CBT Exam Questions for Welding Inspector

This article is about CBT Exam Questions for Welding Inspector and questions are prepared by noting international standards and codes for Welding engineering aspect and safety.

CBT Exam Questions for Welding Inspector

1) What are specifications?

Specifications (Specs) are detailed guidelines that outline the construction requirements for a project or product. They define the minimum quality standards, materials, dimensions, performance criteria, and other technical specifications that must be met. Specifications serve as a reference for engineers, architects, contractors, and suppliers to ensure consistency, safety, and compliance with applicable codes and regulations. They provide specific instructions and criteria for the design, fabrication, installation, and testing of components or systems.

2) What is an SIS?

SIS stands for Safety Instruction Sheet. It is a document that provides comprehensive design details and instructions related to a specific piping system or line. The SIS includes information such as system layout, materials, dimensions, valve and instrument specifications, operating conditions, safety considerations, and emergency procedures. It serves as a reference for personnel involved in the operation, maintenance, and troubleshooting of the piping system, ensuring that safety requirements are followed and proper procedures are in place to prevent accidents or incidents.

3) What is Schedule ‘Q’?

Schedule ‘Q’ refers to the Owner’s minimum quality requirements for a Contractor or Subcontractor’s quality system. It outlines the specific quality assurance and quality control measures that must be implemented throughout the project to meet the owner’s expectations and standards. Schedule ‘Q’ typically includes requirements related to documentation, inspection and testing procedures, material control, personnel qualifications, record keeping, and compliance with applicable codes and standards. It ensures that the contractor’s quality management system aligns with the project’s quality objectives and meets the owner’s quality expectations.

4) What are the points to be checked before pipe fit-up?

Before pipe fit-up, several points need to be checked to ensure proper alignment and welding:

The weld surface and at least 25 mm (1 in) of adjacent base metal should be free from oil, moisture, rust, scale, paint, metallic coatings, or any other foreign matter.
Pipes and fittings should be placed on a secure temporary pipe bed or supports.
End preparation should be done properly to ensure proper fit-up.
Alignment, fit-up, and tack weld activities should be carried out to achieve exact pipe spool fabrication.
Important information such as Line Number, Component Heat Number, Joint Number, Fit-up inspection signature, Welder Number, Visual inspection signature, and date of welding should be marked near the joint using a metal paint marker.
For stainless steel and other alloy materials, markers with low lead, sulfur, and water-soluble chloride content (not exceeding 50 ppm) should be used.

5) What should be done in case of damage to received material?

In case of damage to received material, the following actions should be taken:

The damaged material should be placed in a designated quarantine area with visible identification.
An Over, Short, and Damage (O.S&D) report should be issued to document the damaged material.
A Non-Conformance Report (NCR) should be raised for materials with severe damages.
The Quality Control (QC) inspector should monitor all O.S&D and NCR issues and ensure that corrective and preventive actions are taken.
Non-conforming materials should be clearly marked, segregated, and controlled to prevent their unauthorized or inadvertent use.
The final disposition of non-conforming materials should be formally documented and recorded, indicating whether they are returned, repaired, replaced, or disposed of according to established procedures.

6) How will you store the material in the storage area?

Proper storage of materials is essential to prevent damage and ensure their integrity. Here are some guidelines for storing materials:

All materials should be handled with care during fabrication and installation to prevent damage.
End protectors should be securely attached to pipes, flanges, weld bevels, threads, and socket ends.
Pipes should not be rolled or dropped off trucks to avoid impact damage.
End bevel protectors should remain on pipes and fittings while in storage, ensuring they do not damage the internal or external coating.
Flange faces and threads should be protected from rust by applying suitable rust preventives.
After pre-fabrication, spools should be cleaned, ensuring they are free from weld spatters, arc strikes, and foreign materials on both the outside and inside of the pipes.
Lined and coated pipes and fittings should be lifted using wide fabric or rubber-covered slings, with padding used to prevent damage to the lining or coating. Wire rope slings should not be used.
Stainless steel (SS) materials should be covered and protected from water splash and other contamination during storage.

7) What are the ASME codes for Flanges?

The ASME codes for flanges are:

ASME B16.5: This code covers pipe flanges and flanged fittings up to 24 inches in size.
ASME B16.47: This code covers large diameter flanges above 24 inches in size.

8) What is the color code for the material? (standard)

The standard color code for materials is specified by the Piping Fabrication Institute (PFI) ES 22.

9) What is the code for PMI (SAES)?

The code for Positive Material Identification (PMI) is specified by SAES-A-206. It outlines the requirements and procedures for conducting PMI to verify the composition and quality of materials used in piping and other applications.

10) How do you inspect flush grinding?

When inspecting flush grinding in piping, the following steps are typically followed:

Any distortion resulting from the butt weld should be removed, and the surface should be ground flush with the inside diameter of the pipe. Penetrant Testing (PT) is commonly performed to detect any surface defects.
The inside surface of welded joints at orifice flanges should be ground or machined smooth to ensure proper flow and prevent turbulence or pressure drop issues.

11) What information can be found in a Piping Isometric drawing?

A Piping Isometric drawing provides detailed information about the piping system. It typically includes the following:

Line conditions: Indicating the fluid, pressure, temperature, and flow direction in the pipe.
References to drawings: Identifying other drawings or documents related to the specific piping system.
Materials of construction (Bill Of Materials): Listing the specific materials used for each component in the piping system.
Continuations: Showing the continuation of piping runs on multiple drawing sheets.
Orientation: Indicating the spatial orientation and alignment of the piping.
Piping and drawing details and notes: Providing additional specifications, dimensions, or instructions related to the piping system.
Revision control and approval status: Documenting any revisions made to the drawing and indicating its approval status.

12) What kind of inspection is required during gasket installation?

During gasket installation, the following inspections are typically required:

The QC Piping Inspector should ensure the cleanliness of the gasket surfaces of the flanges and check the condition of the gasket. Care should be taken to prevent the entry of debris into the pipe or equipment.
Prior to installation, the QC Piping Inspector should verify on-site that each gasket has the correct material, size, and rating according to the drawings and line class specifications. Each gasket should have an individual painted mark that identifies its rating number.
For gaskets with a size of 24″ and below, color coding should be applied to the outside surface of the gaskets. The mark should be approximately 1 inch in length and applied circumferentially.
For gaskets with a size of 24″ and above, marks should be placed in two locations.
Spiral wound gaskets should have three colors that identify the particular material specification, rating, and gasket with an inner ring, respectively.
During reinstatement, the QC Piping Inspector should verify that bolting is tightened according to the specifications outlined in JERES-L-351.
Before the hydro test and during lines reinstallation, the QC Inspectors should inspect that all permanent gaskets are installed correctly.

13) What is the difference between torquing of carbon steel (CS) and stainless steel (SS) bolting?

The main difference between torquing carbon steel (CS) and stainless steel (SS) bolting lies in their yield strength. Carbon steel generally has a higher yield strength than stainless steel. Yield strength is the stress at which a material begins to deform plastically, and it indicates the maximum stress that can be applied before permanent deformation or failure occurs. Therefore, when torquing CS and SS bolting, different torque values or tightening procedures may be required to achieve the desired level of tightness based on the yield strength and mechanical properties of the respective materials.

14) Explain spectacle plate?

Blind flange is used to isolate equipment or other piping during the leak test, need not be leak tested.

15) How many threads can be visible after seal welding threaded joints?

After seal welding threaded joints, ideally no threads should be visible. The purpose of seal welding is to provide a seal between the threaded connection, ensuring it is leak-tight. Seal welding involves filling the thread root with weld material, which eliminates the need for a sealing compound. Therefore, after seal welding, the threads should be completely covered by the weld material, making them not visible.

16) What is the basic difference between Pipe specification A106 Gr.A / Gr.B/ Gr.C?

The basic difference between pipe specifications A106 Gr.A, Gr.B, and Gr.C lies in the carbon content. The carbon content increases from Grade A to Grade C, as follows:

ASTM A106 Gr. A: Carbon content of 0.25%
ASTM A106 Gr. B: Carbon content of 0.30%
ASTM A106 Gr. C: Carbon content of 0.35%

The increase in carbon content affects the mechanical properties and strength of the pipe. Gr.C has the highest carbon content among the three grades, providing increased strength and hardness compared to Gr.A and Gr.B.

17) What is WPS?

WPS stands for Welding Procedure Specification. It is a document that provides the required welding variables for a specific welding application to ensure repeatability by properly trained welders and welding operators. The WPS includes information such as the welding process, base material specification, filler metal specification, preheating requirements, welding parameters (current, voltage, travel speed), and post-weld heat treatment (if applicable). The WPS serves as a guideline for welders to follow to ensure consistent and quality welds.

18) What is PQR?

PQR stands for Procedure Qualification Record. It is a record of the welding variables used to produce an acceptable test weldment and the results of tests conducted on the weldment to qualify a welding procedure specification (WPS). The PQR includes information such as the base material, filler material, welding process, preheat and interpass temperature, heat input, and details of any non-destructive and destructive tests performed on the test weldment. The PQR serves as evidence that the welding procedure has been qualified and meets the required codes and standards.

CBT Exam Questions for Welding Inspector