No UiKLMFL SD_AC&Y CONFIDENTIAL | sere | —| UNIVERSITI KUALA LUMPUR Malaysia France Institute FINAL EXAMINATION JANUARY 2011 SESSION SUBJECT CODE : FWD 32502 SUBJECT TITLE : WELDING INSPECTION AND TESTING LEVEL : DIPLOMA TIME | DURATION : 3.30pm — 6.00pm (2.5 HOURS) DATE : 09 MAY 2011 INSTRUCTIONS TO CANDIDATES 4. Please read the instructions given in the question paper CAREFULLY. 2. This question paper is printed on both sides of the paper. 3. Please write your answers on the answer booklet provided. 4. Answer should be written in blue or black ink except for sketching, graphic and illustration. 5. This question paper consists of TWO (2) sections, Section A and B. Answer all questions in Section A and TWO (2) questions in Section B. 6. Answer all questions in Engli ‘THERE ARE 17 PAGES OF QUESTIONS, EXCLUDING THIS PAGE.| ary2011 TION A (Total: 60 marks) “RUCTION: Answers all question and should be write in the OMR st provided in Appendix 1. Full Radiography is applied to metal with P no. 1 Group No. 1 when the material thickness exceeds A. inch B. 1.5 inch C. 1.25 inch D. 1 inch Whats the fluid use in Hydrostatic Leak test A. Gas, B. Water Cc. Oil D. Foam What is the meaning of A-number in ASME IX A. Represent group of weld deposit B. Represent group of material C. Represent group of filler metal D. Represent group of process What is the meaning of P-number in AMSE code and standard A. Represent group of filler metal B. Represent group of gas. C. Represent group of process D. Represent group of material Nhat is the difference between SA 36 and A36 A. Tensile strength B. Yield strength C. Difference Code and Standard D. Difference clauses V 02. WELDING INSPECTION AND TESTING CONFIDENTIAL (1 mark) (1 mark) (1 mark) (4 mark) (1: mark)JANUARY 2011 CONFIDENTIAL 6 — Whats the test pressure of Hydrostatic leak test in metallic piping system. A. Not less than150% times the design pressure B. Less than 150% times the design pressure (1 mark) C. Not less than 110% times the design pressure D. Less than 110% times the design pressure 7 Name the ASME code for qualification of welding procedure A. ASME 8 B. ASME 2 part A C. ASME 9 (1 mark) D. ASME B 31.3 8 — Whats the meaning of Random Radiography A. This applies only to girth weld B. This applies only to GMAW-S weld bead C. This applies only to girth and miter groove welds (1 mark) D. This applies only to welded with porosity 9 How many bend test specimen is needed to qualify a procedure for plate more than 10mm according to ASME 9 A. 2 side bend test and 2 face bend test B. 4 side bend test C. 2 side bend test and 2 root bend test (1 mark) D. 2 side bend test 10 Towhat construction does AWS D1.1 applies? A. To cover Steel structure construction B. To cover pressure piping construction C. To cover Pressure Vessel construction (4: mark) D. To cover Process piping construction 11 Which code governs procedure qualification for process piping A. ASME 8 B. ASME 9 C. ASME B 31.3 (1 mark) D. ASME 2 Part A FWD 32502 WELDING INSPECTION AND TESTING aName the ASME code for the design of Pressure Piping | JANUARY 2011 CONFIDENTIAL 12 A. ASME 9 B. ASME B 31 C. ASME B 31.3 (1 mark) | D. ASME B 31.1 | 43. What is the purpose of shielding gas in an arc welding process? | A. To eliminate hydrogen from the region of the arc | B. To retard the cooling rate of the weld C. To exclude the atmosphere from the region of the arc (1: mark) D. Alllof the above 14 Which of the following will vary the most when varying the arc length using MMA process? A. Voltage B. Amperage C. Polarity (4 mark) D. None of the above 15 According to ASME 9 Sec. QW 142, Radiographic examination may be substituted with mechanical testing for groove weld performance qualification, except or one process. What is the process? A. GMAW-G B. GMAW-P C. GMAW-S (1 mark) D. FCAW 16 Why is it necessary to carry out a welder qualification test? A. To ensure that the welder can weld B. To ensure that the welds can withstand extreme stresses C. To give maximum confidence that the welder can produce welds that meets the requirements of the approved welding procedure(s) (1 mark) D. To make sure that the welder can produce a defect free weld 17 What is the ANSVASME dimensional standard for steel flanges and fitings. AB 163 B. B16.5 C. B169 (1 mark) D. B16.10 _FWD32502 WeLDING INSPECTION AND TESTING 3JANUARY 2011 CONFIDENTIAL 18 19 20 24 22 23 What is the actual diameter pipe with NPS 20 A. 18 inches B. 20 inches C. 40 inches (1 mark) D. 60 inches After flame cut performed on bevels of low-alloy and intermediate-alloy steel what is the next step to do, before proceed to welding A. approximately 4mm of material shall be removed from the surface B. approximately 2mm of material shall be removed from the surface (1 mark) C. approximately 1mm of material shall be removed from the surface D. no need to remove Which electrode group does E 6010 fall under ‘A. Low hydrogen electrode B. Minimum tensile C. High strength electrode (4 mark) D. High impact electrode What is lamellar tearing? ‘A. Aproduct defect caused during steel manufacturing B. A type of crack which occurs in the parent material due to welding stresses acting in a short transverse direction of the parent material C. A type of crack associated with poor through thickness ductility D. A type of crack found in welds, which are subjected to cyclic stresses (1 mark) Why is preheat sometimes carried out on steels? A. To remove moisture from the weld preparation B. To retard the cooling rate of the weld C. To aid fusion between weld metal and parent material D. All of the above (1 mark) In a martensite grain structure what would you expect to increase: A. Ductility B. Hardness C. Toughness (1 mark) D. Allof the above FWD 32502 WELDING INSPECTION AND TFSTING ‘¢ ARV 2011 CONFIDENTIAL, Which of the following is not a type of crack? A. Fissure (1: mark) B. Lamellar tear | C. Fish eye | D. Hot tear | Why is welding procedure qualification test necessary? A. To ensure the welder is able to make-sound-welds meeting the requirements of the agreed welding procedure B. To ensure the welder satisfies the NDT and mechanical requirements of the specification C. To give maximum confidence that the welding variables are compatible and will produce sound welds meeting the requirements of the agreed specification (1 mark) D. To give a guarantee that a defect free welds are going to be produced Aside bend test, is to test for: A. Fatigue fracture strength B. Lack of side wall fusion (C4 mark) C. Toughness value D. All of the above Maximum allowable limit for butt welding of piping components with internal misalignment A. 1.0mm 8. 1.5mm (1 mark) C. 2.0mm D. 2.5mm What is the range of temperature of Carbon steel use for ASME B 31.3 | A. Limited to 800°F B. Over 800°F C. Limited to1100°F with reduced allowable stresses an D. Over 1100°F with reduced allowable stresses What is the preheat temperature for material in P No. 6 A. 400°F rk) B. 200°F - 400 °F cs ae ©. 250°C D. 200 °C - 400°C. ., 802 WELDING INSPECTION AND TESTING 5JANUARY 2011 30 31 32 33 34 35 ‘What js the length of reduced section of reduced-section tension specimen according to AWS D1.1 A. Widest face of weld + 1/2" (12mm) B. Widest face of weld + 1” (25.4mm) C. Widest face of weld + 1/2" (12mm), minimum 2 4/4” (60mm) D. Widest face of weld + 1° (25.4mm), minimum 2 4/4” (60mm) The term of PIPING refer to the... A. overall network of pipes included flange, fitting, valve and other system to convey fluids. The length of pipe all diameter The pipe below NPS 2 inch The pipe above 2 inch. con Pressure tube normally involved with. internal heat applications as in boiler or superheaters external heat application as in boiler or superheaters. Atmosphere and internal heat application as in boiler or superheaters Atmosphere and external heat application as in boiler or superheters. o op> ‘The diameter of pressure tube normally produces by measured... actual inside diameter actual outside diameter actual wall thickness average outside diameter com> The pipe indicated with API SL is normally use for. A- high temperature service B. low temperature service C. moderate temperature service D. line pipe for transmission service What is actual outside diameter of NPS 2 A. 2inch B. 25mm C. 2.50 inch D. 2.374 inch FWD 32502 WELDING INSPECTION AND TESTING CONFIDENTIAL (1 mark) (1 mark) (1 mark) (1 mark) (1: mark) (4 mark)JANUARY 2011 CONFIDENTIAL, 36 The term of schedule (Sch) was invented to specify A. the outside diameter of pipe B. the inside diameter of pipe C. the nominal wall thickness of pipe D. the average outside diameter (1 mark) 37 Diameter nominal (DN) calculated in unit of. centimeter millimeter inches meter (1 mark) gom> 38 According to ASME. 831.3, minimum temperature for pre-heat | temperature recommended for material with P no. 1 with nominal wall | thickness < 25mmis...... | A. 10°C | B. 25°C | ©. 30°C D. 60°C (1 mark) 39 Heat treatment shall be according to ‘A. Material grouping B. Thickness range C. Material grouping and thickness range D. Material grouping, thickness range and batch number (1: mark) 40 According to ASME B31.3, examinations perform by manufacturer only cover for. : A. girth weld B. longitudinal weld C. components only D. butt weld (1 mark) 41 What type group of material which can perform by Magnetic Particle Examination A. SA 106 B. SA358 (1 mark) Cc. SA249 D. SA213 FWD 32502 WELDING INSPECTION AND TESTING 7JANUARY 2011 (CONFIDENTIAL 42 The permitted misalignment according to ASME B31.3 is. 1/32 inches 1/20 inches 4/16 inches 41/8 inches (1 mark) gom> 43 Who is owner's inspector? A. manufacturer inspector B. erection inspector C. fabrication inspector D. an employee of the owner (1 mark) 44 The changing of groove design in Welding Procedure Specification (WPS) is categorize as.. A. Essential variable B. Non-essential variable C. Supplementary essential variable D. Changing with permit (1 mark) 45 How many specimens are needed to qualify Welding Procedure Specification (WPS) for plate less than 8mm? A. 2 pieces B. 4 pieces C. 6 pieces D. 8 pieces (1 mark) 46 What is the grouping of electrode with AWS classification E 7018, AFI B. F2 Cc. F3 D. F4 (1 mark) 47 Whats the main purpose of Welding Performance Qualifications. A. To qualified the welder B. To qualified the welding operator C. To qualified the welding procedure D. AandB (4 mark) FWD 32502 WELDING INSPECTION AND TESTING °JANUARY 2011 CONFIDENTIAL 48 49 50 51 52 53 _..used is to transmit the wave from prob to specimen. air couplant glue ferrous partical (1 mark) 9Op> Dye penetrant examination is very effective to detect A. surface defect — B. open surface defect C. sub surface defect D. A,B, and C (1 mark) Medium for Hydro test A. Oil B. Water C. Air >. Gas (1 mark) What is PQR (Procedure Qualification Record) A. Arecord for welder during welding of the test coupon B. A record for welding position during the welding of the test coupon C. A record of variables recorded during the welding of the test coupon D. A record of variables recorded during the welding of the specimen (1 mark) Which of the following is not on a typical written welding procedure? A. Joint preparation B. Amount of stress C. Preheat D. Consumable filler material (1 mark) What is the UTS value of a material ? A. The fracture point of a material B. The fracture point of a material C. The proof stress of a material D. Both a and b FWD 32502 WELDING INSPECTION AND TESTINGJANUARY 2011 CONFIDENTIAL 54 Temp stick is use to .. A. write on specimen B. determine the surface defect . determine pre-heat temperature (1 mark) D. determine welded temperature 55 Which one is the most dangerous light source. A. Gamma ray B. Ultra violet light C. Infra red light (1 mark) D. Welding arc light 56 Whatis the value of heat input if the Voltage -18, Amperage - 110 and travel speed (mm) - 1’ 30” 1.50 kJ/mm 1.32 kJ/mm 1.40 kJ/mm (1 mark) 1.52 kJ/mm com> 57 Which of the following NDT methods would be the least effective on a butt weld made from austenitic stainless steel A. Dye penetrant B. Radiography C. Ultrasonic (1 mark) D. Magnetic particle 58 Which mechanical test(s) can be used to make an assessment of surface breaking defects A. Bend test B. Nick break test C. Macro test D. Alllof the above (1 mark) 59 What is the term used to describe the ability of material to be drawn into wire without fracture ? A. Plasticity B. Ductility C. Elasticity (1 mark) FWD 32802 WELDING INSPECTION AND TESTING 10Ry 2011 CONFIDENTIAL, as D. Malleability What does the number 70 represent on an E7010 AWS classified electrode? A. 70 Nimm? minimum UTS (1 mark) B. 70 N/mm? minimum impact strength C. 70,000 p.s.i. minimum UTS D. 70,000 p.s.i. minimum yield strength og '2502 WELDING INSPECTION AND TESTINGJANUARY 2011 CONFIDENTIAL SECTION B (Total: 40 marks) INSTRUCTION: Answer TWO questions only. Please use the answer booklet provided. Question 4 a. What is the purpose of heat treatment and what is the suitable holding time for material with P number 9 and nominal wall thickness > 19mm? —_(10 Marks) b. When the Leak Test is required and what is the pressure limits if a , (6 Marks) combination of hydrostatic-pneumatic leak test is used. c. What is the particular shall be taking into account for each piping system during the test. (5 Marks) NOTE : All answers to be in accordance with ASME B31.3 Question 2 a. What is the status of Unknown material in construction of boiler piping contains a pressure. mir (5 Marks) b. What is the procedure of making Fillet weld and sketch the typical minimum fillet weld for SO and SW components. (10 Marks) c. Who was performing the inspection jobs. (5 Marks) NOTE : All answers to be in accordance with ASME B31.1 WD 32502. WPLDING INSPECTION AND TESTING vJANUARY 2011 CONFIDENTIAL, Question 3 a. When the incomplete filing shall be consider as defects and give another name for incomplete filling. b. What is the meaning of repair and list down the procedure to repair a (5 Marks) crack area? (10 Marks) c. List down the requirements of bend test for butt weld. (6 Marks) NOTE: All answers to be accordance with API 1104 Question 4 FRORISD PR oR aR CYC Sele GTA a. Can the propose PQR be made from the example + POR 2 + PAR 3 b. Considering the individual deposited thickness as per the proposed PQR, (2 Marks) give the maximum allowable thickness as allowed by ASME IX. c. Can SMAW process be used for proposed PQR, through thickness. (9 Marks) NOTE: Refer to appendix 2 attached (9 Marks) END OF QUESTION FWD 32802 WELDING INSPECTION AND TESTING 13JANUARY 2011 APPENDIX 1 CONFIDENTIAL QW-St_ Procedure Qualicaton Thickness Lins and Test Specs awash SGROOVE.WELD TENSION TESTS AND TRANSVERSE BEND TESTS Tae dae Tp tn dos Fos So eal tet nun cisco Stn ae Ten ea inn gy ose We a eg Fae ids 70 ca, oD ites Tenant ete eto ibe tne 20 Weis aieo evita oto Tee) 7 7 7 ay Soe015030 a 2 2 mere) 2a i ere nsonisdn% ——%I5)aF z 2 weiss 22 & ‘eu9 wleseans400 aig) ar zene 00 ateriay uvememrion ga ite Hiwetas 3 1428) an nt aor nares (3) stositlwe Gn zen a9) 2 ite (3) Goo) ae GN s Goole Wistenr2 Cay) 2 oe ll (3) The ete arabes tamer sic ins sho fs abe ten tea eee G.250 fr pees wt center: Qann2 2.10, Q-4083, a (sor. sa, QH-222, 2023, ans qN.22« protege at pete Ens of ale {21 Fr conan ef weling pct 0-200. (5) Far fe wig process of 037 eerie per Me 27, 2 cee be pale 4 See Gas, Qvas.2, a4 Gash. fr deals on mip specie ie cap fhe eet 25 em (5) Forse bend es mye ated fre rege ae at rncberd ws, men kes 15%, 0 ta FWD 32502 WELDING INSPECTION AND TFSTING “4