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Aramco Specific Evaluations for Welding / Mech. QC candidates 1. Describe the difference bet een QA/QC!

QA provides the ob"ective needed to give a ma#imum confidence for $ualit% hile QC is involved ith the monitoring of a process and eliminating the causes of an% deficient output ith an% process& hich has effect on $ualit%. '. What is an essential variable as related to a Weld (rocedure Specification )W(S*! Essential variables are those in hich a change& is considered to affect the mechanical properties of the eldment and shall re$uire re$ualification of the W(S. +. What is the relationship bet een (rocedure Qualification ,ecord )(Q,* and a W(S! (Q, is a record of the elding data used to eld a test coupon& it contains the result of the tested specimens& hile the W(S is the ritten form of the elding procedure for ma-ing a specified -ind of eld "oint using specified base and filler materials. .. /eat input )SMAW per ASME SEC 01* is a common of characteristics 2 travel speed! hat t o electrical

3olts and amperes& heat input 4 volts # amperes / travel speed. 5. E#cessive heat input is mainl% attributed to during SMAW process! 0ncorrect elding techni$ue hat poor elding techni$ues

6. What are + potential sources of /%drogen encountered during SMAW process! Damp electrodes Moist surface 0mproper eather condition. elds using the

7. What are several li-el% causes of porosit% in carbon steel SMAW process! E#cessive moisture in the flu# Arc length too long 8se of lo elding current Damage electrode flu#

9. What dimension is measured to determine the si:e of a concave fillet

eld!

0ts height and length ;. What dimension is measured to determine the si:e of a conve# fillet 0ts throat thic-ness 1<. Where ould crac-ing most li-el% occur from e#cessive current input in a single pass eld! =i$uation crac-ing 11. 0t 8sing >?AW process& describe hat happens to a root pass applied ithout purging/bac- gauging on SS! ill produce o#idi:ing& co-ing to the eld metal. eld!

1'. @ame + of the 5 mechanical tests in ASME 01 emplo%ed for procedure 2 performance $ualifications! ?ension test >uided bend test AillerB eld test @otchBtoughness test Macro test

Mechanical/NDT, assume SMAW process for all questions. 1. /o is Magnetic (article inspection of a method performed! eld using et continuous test

Measure and record the temperature of e#amination surface& temperature shall not e#ceed 1+5CA )57 CC * Clean e#amination surface and ad"acent area ithin + inches ) 76.' mm * of the e#amine area (erform visual inspection of the e#amination surface for cleanliness and discontinuities Chec- for remnant magnetic fields e#ceeding D ' gauss.

'. 0ndications ith =i$uid (enetrant ?esting are easil% seen if the surface has been prepared b% grinding prior to testing! ?rue or Aalse! Wh%! Aalse& surface discontinuities of the e#amine area ill not be seen or occur

+. @ame an @D? method and techni$ues that emplo%s a reflected sound beam that can be used for the volumetric e#amination of elds! 8ltra sonic test .. =ist + advantages of ,? over other @D? Methods! Advantages: (ermanent record =ittle surface preparation Defect identification ver% eas% @o material limitation @ot so reliant operator s-ill Disadvantages: ,e$uires bul-% and e#pensive machiner% E#pensive consumables Cannot detect plate laminations& lac- of interBrun fusion or crac-s perpendicular to #Bra% beam 5. 0f a product is to be stress relieved& h% is it important to use e#actl% the same ,? procedure before and after stress relieving! ?o ensure the eld has no crac-s or defects.

6. A dar- narro area 'B+ mm ide appears on a radiograph all along the edge of the area of the representing the eld. ?he "oint has a 6< Degree double vee groove. What is the indication most li-el% to be! Slag inclusion

7. A locali:ed dar-er densit% ,adiographic image ith fu::% edges in the center of the eld image that ma% or ma% not be ider than the idth of the root pass images is most li-el% hat ! Eurn through 9. @ame 5 common film artifacts that ma% be cause for re"ection of the ,adiographic film! Ailm mar-s =o densit% (oor identification Aog and processing irregularities 8nacceptable techni$ue and setBup

;. When the radiation source is located inside piping ith the film located outside& singleB all e#posure and singleB all vie & name this t%pe of e#posure! (anoramicB single image* 1<. /o all e#posure& single all vie ing )single all single elds!

do gamma ra%s compare

ith #Bra%s

hen applied to ,? of

#Bra%s generall% produces better $ualit% radiograph and safe& hile gamma sources permanentl% produces radiation and re$uire shielding hen not in used. 11. (er ASME E+1.+& name three of the four Categories of Aluid Service! Categor% FDG Aluid service Categor% FMG Aluid service @ormal Aluid service )@AS* /igh (ressure Aluid service ho is responsible for classification of service to a given

1'. (er ASME E+1.+ categor%! H ner

1+. (er ASME E+1.+ hat are the ,? re$uirements for Soc-et severe c%cle service! ,andom ,? 1..

elds in a

,elating to the above $uestion& give ' reasons h% random ,? of soc-et elds is recommended even though code does not re$uire ,?! >ap verification 4

15. Eriefl% describe good QC practice relating to the installation 2 bolting of flanges! Eolt holes shall be aligned ithin 1.9 mm ma#imum offset Alange bolts and studs shall be long enough to penetrate completel% through the nuts minimum of + threads protrusion Eolts nuts faces and nut bearings surfaces shall be lubricated before installation

16. What is an oftenB overloo-ed inspection/ @D? re$uirement on the installation of the orifice flanges! Welds root at orifice flanges shall be ground or machined smooth and flush on the inside of the pipe& and it re$uires ,?. 17. What A(0 documents appl% to the replacement of the e#isting floor for an Aboveground Hil Storage tan-! A(0 65+ 19. ,elating to eld fabrication shop evaluation prior to the beginning of pipe elding for a ma"or pro"ect& hat are several -e% items %ou ould loo- for as the 0nspector before %ou approved the shop for elding! ?he inspector must considered the follo ingI material specification& $ualification& W(S /intI 5M D E formula 4 Manpo er& Methods& Materials& Machines& Measurements& Environment (er SAES J WB<11 1. What is the ma#imum si:e of lo h%drogen )E7<19* permitted! elders

5mm for the 1g/1f position& .mm other positions Aor nonBh%drogenK 5mm for all positions '. What are the diameter limitations )per pipe si:e* for the different processes! SMAW +GB up >?AW LG to 1< M >MAW +GB up elding

+. What is the re$uirement )Material& location* for bridges tac-s! 0t should be same materials& electrodes& minimum preheat and should be located above the root area .. Aor temporar% supports and attachments re$uirements related to Materials! @D?! 5 elded to the pipe& hat are

0t should be same materials& and (? or M(? 5. What is the minimum amount of time that EB7<19 electrodes can be -ept out in the field! 8p to . hours 6. What is the minimum dr%ing temperature and dr%ing time! '6<NCB .+<NC for ' hours 7. /o man% times can electrodes be reBba-ed! Hne time onl% 9. What is the ma#imum internal misalignment of butt "oints! 1.5 mm ma#. ;. (iping during preparation before fitBups shall be cleaned/ground nternall%/e#ternall% for hat distance from the edge of the prepared "oint! >round internall%/e#ternall% for at least '5 mm& and should be clean 1<. Moist surfaces re$uire moisture removal and surface to be preheated must be preheated to hat distance from the "oint edge! 75mm from the "oint edge