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Quality Systems
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1. OescriS~,the difference b e i w e ~ nQA & QC?
Answer: Qceliv Control is the 0para:ional : e c h n i q u ~(Insp~c:icn.
~ Exrninaiicn & Testing) R a t arc
cszd to fuliiii requirenesis :or qudiiy- Q u ~ l i i yC.sstlrence is the sysiem o i action and plafining
needed to provide confidence ;ha[ 2 Praduclor Service will s a l i s quality
~ requirements
2. ~ ' l :dc~qualily
~ l system audits.evaluaie?
Answer: Tns degrse oi qc2lity.sys:ern conformance to esra9lisher' requirements.
3. Szudi .?\rarncohas adoptzd the besic framework and definitions of the In:er.%?tiOc21 Quality System
Standards !SO-9000 Series. This has been done to provide universal ~nsersiandingand improve
Y prospective CONTaACTORS whose Quality systarn is
communication behveen the C 0 k l i ) ~ b ~and
mngrCent with the ISO-9000Series. Desoibe the b~sic,elementsof 20 IS0 a000 S2ries Quality ?ragram?
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, Answer:
.j

Oaiaii>!t4anacenen.t & Ouzlip, p.ssur=r,ce Sirneeids Fer ISO-3rJGI)

o u a ! i r ~Svsiems per ISO-9001. 90C2. 99G3
Oueli!v ?Ian Guidelines per I S 0 10CO3
! ;
hlccl~anical~~rldi~~~
6 . b'lhat is an essential variable 2s rela;ed to a Weld ?:acedura Soecificaticn (WPS)?
Answer: A change in 3 ~ ~ e 1 3 i ncondi;i=n
g tke; will afiec: the wtld's nsc3anical ~ r o p e n i e s .
i.
Wha: is !he rclatronship bewleSn 2 .'irre '
Ouelification 8zcord (r7Q3)and a WPS?
.<
Answer: The POR docgmen:5 \.,:.a; occurrod during the u1elcir;g and testing of :he resl coupon.
s. s e a l input (SMAW per ASME 1x1is comjir;a:ion oi what two electric~lcharacteristics 8. travel speed?
Anst-ley: Voltage and Amperage
7. Excessive hea! input is mainly anrijuted to what poor walding techniqczs du:ing ShIAW ??OC~SS?
Answer: Excessively wide wsaving acd slcw tiavel spsad.
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' ,. -,.' r r.~ : 7 3 ~ ~ r c n : i a C . s o u0r cHydropar,
~s encounterzd during SMAW pr,3cass? . . . ,. .. ; . . ; ,..r:i.:,:..T , . : . i c . j - . i . i ; ~ :
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Answer: Mois:urc in the n t a i 2nd eiec;ro& ccaiing, oil, elenen!el Flydrogen in the base metal
9.kvhai ars s;vs:al likely Causes 01 POrOjityin c a i j c n steel welds using the ShIA\N ~ ~ O C P S S ?
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Ansu~er: Poor welding technique 2nd equipment, excessive win?. rnois,ture & weld c3n:aminan:s.
'13.What dimension is measured delermina :he s;ia of a concave i i ~ ! f i tweld?

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Answer: Throat . . . -,.. ...
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! . a c=nva:: iillet weld? a
; What dimension is measured to ,je[ernine the sirs t d d '

- b ' h e r t would cracking most lik2iy occc;

.#a. Answer: I-eg
from excessive curien: ir?pl~tin a single p2sS wdd?
Answer: Centerline of the weld . .
14. Using GTAW process, describe r ~ h zhappens
t to a weld without proper purginghack gassing On SS
marerial?
h s w e r : Oxidation at the 10 (Sugaring)
1 5 Namg 3 if
the 5 mechanical tests in ASME IX employed'for procedure & performance qualifications?
Answer: Tension, Guided Bend, Fillet-weld, Notch-toughness 8 Stud-weld tests ' ' - . ..

INTERVIEW AnACHMENT w/ANSWER KEY . . . ...

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Interviewer(s): . .
Rate Technical Knowledge (h.lechanica1, GC-12)
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MechanicalMDT
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(assume SMAW process used for all questions)
.fi.16:. How is Magnetic Particle inspeclion of a v e l d using the wet conlinuous test method performed?
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.... . Answer: The particles (usually fluorsscent) zre sprayed, pourad on or a3plied by immersion and
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.'-' the magnetizing current is applied ::.bile In€ panicles ar? still flovling. ..
17(lndications With Liquid.Penelran1 Tasting ars easily sean ii tnz surfaca hes been prepared by grinding
- prior to testing? Truelfafse? Why?
5. Answer: False, because grinding c t n smear natal and mask'cover disconiinuities.
1 8 . ' ~ a r n ean NOT method and technique [ha; ~ m p l o y sa ra!lec:ed sound beam lhal can be used for the
volumetric examination of \velds? ..
Answer: Ultrasonic Testing using Sha=r Wave Technique provides good volunelric exam covzrage.
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!List 3 d i s a a v a n ~ a ~ eosf AT over other FIDT kI~!hods.
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Answer: Radiation Safety ?rc-cautions.:~=ardafects no_! readily delectable, Heavy equipment
20. If a product is to be stress relieved, why is il imporiafit lo use exactly the same RT procedure before and
after stress relieving?
~nswe;: So that a bcseline evalualion Is performed to cnsura lhal borderline indications are not
misinterpreted after stres's relief.
21. A dark narrow area 2-3mm wide appears on a radiograph all alonq the edoe of Ihe area rspresenling the
I weld. The joint has a 60-Degree double-vee groove. What is ths indication most likely to be?
. Answer: External Undercut
22. A Iccalized darker density Radiograpn~cimage with f u u y edges h t h e center of the width of the weld
image that may or may not be wider than rha wid:h 01 (haroot pass image is most likely what?
Ansrver: Burn-through
23. Name 5 common film afiilacls that may be cause far rejection of Radiographic Film?
Answer: Film Scralches. ligtlt leaks, chemical stains. iocged film, static marks, water marks.
streaks. crimp marks, finger marks, lint. did
23.4Vhe.n the, radialion source is localed insi.de,pi?i(.lg wi:? tbg film
. . . . . , !ocaled outside,
,-- . .
single-wall exposure and
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single~wallviey, name this Qpe of exposupe?-

Answer: Panoramic
. ~ s . . H o wdo gamma rays compare with X-rays when applied lo RT of welds?
$ ;
Answer: Gamma rays have greater penelralion ability, but give poorer contrast.

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Rate Specific Knowledge (Experience)
26. P e r ASME 831.3 (assume latest edilion). nams threz of the tour Categories of Fluid Service?
Answer: Categories 0,M , High Pressure Fi Normel
27. Per ASME 831.3; who is responsible for classiiication of service to a given category?
~ n s w e r :The Owner
28. Per ASME 831.3 (assume lafesl edition), what are the RT requirevenis for Socket welds in severe cycle
. servcie?

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 I
corr&tive action taken..& Gap can be verified. .
describe good QC practice relating to the installation & bolting of flanges?
er: Verify Mateiials (type, size and rating) are acceptable, gasket verification 8 good bolting

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practices (torque value requirements met) in accordance with approved procedures.
a1 is an often-overloo~edl n s p & c t i o n / ~requirement
~~ on the installation of an orifice flange? .
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17:;~ h z ist the Saudi Aramco ieGuirtnenl ior Hzrdnass Testing sfier.heel trzttmsnt? Is 100% required for.
$2
- .t:;. P-I? i
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Requirsd is Hardness Tss;ing per 14.1 requiremenrs (100?'0). Heal-trsa:ed P-1 welds requires
lOO%BHT.
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< 8,I. J I f hardness limits are speciiied and hear ireri07entis requirzd b y fluid ssr~ice,how long must production
. . .:I.. welds soak?
..
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:
. 80% o f the soak time indicziec! ifi !:,a PO2 u n l i r s zpprovsd b y CSD ( 1 Z.8.c)
19 What is the maximum hardness for P-1 malerials aher heal trcatmanl?
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, - 225 BHN for sweet service, 200 8Hf.f ior sour sarvice (la. 1)
20 ARer cornple(ion o l heal treatmer~t& TC rc~noval.\!ha1 surface condilion is required for visual
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inspection?
- The surfaces where TCs \./ere removed must be yround smooth to clean and sound metal. ( 1 3.20)
21 rz 'ardness testing a[ Aramco is mendarory &.must f.r.!low les:ing guidelines cii what common
recL.r/mended practice?'
NACE RP0472 Appendix A ( 11.3)
2 2 The temp range within the heated zone shall exceed minimum holding temp for all TCs. TrudFalse?
Max. Spread?
- True, and lhe spread maximum allovted lor all TCs is 40 degrees C. (13.9)
23 Saudi Aramco allows b o types o f heal sources lo be used lor heat treatmenl. What are they?
Permanent or semi permanent furnaces (g2.s. oil, electric). Electrical resistance heaters (13.1 1)
24 : How sliall multipoinl chan recoc :learly iden!ii)! each poinVchannel? Each welc?
..- .' Colored inks or automatic number stamping ID.sach-channel. Dated charts with Unique ID n's are. . . .. .. .-
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needed for each weld trealed. (1 3.1 3)
25 How far away must the junction ( b e h v ~ e na coppcr.Cons:anlan compensating cable and Type K,
Thermocouple Lead) be located.irom the r d being heal treated when a Copper-Conslanlan compensating
. ..

cable is used?
- Answer is 'iz meter ou!side the insulaled aree. unkna*,vn !rom the weld. (13.1%)
. . . .
26'' H ~ okenmvst
G temp r e c o r b r s ba calibrated?
. ..
t - Every three months (1 3.14)
When heat treating piping. why must ends be closed off?
;:! <
, , T o eliminate drafts or air circulation that could lower temperatures (13.18)
28.:-What are the Saudi Aramco requirements regarding restraint and support of piping during heat
treatment? . .
j. . . .
Free expansion/czntrac!i=.?. and suitaSldsuf!icienl su;~o."ls are required (13.16)
I.

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29 What is an acceptable protection against thermal oiidalion lor flange serralions. threads. and bollholes?
Deoxaluminite applied carefully and evenly over exposed nieas (13.17)
30 w h o will be responsible to see that MT or PT exams are performed as requi;ed, i f specified by
Inspection after TC removal and grinding?
The Contractor QC Inspector v:il! Se require5 tc see that [his is.-.r
nerforrned any time h e feels the
eed, or if specified by SA Insp8ction. ( 1 3.20)

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 2. Per ASME Sectioa V111, Div. i. ;an 2 nzzzle to 32 a:zcned to the exterior,suhace of a pressure vessel
' t h h any portion of the nozzle projecting inlo Ins sh?il?
I

. Answer: Yes, with many reslrictions

3. Explain the ditierance bsrusen a 211 Ell~psoic'.-lhcad and a hemispherical head?
Answer: A hemispherical heed has na i l r n g r 2nd k,~uckl; ragion and holds grzater vdume. ' '

i.,:Which of the above hvo h a ~ d given

s ~ q u zthickness
l c2n withstand greater inl;rna!'pressure?
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Answer: Tha 2:l elliplical heed can wir5slnn5 nucl, more inlzrnal pressure given equal thickness.
i. In ASME ~ e c t i o ~ ~Division
l l l . 1, Pans UW and UFS cover wQat scopa of work?
Answer: UW designzles requiremenis for prsssurs vessels and vessel parls fabricalad by
welding, and UCS designates rsquirsrnents lor pressu:~vessels and vessel parts constructed o f
carbon and low alloy steels.
' Name several Inspection items on inlernsl'conponanr:t:zy ins:sllation for new columns?

fl- Answer:
- 1 Drawings. Calcs & Data (evieiv
2. Verification of Malerial ~onstructionof Internal components (fray zssemblies 8 systems.
hardware. packing medium)
3. Location, levelness and orientalion o l inlernal componenls per Mlg. Dra.~ingslloleranccs.
4. Seams, holes, gaps, missing items. loosctiess of hardware in trays
5. Leakage Tests as needed for !r2);s. troughs. v~eirs,elc.
5. Final C1eanlines.s 01 Tray Assemblies
..WhaT API documents apply 10 the . ..;emen( o i an sxisting lloor for an Aboveground Oil Storage tank?,
. . . . Answer.c...AS!653.84?!.650. . . . . . . . . . . . . *. . . . . ..: .,"
.W h a t are two kay items lo be resolved prior to addition o l new nozzles to older tanks per API 653?'
Answer: Tank ~ a i e r i aiddntilicalion.
l Material Gesign Considerations & selection (need lor shell
,: insert).
. Briefly describe an area inipressed Cathodic Prol-.ction Syslern? .
Answer: Electrical current & use ol salectivefy placed sacrificial anodes is employed lo stop/slow
,.1.efectrcxhemiczl reaction that occurs during tha corrosion prscess. -. .
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. Relating t~Contractor Weld ~ h c cvnluatton
p prior to th;? 6&ginninb ot.ij.ifiev~eldingfora'inijb; project;
at are several key items you would look lor as [lie Inspector assigned to approve the shop for Company?
Answer: SM + E formula = Manpozer. hlilhods. Materials, Machines, f$easurern:nl,, Environme~t-
I
.... > . .. 1. Manpower=Ensure adeq;ale Personnel that are.trained. qualified, certified 8 approved
. . 2. Mellfods=Ensure [hat standards are followed and lhal welding procedures. special processas
(PMI. PWHT, P!C)are ac~sptab!,oax! !ha there is 2 good quality sys!en (paper Ireil) in place.
3. Materials=Ensure Ma(prisls are approved. certifiad. documented (traceable), stored correctly .
with area for deficient items (quarantined), and segregation of dissimilar metals.

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. 4. M a ~ h i n e s ~ E n s u Equipment
f
re is adequaia for Ins intended work and in good w0rkir.g condition.
:.... 5. Meas,urembnt=~nsureConlractor OC Program '8 lesting/calibration program is in place lo?

$&g8
S.
il c
6.
ehuipmknt and work.
Envimnmenl=~nsurelhal [he working eovironnenl (building) b2afe, sheltered lrom lhs
elements and adequak to ensure qu2liI-y work. ;lir M ,,&&.& '

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1.

CSAES-W-01 1 (show gection where informztion is found, review with candidate)

Hydrogzn (E7018) permitled? 3 I

(per pipe size) lor diHerent welding processes?.

i
 b W 0-1 je6~a aql WOJJ ajuels!p
laqAt 01pareeqe~daq :snw palesq2~daq 01 sa3eljns' pun i ~ r ~ o w aJ!nba~sa3epns ls!oW
IJ~~~S!OW
a~

6u&p lonu!u!w aql s! leqM

' a w l 6u!hp pue e~nrz,'adur~~
 er SAES - Vim0 i i . .

. 1/,%3t is t-,s maximi~lnsize of low hyciragen (E7CI18) pe;rrlitted?

5mm for th2 ~ G / I Fpo5itian, 4n1m other positbas

For non-hydrogen; 5mm for all positions
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. What are the diameter limitations (per pipe size) for the different welding processes?

SMAW GTAW
3" up '/2,' to 10 ' .

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. d,.Bt is the requirement (Material, location) for bridges tacks?

I t should be same materials, electrodes, minimum preheat and must be made completely within the
weld groove, and shall be removed prior to the completion of the weld.
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. or temporary supports and attachments welded to the pipe, what are requirements related to
Materials? NDl?

Temporary attachments, grounding lugs or supports welded to the pipe shall be made with a
cornpatible_material,and it should be removed after welding, cleaned and PT.
,I
i
. What is the minimum amount of time that E-7018 electr~descan be kept out in the field? .

May not be exposed to atmosphere for more than 2 hours.

, What is the minimum drying temperature and,drying

. . time? .. . . . .. . .., . ,.

All electrodes shall be dried'at 260-430*C for 2 hours minimum.

. t many.times can electrodes be rebaked?

Electrdes ma\j be .re-baked only once.

What is the maximum internal misalignment of butt joints?

.Internal misalignment shall noL exceed 1.5 rnm.

Piping during preparation before fit-up shall be cleaned!groclnd int=rnally!externally for what
distance from the edge of the prepared joint?

c::6,ir.d inicrn~l!y!wt.n:aIly T;?; at ieas: 25 mm of adjacerl; base me;?,! y i o r to welding an< it should
! e n I.

. Moist surhces !$:.rui;s imijtcre removal and sul%'z? PJ be preheatit+ must be pmheated to what
disbnce from ti8jeb:t edge?

100mk iron; :he welC joi17;:.

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Systems
llit~
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Rate. Technical K n o w l e d g e (Mechanical, GC-12) .:-..-.%'t

Answer: Qcelib Conl:d is :,?2 oceratlcnzl iechnique~(Ins??c:icn. Exenin2:icn Tas:ing) thzt nre
Cst"o iuliiil requir.n=n;s :or ~ c d i ? .Ou=Ii;y
~. k s s u r ~ n c eis ths systen oi ection and pl2r;ning
nesded lo gravid? coniide,ncs $121 2 ?:acuct or S e w i c ~will satiss{ .jc;udity requirements
':121dc ~ p a l i i ysysien 2udi;s.-=valuais?
Answer: Tina degree o i qcelity system conforn?anc= to esia9lisked rec;uiremerits.
? u l i.\r2;;l:o has 3dopts-j ;he b ~ s i cfrzmework 2nd d2finiiions 0:the Is;er.Z2!ior,2[ @uality S y s i e n
dards !SO-9000 Series. This hss been dcne to provide universal ~:nlsrsiandingand improve
~ u n i c e t i o nDeP.ue5n :he COh.l?~,tlYand prospac!iv? CONT;IACTOi=lS whcse Quality System is
.nt with the ISO-9000 Sariej. Dsscribe the bzsic el2rnzn;s of an I S 0 9600 Series Ocalii\/ ?ragrem?

biafi:., Llonao~,r;l=nlg O u i l i fi.;sur~nce

~ S ; s < z i d ~;Br ISG-%GO
.
o u a ! i r ~Svsiems per ISO-SO01 90C2. O K 3
Ovelih/ ./!an Guiberines per ;SO 10C05

:31 is a n essential v ~ r i o b2s

; ~ rela;ed to a V/cld Prjcedure Sptciiicaii~n('vVPS)?
Answer: A change in 2 welding condi;i=n rks; :viil aHzc: the \veld's mec5anical ~roperries.
la; i5 !he felzilcnship benr:..r, 2 F . ' u r O u a l i l i c ~ ~ l oaecord
n (r333)and 2 WPS?
,.Answer: 7 h e ?OR dccgmer;:r, occl;r;sd
\;:.~i during the w e l c i n ~and ipsiing 31 :he (?st coupon.
3: inpu( iSh.I.4Vl per ASILIE IX) is conjina:ion o i whot two eleciric~lck2racteristics 8 travel spezd?
Ans\'/er: Voi:ag? and A,npsrage
: " s s i v ~hsa! input Is mainly 2r;;ijuled I:, what poor welding 1echnicu;s dv:ing SI\,!A'I\I ?recess?
Answer: Excessively wi62 wssving acd s!cw :iavsl s?aei.
are 3 p0tpn:ial sources o i H y d : o ~ ~encounierec!
n durins SMA'vV 2,rscess?
Answer: Ivlois:vie in [ha n?t,& 2nd eiec;roda ccatinc;, oil, eIene?!21 '-lydrogen in the bzse rnstal
".--.a. r t likely czcses 0:p~rosjp/in
SJVO:~~ c z i b c n s;eel walds csing Ihe SMA\N prscsss?
Answer: Poor weldinn, tzchnique 2nd equipment, excessive win<. noisturz & weld ccc:aminan:s.
, .
:a\ ension is measured dal=rmin= ;;ye size o i a concave fillel weld?
Answer: Throat . .....
1st dimension is measured to det=rr;l.ine the size zi a cs.:.!ex iille; w d d ?
Ansvrer: Leg
Ier? ~ ~ O ucracking
ld most likei); GC:~: fr~m
~ x t 2 s s i v 2CU:;?~: ifip~ilin a single p2SS we!d?
Answer: Centsrline 01 the weld
GTAW precess, d ~ s c r b what
t happscs to s. weld without prcper pu:ging/back gassing on SS
3I?
Answer: Oxidation at the ID (Sugaring)
ns 3 df the 5 mechanical tests in ASME IX employed'for procedurs & performance quaificatidns?
A-Iswer: Tension, Guided Bend, Fillet-weld. Notch-toughness 8 stud-weld tests . - - - ..

INTERVIEW ATTACHMENT~/ANSWERKEY
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 .- JFELDING CUNSUMABLES SELCiTION CHART FOR SIMILAR MA TERIALS . ' 1 .. ..

I'he~nical Material specification - Product wise-ASME Specification Welding consurnables - Process wise-AWS Classification
)mposition
, Plate Pipe Tube Forging Fitting Casting GTAW SMAW FCAW GMAW SAW
' . . . - .
arbin Steel .
'.Mn'Si'S'P
SA 5 15 Gr. 60170 1
SA 5 16 Gr. 601 70
SA106Gr.B
Sdz.l78 'Gr. D
SA!lOGr.AI
SA 209 Gr. C
Io5
s.4 234 W P i ~
SA 234 WPC
SA35O LFI
SA 350 LF2
Ei:gz:
ER 80S4
' E ,018;
E 7018-1
71T-115
E 70T-115
ER 70s-6
EM12IC

.. -. .. .. ..
SA204 Gr. A
O.j%Mo SA335 PI SA209 TI SA182 FI SA234 WPI SA352 LC1 E 7018-A1 E71T5-A1 ER70S -Al
SA 204 Gr. B ER70S-A1
ER80S-G
- -. - . .- .. . . . - .. . <

1.25%Cr
~~~~~
5
SA387 Grl1112 SA331 PI 1 SAl82 FI ICI.2 SA23-4 WPl lC1.l S.4217 WC6 ~8018-B2 E80TI-B2 ER8OS-82
0.5%Mo

2.25%Cr SA213 T22

SA335 P22 . $A112 F2? , \i1P?.?SI.I
%*??.I : S.4217 WC9 ER90S-G E9OlX-R3 I F9nT I-R3
LLit90S-B3 ER9nCR3
I %&lo SA3S7 Gr22 ,

5%Cr
SA.'3,5 P5 w;5 E80-I36 E80186 E8OT5-B6 , ERS-l36
0.5%Mo SA387 Gr5.CI.I
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SA387 Gr.91.CI2 SA335p9?.:: T9L / SA-I82F91 1 5.1234 WW1 I :i,VllCIZ '9R90S-B9

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1 EPOIS-B9 I
i
i - I ER90SlR9 / -