QUESTIONNAIRES FOR WELDING ENGINEER / SUPERVISOR &WELDERS

1. What are the main 3 dangerous things to be controlled during welding?

2. What is the difference between the filler wire and arc electrode?
3. When and what purpose filler wire is used?
4. What is the polarity during GTAW & SMAW welding?
5. What is the difference between the GTAW and SMAW welding?
6. What are the welding machines are normally used for welding?
7. What is arc and arc length?
8. What is the difference between welding generator and transformer?
9. What is the root gap for GTAW & SMAW?
10. What is low hydrogen electrodes and basic coated electrodes?
11. What is backing and what are the electrodes are to be backed?
12. What are the checks to be carried out during electrodes receipt at stores?
13. Why AC current is not used with welding generator?
14. Which machine gives the required polarity?
15. What is the difference between the GTAW torches and SMAW electrode holder?
16. What is the material used for welding & cutting nozzles?
17. What is the color for the following cylinders
a) Organ b) oxygen C) acetylene d) nitrogen
18. What is the difference between the organ regulator and gas-cutting regulator?
19. What is the function of the gauges fitted on the above regulator?
20. What are the different flames set on the gas cutting torches?
21. What are the different glasses used for the welding goggles & gas cutting goggles?
22. What are all the different types of welding?
23. What are all the different types of weld joints?
24. What are all the different types of weld defects?
25. What are all to be checked during pipe joint fit-up?
26. What is welding symbol?
27. How a welder can be classified?
28. What is WPS and PQR ?
29. What is welding job card?
30. What is pree heat and post weld heat treatment?
31. What is shielding and baking?
32. What gas is to be used for purging?
33. What is the purpose of portable oven?
34. Electrical lose connections gives what hazards?
35. What is the electrodes baking temperature and baking duration?
36. What is P number for CS, AS &SS materials?
37. What is AWS number for the electrodes used for CS,AS &SS materials welding?
38. What is AWS number for the filler wires used for CS,AS &SS materials welding?
39. What is the current and voltage requirement for SMAW (dia-2.5, 3.15,4.0mm)?
40. What is the current and voltage requirement for GTAW?
41. What are the different types of welding groves?
42. Where single and double groves are used?
43. Define ark blow, burn through ,cavity, undercut &gas hole

44. Define Lack of Penetration, Lack of Fusion &Excess Penetration

45. Define tungsten inclusion ,slag inclusion &porosity
46. What are the different welding positions on pipes and plates?
47. What are the essential variables?
48. What are the non- essential variables?
49. What are the supplementary essential variables?
50. Define reinforcement.
51. What is back fire ?
52. How to prevent back fire ?
53. What is the purpose of metal cap for gas cylinder/
54. Explain oxidation, reduction &carbonizing flame.
55. what is the difference between welding torch and cutting torch?
56. What is inter pas temperature and why it is to be maintained?
57. What non consumable used in GTAW?
58. What is tungsten rod angle during welding?
59. What is the advantage of GTAW welding?
60. What is distortion and how to control it ?
61. What is arc strike?
62. How to handle SS materials?
63. What are the additional care to be taken during SS welding?
64. SS materials are not permitted to mix up with other materials why?
65. What are the different types of grinding machines?
66. What are the protective welder should use during welding ?
67. What are the pree-cleaning activities to be completed before fit-up?
68. What NDT to be used for root check?
69. During visual inspection on root weld and final weld, what are all to be looked for?
70. Why weld spatters occurs?
71. What is GA drawing?
72. What is isometric drawing?
73. what is flow sheet?
74. What is fabrication drawing?
75. What is pipe?
76. What is tube?
77. What is tolerance?
78. What is unit for current and voltage?
79. What instrument normally used for measuring current and voltage?
80. What is current loss?
81. What is open circuit voltage and ARC voltage?
82. What are the harm rays produced during welding?
83. How current control is possible on AC &DC welding machine?
84. What is up-hill and down hill ?
85. What is miss-match?
86. What is mean by slope on the pipe line?
87. What precaution to be taken during welding of valves?
88. How to measure the size of fillet welds?
89. What is the purpose of ultrasonic thickness measuring gauge?

90. What is DT and NDT ?

91. What is tensile strength?
92. What are all the different NDT used in welding field?
93. Define the term stress and strain ?
94. How carbon steel is classified?
95. How alloy steel is classified?
96. Define stress reliving and why it is required?
97. Why welding is specified as special process?
98. How weld joints are identified?
99. What is mean by a good welder?
100.Explain the function of coating of electrodes?
101.Explain the meaning of low hydrogen of electrodes?
102.What are the different mode of heat transfer?
103.What are the different accessories used for GTAW?
104. What are the different accessories used for SMAW?
105. What is the role of welding helper?
106.What is first angle and third angle projection?
107.Which ASME section deals about welding and bracing qualification?
108.ASME section VIII deals about what?
109.How you will calculate welder performance?
110. What do you mean by a sound weld?
111.What is a defect?

QUESTIONNAIRES FOR FITTERS

1. How to read the drawing?
2. What is the isometric drawing?
3. What is GA drawing?
4. What is DD drawing?
5. What is flow sheet?
6. What is fabrication drawing?
7. What is first angle projection?
8. What is third angle projection?
9. What is slope?
10. How slope is marked on the drawing?
11. How hangers are marked on the drawing?
12. What is weld joint fit-up?
13. How you will do a joint fit-up?
14. What is root gap?
15. What is mismatch?
16. What is over lap?
17. What is ovality?
18. How you will measure an edge preparation as per drawing?
19. How to measure root gap?
20. What is least count?
21. What is calibration?
22. What is least count of measuring tap?
23. Where you will use venire caliper and micrometer?
24. What is in side micrometer?
25. What is out side micrometer?
26. Where you will use dial gauge?
27. How to set a dial gauge?
28. How much mismatch permitted for GTAW welding?
29. What is land?
30. How much land should be maintained for manual welding?
31. What is arresting?
32. What is distortion?
33. How you will prepare a V groove?
34. How you will prepare a J groove?
35. What is blue matching?
36. Where blue matching required?
37. What is the purpose of file?
38. What are the various files you have used?
39. What is square ness?
40. What are all the instruments used for leveling?
41. How to check the correct ness of the sprit level?
42. Where you will use water level?
43. What is the accuracy of water level?
44. How you will remove air in the water level tube?

45. How to check there is no air in the water level tube?

46. Where to take the measurement in the water level (bottom or top)?
47. During fit-up what are all the points to be checked?
48. How materials are identified?
49. How materials are stacked?
50. What is handling procedure?
51. What is erection procedure?
52. How you will erect a permanent support?
53. Where you will weld a temporary support?
54. What are the safety precautions to be taken when you are working at very high level?
55. What is the purpose of safety belt?
56. What is scaffolding arrangement?
57. How to identify vertical and horizontal rolling in drawing?
58. What is the inclined position of the isometric drawing?
59. How to identify the direction in the drawing?
60. Before starting piping erection at site, what are all the clearances to be obtained?
61. How to identify the joint whether that is shop joint or field joint?
62. What are all the in formations taken from the drawing?
63. Revision R1, R2,R3 of the same Drawings are given to you. Which drawing you will use for job?
64. Vertical hatch lines and horizontal hatch lines on the drawing indicates what?
65. What is tolerance?
66. What is weld symbol?
67. What do you mean by fittings?
68. How to erect a valve?
69. What are all the different types of hangers?
70. How you will identify the flow direction?
71. How valves are erected on the flow direction?
72. What is NRV?
73. How flanges are identified on the drawing?
74. How you will erect the flanges?
75. What is gas-cut?
76. What is torque value?
77. What is dame? And what for it is used?
78. How a weld joint number is identified?
79. Where weld joint number is to be punched?
80. What is line number?
81. How you will preserve the fit-up?
82. What are the various way to avoid fouling of lines?
83. What is house keeping?
84. What are all the fire safety measures to be taken during erection?
85. Drain points are to be fixed at what location?
86. Vent points are to be fixed at what location?
87. What is shipping list?
88. What is DU ,NO ?
89. How direction is found on the drawing?
90. Bill of materials is given for what?

91. What is the purpose of rectangular try square?

92. How sings are put on valves for lifting purpose?
93. How cleats are placed over the pipe during fit-up?
94. How you will fix the dams?
Dos
1.
2.
3.
4.
5.
6.
7.
8.

Us the latest revision of drawings for the job.

Confirm the revision of the drawing before starting the fabrication.
Understand the requirement of piping material as per drawing fabrication.
Check for completeness of all the required information in the drawing.
Check for correctness of Bill of Material with reference to spool quantity.
Deviations from the drawings should be taken only after concurrence of the engineer is taken.
Preserve and store drawings after use.
Return the old revision immediately on received of the latest one.

Dont
1.
2.
3.
4.
5.

Dont use the old revision for fabrication.

Dont deviate from the drawings without written approval.
Dont mistake between shop & field joint.
Dont scatter the drawings in shop and at field.
Dont assume any thing, if not explicitly given the drawing.

QUESTIONNAIRES FOR RIGGERS

1. What are slings?
2. What is wire rope?
3. What is rope?
4. What is safe angle?
5. What is safe load?
6. How to lift a material from one place to other place?
7. What are all the in formations required before lifting a pipe?
8. Shall we directly wind the sling on the pipe?
9. How you will communicate the information to the operator?
10. What are all the different signals being followed among rigging group?
11. What are all the safety points to be followed during the lifting of pipe material?
12. What are all the safety points to be followed during the lowering of pipe material?
13. What for the hand gloves?
14. What for different size (dia) of ropes/slings are required?
15. What for different size (dia) of ropes/slings are required?
16. What for different length of ropes/slings is required?
17. Who will instruct you to do job?
18. What you mean by house keeping?
19. What are all the safety practices are to be followed at your job?
20. What is the requirement of lighting arrangement for rigging job?
21. How you will maintain the slings/ropes?
22. Why grease or oil is applied over rope/slings?
23. How you will check the healthiness of rope/slings?
24. Where you will keep the damaged slings?
25. What is contact angle?
26. An eye check-up is required for rigger?
27. Why whistle is required?
28. What Extra care should be taken during valve lifting?
29. What Extra care should be taken during equipment (machine) lifting?
30. For fire protection what are all to be done?
31. Why signal failures are happening?
32. What is mean by slippage?
33. Why wooden blanks are provided between job and ropes during lifting?
34. How materials are balanced during lifting?
35. What is the responsibility of a rigger?
36. Any document is required for rigging job?
37. Why job knowledge is required for rigger?
38. Who will lead the rigger team?
39. Method of lifting and movement is to be preplanned
40. In emergency how you will act to save material and machine?