Rate
Technical Knowledge (Mechanical, GC-12)
Quality Systems
1. Describe the
difference between QA & QC?
Answer: Quality
Control is the operational techniques (Inspection, Examination & Testing)
that are used to fulfill requirements for quality. Quality Assurance is the system of action and
planning needed to provide confidence that a Product or Service will satisfy
quality requirements
2. What do quality
system audits evaluate?
Answer: The degree of quality system conformance to
established requirements.
3. Saudi Aramco has
adopted
the basic framework and definitions of the International Quality System
Standards ISO-9000 Series. This has been
done to provide universal understanding and improve communication between the
COMPANY and prospective CONTRACTORS whose Quality System is congruent with the
ISO-9000 Series. Describe
the basic elements of an ISO 9000 Series Quality Program?
Answer:
Quality Management & Quality Assurance Standards per ISO-9000
Quality
Systems per ISO-9001, 9002, 9003
Quality Plan
Guidelines per ISO 10005
Mechanical/Welding
4. What is an
essential variable as related to a Weld Procedure Specification (WPS)?
Answer: A change in a welding condition that will
affect the weld’s mechanical properties.
5. What is the
relationship between a Procedure Qualification Record (PQR) and a WPS?
Answer: The PQR documents what occurred during
the welding and testing of the test coupon.
6. Heat input (SMAW
per ASME IX) is a combination of what two electrical characteristics &
travel speed?
Answer: Voltage and Amperage
7. Excessive heat
input is mainly attributed to what poor welding techniques during SMAW process?
Answer: Excessively wide weaving and slow travel
speed.
8. What are 3
potential sources of Hydrogen encountered during SMAW process?
Answer: Moisture in the metal and electrode coating,
oil, elemental Hydrogen in the base metal
9. What are several
likely causes of porosity in carbon steel welds using the SMAW process?
Answer: Poor welding technique and equipment, excessive
wind, moisture & weld contaminants.
10. What dimension
is measured to determine the size of a concave fillet weld?
Answer: Throat
12. What dimension
is measured to determine the size of a convex fillet weld?
Answer: Leg
13. Where would
cracking most likely occur from excessive current input in a single pass weld?
Answer: Centerline of the weld
14. Using GTAW
process, describe what happens to a weld without proper purging/back gassing on
SS material?
Answer:
Oxidation at the
ID (Sugaring)
15. Name 3 of the 5
mechanical tests in ASME IX employed for procedure & performance
qualifications?
Answer: Tension, Guided Bend, Fillet-weld,
Notch-toughness & Stud-weld tests
INTERVIEW ATTACHMENT w/ANSWER KEY
Rate
Technical Knowledge (Mechanical, GC-12)
Mechanical/NDT (assume SMAW
process used for all questions)
16. How is Magnetic
Particle inspection of a weld using the wet continuous test method performed?
Answer: The particles (usually fluorescent) are
sprayed, poured on or applied by immersion and the magnetizing current is
applied while the particles are still flowing.
17. Indications
with Liquid Penetrant Testing are easily seen if the surface has been prepared
by grinding prior to testing? True/false? Why?
Answer: False, because grinding can smear metal
and mask/cover discontinuities.
18. Name an NDT
method and technique that employs a reflected sound beam
that can be used for the volumetric examination of welds?
Answer: Ultrasonic Testing using Shear Wave
Technique provides good volumetric exam coverage.
19. List 3
disadvantages of RT over other NDT Methods.
Answer: Radiation Safety
Precautions, Planar defects not readily detectable, Heavy equipment
20. If a product is
to be stress relieved, why is it important to use exactly the same RT procedure
before and after stress relieving?
Answer: So that a baseline evaluation is performed to
ensure that borderline indications are not misinterpreted after stress relief.
21. A dark narrow
area 2-3mm wide appears on a radiograph all along the edge of the area
representing the weld. The joint has a 60-Degree double-vee groove. What is the indication most likely to be?
Answer: External Undercut
22. A localized
darker density Radiographic image with fuzzy edges in the center of the
width of the weld image that may or may not be wider than the width of the
root pass image is most likely what?
Answer: Burn-through
23. Name 5 common
film artifacts that may be cause for rejection of Radiographic Film?
Answer: Film Scratches,
light leaks, chemical stains, fogged film, static marks, water marks, streaks,
crimp marks, finger marks, lint, dirt
24. 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?
Answer: Panoramic
25. How do gamma
rays compare with X-rays when applied to RT of welds?
Answer: Gamma rays have greater penetration ability,
but give poorer contrast.
Rate Specific Knowledge
(Experience)
26. Per ASME B31.3
(assume latest edition), name three of the four Categories of Fluid Service?
Answer: Categories D, M, High Pressure &
Normal
27. Per ASME B31.3,
who is responsible for classification of service to a given category?
Answer: The Owner
28. Per ASME B31.3
(assume latest edition), what are the RT requirements for Socket welds in
severe cycle service?
Answer: None
29. Relating to the
above question, Give good reasons why random RT of socket welds is recommended?
Answer: Both gross welding defects & poor quality
welders can be identified, with repairs and corrective action taken, & Gap
can be verified.
30. Briefly
describe good QC practice relating to the installation & bolting of
flanges?
Answer: Verify Materials
(type, size and rating) are acceptable, gasket verification & good bolting
practices (torque value requirements met) in accordance with approved
procedures.
31. What is an
often-overlooked Inspection/NDT requirement on the installation of an orifice
flange?
Answer: Visual weld inspection of the seal weld
& NDT has been missed prior to bolting of flanges
32. Per
ASME Section VIII, Div. 1, can a nozzle to be attached to the exterior surface
of a pressure vessel without any portion of the nozzle projecting into the
shell?
Answer: Yes, with many restrictions
33. Explain the difference
between a 2:1 Ellipsoidal head and a hemispherical head?
Answer: A hemispherical head has no flange and knuckle
region and holds greater volume.
34. Which of the
above two heads given equal thickness can withstand greater internal pressure?
Answer: The 2:1 elliptical head can withstand much
more internal pressure given equal thickness.
35. In ASME Section
VIII, Division 1, Parts UW and UCS cover what scope of work?
Answer: UW designates requirements for pressure
vessels and vessel parts fabricated by welding, and UCS designates requirements
for pressure vessels and vessel parts constructed of carbon and low alloy
steels.
36. Name several
Inspection items on internal component/tray installation for new columns?
Answer:
1.
Drawings, Calcs & Data review
2.
Verification of Material Construction
of Internal components (tray assemblies & systems, hardware, packing
medium)
3.
Location, levelness and orientation of
internal components per Mfg. Drawings/tolerances.
4.
Seams, holes, gaps, missing items,
looseness of hardware in trays
5.
Leakage Tests as needed for trays,
troughs, weirs, etc.
6.
Final Cleanliness of Tray Assemblies
37. What API
documents apply to the replacement of an existing floor for an Aboveground Oil
Storage tank?
Answer: API 653 & API 650
38. What are two
key items to be resolved prior to addition of new nozzles to older tanks per
API 653?
Answer: Tank Material
identification, Material Design Considerations & selection (need for shell
insert).
39. Briefly
describe an area impressed Cathodic Protection System?
Answer: Electrical current & use of
selectively placed sacrificial anodes is employed to stop/slow the
electrochemical reaction that occurs during the corrosion process.
40. Relating to
Contractor Weld 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
assigned to approve the shop for Company?
Answer: 5M + E formula
= Manpower, Methods, Materials, Machines, Measurement, Environment
1.
Manpower=Ensure adequate Personnel
that are trained, qualified, certified & approved
2.
Methods=Ensure that standards are
followed and that welding procedures, special processes (PMI, PWHT, etc) are
acceptable and that there is a good quality system (paper trail) in place.
3.
Materials=Ensure Materials are
approved, certified, documented (traceable), stored correctly with area for
deficient items (quarantined), and segregation of dissimilar metals.
4.
Machines=Ensure Equipment is adequate
for the intended work and in good working condition.
5.
Measurement=Ensure Contractor QC
Program & testing/calibration program is in place for equipment and
work.
6.
Environment=Ensure that the working
environment (building) is safe, sheltered from the elements and adequate to
ensure quality work.
Per SAES-W-011
(show section where information is found, review with candidate)
1.
What is the maximum size of low
Hydrogen (E7018) permitted?
2.
What are the diameter limitations (per
pipe size) for different welding processes?
SMAW=
GTAW=
GMAW=
3.
a) What is the requirement (Material,
location) for bridge tacks?
b)
In what must bridge tacks be contained to avoid the need for Surface Method
NDT?
4.
a) For temporary supports and
attachments welded to the pipe, what are requirements related to Material?
b)
NDT?
5.
What is the maximum amount of time
that E-7018 electrodes can be kept out in the field?
6.
What is the minimum drying temperature
and drying time?
7.
How many times can electrodes be
rebaked?
8.
What is the maximum internal
misalignment of butt joints?
9.
Piping during preparation before fit
up shall be cleaned/ground internally/externally for what distance from the
edge of the prepared joint?
10.
Moist surfaces require moisture
removal and surfaces to be preheated must be preheated to what distance from
the joint edge?
