Question -1 Describe your duties as a welding inspector, as applicable to your selected applicable standard or code of practice (approx. 300 words) ‘Answer - My duties, as a welding inspector is involved + Before welding «During welding + After welding BEFORE WELDING Ensure that all applicable documents are available. These documents can be PCP, QCP, WPS, PQR, WOTR, Drawing specification, standard or code etc. Review applicable documents. + Check approved WPS Check welder individual qualification + Ensure that welding equipment such as welding units, Ovens and Quivers are calibrated-and valid + Ensure that instruments, which will be used by inspector, are calibrated and valid. This instrument can be long tester, Digital thermometer etc. + Ensure that material received Is as per purchased order. Check the material against mill cerlificate. © Check the condition of base metal according to project requirements + Check the condition of consumable ie. electrodes, filler wire, shielding gases, flux etc. Ensure that low hydrogen electrodes and fluxes are dried and stored in an appropriate oven and make sure they are free from contamination Ensure that foreign materials are away and dedicated tools are being used for stainless steel Ensure that for bridge tacking same grade material is being used. Check clearance dimensions, tolerances and type of backing if any Check fit-up and ensure that bevel angle included angle root gap etc, are as per WPS Check wind protection Check pre-heat if required DURING WELDING Ensure that the welding processes being applied are as per WPS Check welding current voltage and travel speed Check pre-heat and interpass temperature Check the colour code of filler wires Check the root prior to close in such cases where not possible to see the root after completion Check interpass cleaning Check weave width as per WPS Control distortion by presetting AFTER WELDING «Check dimensional accuracy + Acceptability of weld regarding the appearance nn nar deauing and ctandard raniiiramants+ Ensure post weld heat treatment performed if required + Check any repair + Repair + Ensure a skilled and approved welder has been assigned Check proper tracing is issued + Mark the area clearly and positively + Ensure proper method is being used during excavation and removed of defect + During excavation and after excavation check visual and by NDT to ensure that defect had been removed + Ensure that the joint design is as per WPS after excavation + Check repair weldingis performed as per WPS + Re inspect and perform NDT to insure weld integrity + Ensure all documents are prepared and signed off. Question - 2 Write a short account of the causes of hydrogen cracking in the welding of carbon manganese and low alloy steels, Sketch a cross section of weld showing this type of cracking Answer:~ Hydrogen crack can be caused due to these Hydrogen level > 15ml / 100g. H2 Weld metal Stress > % Yield Temperature < 350°C Hardness > 400 Vicker pyramid Number (VPN) Hydrogen cracking could be result due to presence of hydrogen in the weld zone. The source of hydrogen could come from the base the base metal filler metal surrounding atmosphere or organic surface contamination. During the actual welding process the molten weld metal may absorb it. At this stage molten weld metal can hold a grate deal of atomic. Once the metal solidified it has much less capacity for the hydrogen. The tendency of hydrogen iron is to move through the metal structure grain boundaries in HAZ. At this stage the hydrogen atoms may combine to gather to form hydrogen molecules. These hydrogen molecules are too large to move. They are now trapped. If the surrounding metals does not exhibit sufficient ductility. The internal pressure of trapped molecules will cause hydrogen crack Avoidance: Hardness by preheating carbon contents stress by PWHT joint design clamping, ‘Temperature by preheating. Hydrogen level by using Basic electrodes that low hydrogen electrodes. It should be baked and shall be kept in an appropriate oven to maintain its low level: Cleaning of contamination from the joint surface of parent metal is also helpful Hydrogen Crack Hydrogen CrackFused flux:: Elements are build up and dried giving a glass like appearance. It has dark brown or black clour. It is moisture resistant therefore no needs preheating. It is used for general purpose similar to rutile electrodes. ‘Aggiomerated flux: It has light green colour basic type normally spherical globular appearance. It absorbs moisture therefore need preheating. It has best mechanical properties. It is @ low hydrogen type flux. It shall be removed from the topper at the end of the day to prevent from moisture. The typical defects in this process are: «Center line cracking or solidification cracking Porosity Slag inclusion Risk of hydrogen cracking Pock marked surface from gas entrapment (Flux depth compression) Question: Discus the differences between various types of submerged arc fluxes Distinguish between fused and agglomerated fluxes as used for submerged are welding Answer: Fused flux: Elements are build up and dried giving a glass like appearance. The colour is dark brown or black. No need preheating ‘Agglomerated flux: Light green colour basic type normally spherical globular appearance. If will absorb the moisture need preheating, Best mechanical properties low hydrogen flux Condition: Shali be dry and free from scale or other foreign materials. Damaged packages shall be removed or shall be dried on minimum 300° C temperature of one hour before use. Question - 4 Explain the causes of weld decay in austenitic stainless steel (Sensitized) ‘Answer: Occurs in HAZ due to chromium forming with carbon to give chromium carbide (Precipitation) Knife Edge corrosion Temp Temp Occurs in 600 - 800° C temperature range Chromium has a great affinity to the carbon Avoidance: + Use low carbon grade SS (3461, 304L (L-Low carbon)* Add stabilizer Nb, Ti (Stabilizers) which have greater affinity for the carbon these forms titanium carbide, Niobium carbide which leave the chromium in solution © Low heat interpass temperature Question: § it has been necessary to remove part of a weld joint for macro examination, describe how for subservient examination Answer: First of all cut the section of the test piece by using mic or any other type of cold cut preparations Inspect + File it with a rough file progressing to smooth + Emery paper wet dry down to 600grit Inspect * Each in NITAL (Nitric acid 5-10% alcohol) This is for carbon steel Take NITAL in a dish, get gloves, tongs and cotton Wash with cotton wool Wash in water and clean with acetone Ready for inspection Answer For Question - 5 Cut out the specimen by using any type of cold cutting methods * Visually inspect for any possible defect File it with rough file as smooth s possible There after polish with wet come dry emery paper into 600 GRIT finish Again visually inspect for any possible defect Etch with NITAL (Nitric acid 5-10% in aloohol) for CS Nital in a dish using gloves tongs and cotton carry out the etching Wash with cotton wool * Wash in water and clean with acetone , [ue ute Ready for inspection 2uestion - 6 Distinguish between macro and micro Macro Micro Magnification 10x Up to 1000X (Higher magnification) Finish - 600Grit 1 Micron (Higher Level of Polish) Feature Defects Features Visual Defects inter-granular Structure Reason Reason Welder / Procedure Research and Failure Analysis. Qualification Q-7 Distinguish between the advantage and disadvantage of RT and UT? Advantage of RT 1) Permanent record i.e. Film 2) Itcan be performed on thin material 3) Production can be more by Speed.4) Technician skill level not so high 5) Surface to apply not so critical. Disadvantage of RT. 1) Health and Safety 2) May need to stop production (Other Activities) 3) Will not necessary find all lack of fusion defects due to defect orientation Advantage of UT 1) Safer 2) More Portable 3) Could be cheaper production need not to stop 4) Find all types of defects in respective of where they are laying, Disadvantage of UT. 1) Needs direct contact i.e. good surface finish 2) No Hard copy 3) Technicians need high level of skill, dependent on Technician integrity. Q-8 what is solidification cracking? What are the causes of solidification cracking and how can we avoid it? Ans: Solidification cracking is hot cracking on centerline cracking in the weld metal. The main causes of solidification cracking are sulfur stress and joint design. When sulfur joints with iron, it forms iron sulfide. Iron sulfide solidifies at a lower temperature than steel, Iron sulfide forms a liquid film on the grain boundaries as the center of the weld is last place to cool or solidity. The iron sulfide ends at the center of the weld. Iron sulfide is still liquid when steel has solidified. Therefore any stress may pull the weld a part to form solidification cracking. (a) We can avoid by reducing the sulphur level by checking the mill certificate of the material. (b) By good cleaning of the joint. (c) By changing the joint design. (d) By adding manganese to sulfur forming manganese sulfide which solidifies at a temperature similar to steel. Manganese reduces the sulfur contents in steel any iron sulfide formed is now more discrete and therefore less chances of cracking. 2-9 you have found a Clit Welded on PWHT done vessel, what action you will take. How will you remove the Clit? ‘Ans: Cut and remove the clit approximately 10mm above from the clit weld. Thereafter grind and remove the remaining clit with associated welding by grinding. During grinding avoid any hot spot up on success removed visually inspect and perform MPI (PT for SS). Q-10 Where Lemiller Tearms Occurs? What are the causes of Lameller tearing? How we can avoid it? Ans.: The cause of lameller tearing are poor through thickness ductility in the parent material and stress which causes step like cracking. It occurs in thicker section. Sections specially in T joints and closed corner joints also in rough plates. 1) We can avoid it by changing the joint design by using performed tee and open corner joints where the stress will move in rolling direction. 2) By buttering layer. 3) By using Z quality plates which has been STRA testedQ-11 House Keeping of stainless steel! Shop. ‘Ans.: Carryout SS fabrication welding in a shop which is exclusively made for SS work. 1) Provide separate laydown area for incoming material storage. 2) Ensure all materials are stored on wooden skid. Also SS pipe component should be stored in covered condition to avoid contamination from foreign materials 3) Small pipes shall be cut in the required size by cold cut (use special cutting disc.) 4) Using plasma-cutting unit should cut all big pipes. Ensure proper protection has been provided to avoid contamination, which can result from plasma cutting 5) Use all tools and tackles specially certified and made for SS fabrication and welding works. Use stands and other temporary supports, which are made of SS under any circumstance non- SS materials shall be, contact with galvanized 6) Ensure all the equipments used are calibrated. 7) Use high frequency units for arc initiation. 8) Ensure shielding and packing gases are 99.99% pure argon or any other applicable inert gas with high purity 9) Use clean hand gloves to handling the pipe. 10)Use special type marker (Non-chloride) for fabrication traceability. 11) Ensure always different types of SS materials are fabricated and welded in a separate location and special care shall be taken to avoid the mixing of consumable, Example: Types 316, 304, 309 etc. recommended to store them on separate locations with certificate copy. Also recommended special care while grinding SS works do not allow spatter falling on any other SS surface. This can lead surface corrosion 12) Care shall be taken from receiving through construction to find installation. Avoid any contamination or damages during hydrotest use only approved type water. In case of lube oil system pipe use oil flushing and oil pressure test. y 13)Where necessary perform internal and external chemical cleaning. «.« 5 Bye a Q-12 State 4 factors which must be requires for good welding, wi ‘Ans.: 1) Fusion (Melting) The metal must be melted which requires an intensity heat source 2) The process must remove any oxide or other contamination from the joint faces. 3) Contamination by the atmosphere must be avoided. 4) The welded joint must possess adequate properties. Q-13 Describe at least two different methods of applying preheat and outline the checks you would sonduct to verify that the treatment it was in accordance with procedural requirement. ‘Ans.: The two methods of applying pre heat are flame heating and electric resistance coil heating. Flame Heating: using flammable gases, normally propane, carries out these types of preheating The process is applied by the help of heating torch with hose, which is connected with the flammable gas cylinder. Electric Resistance coil heating: This is similar to the process we use for stress relieving. Itis very controlled heating method. This type of pre-heating can be recorded in graphs. Normally preheat temperature is checked approximately 75mm away from the joint by temple stick or digital thermometer.