowable moisture limit in these electrode coverings are
0.6% or less, as required by AWS SFA 5.1. Careless handling & storing of these
electrodes when used for welding may cause hydrogen induced cracking in the
weldment.
27. Name the gamma ray source used for industrial radiography work?
Iridium 192
28. What is the depth of penetration in steel by cobalt 60, cesium 137, Iridium
192 &
Thulium 170.

Isotopes Steel Thickness

Minimum Maximum

Iridium 192 2

Cesium 137 1 3
 Cobalt 60 1 8

29. What do you mean by photographic Density?

Density is the degree of darkness also given by log of opacity
Density = log 10 (Incident Intensity / Transmittance Intensity)
Density requirements for X-ray are 1.8 min and 4.0 max and for Gamma-ray are
2.0 min and 4.0 max
30. Name the instrument used for measuring density of photographic or radiographic
film?
Densitometer
31. What are the factors on which the density of radiographic film depends?
Transmittance and Reflection
32. How the intensity of source is related with film distance?
Inverse square law
Intensity is proportional to (Curie Strength/Distance 2 )
Intensity is inversely proportional to square of distance
33. What is Radiographic sensitivity?
Ability to see the smallest defect in the radiographic film
Percentage Sensitivity = Thickness of the least wire visible / Job thickness in mm x
100
34. What is the general requirement of Radiographic Sensitivity?
2%
35. What are the commonly used IQI?
DIN Type- 54109, also known as wire type
ASTM type- E1025, also known as strip hole type
BSS / AFNOR type also known as step hole type

36. What do you mean by Intrinsically Safe Zone?

Intrinsically Safe Zone is a protection certified area for safe operation with
electrical / electronic equipment in explosive atmospheres. The concept
was developed for safe operation of process control instrumentation in
hazardous areas, particularly around petro-chemicals.
37. In electrical what is meant by Zone A & Zone B?
 These are hazardous area classification as per electrical engineering. Each zone is
classified based on the ignitable property and flash point of gases in a small
electrical spark and the severity is according to that classification.
Zone A comprises of gases like methane, propane, butane, petrol and other such
hydrocarbon gases which are highly ignitable.
Zone B comprises of ethylene, coke oven and other less ignitable gases.
IS certification and IP protection are designed in electrical engineering based on
the same by classifying the whole plot plan area prior to start up of work. These
are known as area classification drawings.
38. In civil what is cube test and slump test?
Cube test is a most commonly used test in Civil Engineering for determining the
Concrete Compression strength which is done as per BS 1881. Cubes 150mm X
150mm X 150mm are casted and are soaked in water. Samples are tested after 7
days, 14 days, 21 days, and 28 days from the date of casting. The results should
be higher than as specified for each grade of concrete.
Slump test is to determine and measure how hard and consistent a given sample
of concrete is, before pouring. Slump test is performed according to ASTM C 143
with the newly mixed concrete. The slump cone is filled at 1/3 rd , 2/3rd , and then
at overflow alternatively rodding 25 times. The height of the slump is measured
against the height of the cone by placing it inverted with a straight egde.