API 577 : Practice Exam Questions Instructions: Choose the most correct answer for each question. You may only choose one answer for each question. 1. What is the purpose of API 577? 8) to provide guidance to the API authorized inspector on welding inspection b)_ to provide guidance to the API authorized inspector on welding procedures ©) to provide guidance to the API piping engineer on welding inspeetion ito provide guidance to the API piping engineer on welding procedures 2. Do all welds need to be inspected? a) no, not all welds are required to be inspected b}_ no, only cortain welds need to be inspected ©) yes, all welds should be at a minimum 100% visually inspected di_yes, each weld requires some type of inspection 3. Whats the shortest distance betwoon the weld root and the face of e fillet weld? 1a) theoretical throat b) actual throat ©) leg d) short leg 4. An inspector notices that a welding are is being deflected from its normal path and the welder Gescribes the problem to the inspector as arc blow. What would be the most likely cause? a) voltage is too low b) amperage is too high ©) magnetic force interference ) both a and b 5. What is ¢ welding anomaly when itis designated as rejectable? @) defect b)- discontinuity ©) imperfection @) flaw Page 1 of 1710, API 577 : Practice Exam Questions What is wold metal that is in excess of the quantity required to fill a joint? a) toe b) crown ° cap 4) weld reinforcement What is the junetion of the weld face and the base metal? a) too b) crown, ° cap 4) weld reinforcement What is a non-standard term indicating a weld discontinuity in which fusion did not occur between weld metal and fusion faces or adjoining weld beads? a) >) ° lack of adhesion lack of penetration Jack of fasion 4) non-weld fusion ‘When verifying that all NDE is performed correctly upon completion of welding, an inspector otic es that the records show that not all welders were included in the random examination, ‘What should be done? a) require additional NDE to address deficiencies in findings b) repeat missing or unacceptable examinations ° correct discrepancies in examination records 4) allof the above For verify post-weld heat treatment procedures and eqiupment, what action should be taken if, ‘themoreouples ware not properly fastened? a) correct deficioncies before heat treatment b) check for delayed cracking of thick se ° on, highly constrained and high strength material joining correct discrepancies in examination records d) develop repair plan if defects are identified Page 2 of 17iL 13, 1. API 577 : Practice Exam Questions During the welding inspection, an inspector identifies a non-conformance to the specification and brings it to the attention of those responsible for the worlk. What should be done before welding proceeds further? a}. the non-conformance should be documented b)_ the non-conformance should be completely removed and re-inspectod €) the non-conformance should be documented and re-inspected @_ the non-conformance should be immediately re-inspected When specified by the referencing code, the qualification of NDB personnel shall be to which standard? a) ASNT SNT-TC-1A, b) ANSI/ASNT CP-189 ©) ASNT SNT-TC-1A or ANSVASNT CP-189 a) ASMEV What are some of the functions of eletrode covering? 8) provides a gas to shield the are and prevent excessive atmospheric contamination of the molten filler metal b) provides seavengers, deoxidizers, and fluxing agents to cleanse the weld and prevent excessive grain growth in the weld metal ©) establishes the electrical characteristics of the electrode 4) all of the above ‘What are some of the flunctions of eletrode covering? 1) provides a slag blanket to protect the hot weld metal from the air and enhances the mechanical properties, bead shape, and surface cleanliness of the weld metal b) provides a means of adding alloying elements to change the mechanical properties of the base metal ©) establishes the electrical characteristics of the weld metal 4) allof the above What are some advantages of the SMAW process? a) equipment is relatively simple, inexpensive, and portable b) process can be used in areas of limited access 1 process is less sensitive to wind and draft than other welding processes 4) all of the above Page 3 of 1716, 1. 418. 19. 20. 21 API 577 : Practice Exam Questions What are some advantages of the SMAW process? @) process is suitable for most of the commonly used metals and alloys ) process ean be used very thin sections, such as thin sheets ©) process is not sensitive to wind and draft 4) all of the above ‘What are some of the limitations of SMAW? a) deposition rates are lower than for other processes such as GMAW ) slag usually must be removed at stops and starts ©) slag usually must be removed before depositing a wold bead adjacent to or onto a previously deposited weld bead 4) all of the above ‘What are some of the advantages of GTAW? a) little post-weld cleaning is required b) allows for excellent control of root pass weld penetration ) can be used with or without filler metal, dependent on the application @) allof the above ‘What are some of the advantages of GTAW? @) produces high purity welds, generally free from defects b) little pre-weld cleaning is required ©) allows for excellent control of cap pass weld penetration @) allof the above ‘What are some of the limitations of GTAW? 8) deposition rates are lower than the rates possible with consumable electrode are welding. processes b) has a low tolerance for contaminants on filler or base metals ©) difficult to shield the weld zone properly in drafty environments 4) allof the above ‘What welding processes can GMAW be operated in? a) semiautomatic b) machine ©) automatic @ allof the above Page 4 of 1723, 24, 25, 26. 27. API 577 : Practice Exam Questions What type of power supply does GMAW employ a) constant eurrent (CC) b)_ constant voltage (CV) ©) variable voltage-current (VVC) @) all of the above What are the GMAW weld metal transfer modes? a) short cireuiting b) globular ©) spray 4) allof the above What are some of the advantages of GMAW? hat can be used to weld most commercial metals the only consumable electrode proct and alloys b) deposition rates are significantly higher than those obtained with SMAW. ©) minimal post-weld cleaning is required due to the absence of a slag 4) allof the above What are somo of the limitations of GMAW? a) the welding equipment is more complex, more costly, and less portable than that for SMAW b)_ the welding are should be protected from air drafts that will disperse the shielding ges ©) when using the GMAW-S process, the weld is more susceptible to lack of adequate fusion 4d) all of the above What are some of the advantages of FCAW? a) the metallurgical benefits that can be derived from a flux )_ high deposition and productivity rates than other processes such as SMAW ©) shielding is produced at the surface of the weld that makes it more tolerant of stronger air currents than GMAW 4) all of the above Slag that supports and shapes the weld bead is an advantage of which welding process? a) SMAW bb GMaw © GTAW a) FCAW Page 5 of 1728. 29. 30. 32. 38 API 577 : Practice Exam Questions ‘What are some of the limitations of FCAW? a) equipment is more complex, more costly, and less portable than that for SMAW b) self-shielding FCAW genorates large volumes of welding fumes, and requires suitable exhaust equipment ©) slag requires removal between passes 4) Allof the above Required backing material for root pass welding is a limitation of which welding process? a) SMAW b) GMAW ©) GTAW a) FCAW What are some of the advantages of SAW? a) provides very high metal deposition rates b)_ produces repeatable high quality welds for large weldments ©) produces high quality welds for repetitive short welds 4) allof the above . Which of the following welding processes has the highest deposition rate? a) SMAW >) GMAW ©) SAW @) GTAW In refineries and petrochemical plants, where is stud are welding used? ) limited to welding insulation and refractory support pins to tanks 1b) limited to welding insulation and refractory to pressure vessels ©) limited to welding insulation and refractory to heater easing 4) allof the above What is the purpose of the WPS? 2). provides direetion to the welder while making production welds to ASME code requirements b)_ provides direction to the welder while making production welds to APT code requirements ©) provides verbal rules for making production welds to ASME code requirements 4) provides rales for qualifying the welder Page 6 of 1734. 35. 36. 38, 89. API 577 : Practice Exam Questions What is a PQR? a) itis a record of the welding data and variables used to weld a test coupon and the test results used to qualily the welder b)_ it is a record of the welding data and variables used to weld a test coupon and the test results used to qualify the welding procedure c) it is a record of the welding data used to test aweld coupon @)_ provides rules for making production welds to ASME codle requirements What is the purpose of the PQR? a) to qualify the WPQ D)_ to establish the properties of the base metal €) toestablish the properties of the weldment 4)_ to establish the properties of the weld metal What is the purpose of the WPQ? a) to establish the properties of the weldment b)_ to establish the properties of the weld metal o the WPS is capable of making a quality weld 4) toestablish the welder is capable of making a quality weld using the welding procedure Which code or standard allows welding procedure qualification by others, provided it is acceptable to the inspector and meets certain conditions? a) ASME BI6S b) ASME B313 ©) ASME See, IX a) APLBTT As a minimum, which electrical characteristic should the WPS contain, in ageordance with API a) welding process >) base metal ©) welding current @) filler metal (andor flux) Why are mechanical tests required to qualify a welding procedure? 4) to demonstrate the properties of the base metal b) to demonstrate the properties of the weld metal ©) to demonstrate the properties of the weldment, @ to qualify the welder Page 7 of 1740. 41 42, 48, 44, API577 : Practice Exam Questions What is the purpose of the tension test when qualifying a WPS? 18) todetarmine the ultimate strength of a groove or fillet. weld b) tadetarmine the ultimate strength of a groove wold ©) todetermine the electrode weldability 4) todetormine the base metal weldability ‘What is the purpose of the guided bend test when qualifying a WPS? fa). to determine the degree of bendability of a groove weld 1b} to determine the degree of formability of a groove weld ©) to determine the degree of soundness and ductility of a groove weld 4) to determine the degree of soundness and ductility of a groove or fillet weld Which of the following is not included in a WPS? a) test coupon thickness the procedure is to cover b) filler metal specification (SFA number) ©) AWS classification number 4) Fenumber What type of variable are current, polarity, amperage range, and voltage range for production welding? a) optional electrical settings b) welding machine settings ©) electrical charactoristies @) electrode characteristies Which of the following is not included in a PQR? a) welding process used ) thickness range the procedure is to eover ©) typo of weld for qualification 4d) P-numbers of coupon welded Why are base metals assigned P-numbers in ASME Section TX? a) to reduce the number of welding procedure specifications required b) toreduce the number of welding procedure qualifications required ©) to reduce the number of WPSs and WPQs required 4) to reduce the number of welders required Page 8 of 1746, 4. 48. 51 API 577 : Practice Exam Questions In the ease of carbon steel SMAW electrodes, welders who qualify with one filler metal are qualified to weld with all filler metals having the same F-number and what else? a) nothing else by only qualfied to weld with other F-numbers after welding 1 more coupon ©) only qualfied to weld with other F-numbers after welding 2 more coupons a) may additionally qualify to weld with electrodes having other ¥-numbers What does the A-number grouping define? 1) the chemical composition of the deposited weld metal b) the chemical composition of the filler and base metals before welding the mechanical properties of the deposited weld metal 4) the chemical composition and mechanical properties of the deposited weld metal What should an inspector do when confronted with electrodes or fluxes that have become wet? a). electrodes or fluxes that have become wet should be dried bj elecirodes or fluxes that have become wet should be re-baked ©) elecirodes or fluxes that have become wet should be diseardled 4) electrodes or fluxes that have become wet should be quarantined for farther evaluation ‘What is the purpose of the welder performance qualification? 2) to establish the welder’s ability (o wold the WPS test coupon. b)_ to establish the welder's ability to weld the PQR test coupon ©) to establish the welder's understanding of the welding specification 4) to establish the welder's ability to deposit sound weld metal ‘What type of welding process do some end users and codes limit or restrict the use of welder qualification by radiography of the initial production weld? a) FCAW by FOAW-S ©) GTAW-S @ GMAWS When does welder performance qualification expires? a) ifthe welding process is not used during a three-month period ) ifthe welding process is not used daring a six-month period ©) ifthe welding process is not used during a 1 year period @ ifthe welding process is not used during a 2-year period Page 9 of 17API577 : Practice Exam Questions 52. What location within the weldment would you commonly find incomplete joint penetration? a) wold metal b) base metal ©) heat affected zone ) weld interface 59, What location within the weldment would you commonly find underfll? a) wold metal ) base motal ©) heat affected zone 4) weld interface 54. What location within the weldment would you commonly find underbesd crack? a) weld metal b)_ base metal ) heat affected zone 4) weld interface 55, How capable is the application of UT to inspect porosity in a weld? a) applicable method b) marginal applicability ©) not applicable 4) somewhat applicable 56, What would be the preferred NDE methods to inspect undercut in a weld? a) RP b) UT o MT @) ET 57. What would be the profarred NDE method to inspect incomplete fusion in a weld? a) RT b) UT © MT 4) BY Page 10 of 1758. 58. 60. 61. 63 API 577 : Practice Exam Questions A welding inspector notices a continuing problem with hydrogen cracking in a carbon steel weld using SMAW. What would be a practical selution? a) low-hydrogen olectrode, preheat, post heat, clean weld joint I proper heat input. propor welding technique ©) reduce travel speed bare length control Awelding inspector notices a continuing problem with lack of fusion in a earbon steel weld using SMAW. What would be a practical solution? a} reduee travel speed b)_ are length control e} low-hydrogen electrode, preheat, post heat, clean weld joint, 4) proper heat input, proper welding technique A welding inspector notices a continuing problem with undercutting in @ carbon steel weld using SMAW. What would be a practical solution? a) are length control b) low-hydrogen electrode, preheat, post heat, clean weld joint ©). reduce travel speed 4) remove by grinding A welding inspector notices a continuing problem with tungsten inclusions in a earbon steel weld using GTAW. What would be a practical solution? a) are length control b)_ proper heat input; vertical uphill ©) reduce travel speed €) remove by grinding ‘A welding inspector notices a continuing problem with solidification eracking in a type 304 stainless steel wold using GTAW. What would be a praetical solution? a) proper filler, ferrite content, proper joint design b) low heat input, stringer bead ©) proper heat input @)_ low hydrogen, low sulfur environment, proper shielding A welding inspector notices 2 eontinuing problem with hot eraeking in a type 316 stainless stee! \weld using GMAW. What would be a practical solution? a) proper fille, ferrite content, proper joint design b) low heat input, stringer bead ©) reduce travel speed & remove by grinding Page 11 of 1764. 66. 67. 68. 69. API ST; Practice Exam Questions When direct visual examination is conducted, what is the sufficient access distance to place the eye within the surface to be examined? a) 6 in, ~24in. (160 mm — 600 mm) b) 10 in, ~24 in. (250 mm — 600 mm) e) 12in, ~24 in, (800 mm ~ 600 mm} 4). with focal distance of the individual inspector's eye ‘When direct visual examination is conducted, what is the proper angle to place the eye within the surface to be examined? fa) aban angle not less than 15 degrees to the surface b)_atan angle not less than 30 degrees to the surface ©) at an angle between 15 to 20 degrees to the surface 4) at-an angle between 80 to 45 degroes to the surface When a MT yoke is placed parallel on the weld, what direction would a discontinuity be found relative to the weld? a) parallel to the weld b) transverse to the weld ©) 30 degrees to the transverse weld axis ) 80 degrees to the longitudinal weld axis When a MT yoke is placed aeross (transverse) a weld, what direction would a found relative to the weld? a) parallel to the weld b) transverse to the weld ©) 30 degrees to the transverse weld axis €) 30 degrees to the longitudinal wold axis For added sensitivity to find surface cracking, what NDE method would be preferred? a) RT b) BC o UT @) WEMT What is the purpose of a pie gauge? 2) to confirm the magnetic flux direction during MT b) toconfirm the magnetic flux direction during EC ©) tocalibrate SWUT 4) tocalibrate gama ray source strength for RT Page 12 of 1770. 2. 73, 14. API 577 : Practice Exam Questions For added sensitivity to find surface cracking, what NDE method would be preferred? a) RT bi EC ©) UT a Fer What type of NDE method is RT? a) surface linear examination method b) subsurface linear examination method ©) volumetric examination method capable of examining the entire specimen rather than just the surface di linear examination mothod capable of examining the entire specimen rather than just, the surface For pipe wall or weld thickness of 0.812 in. (7.9 mm), what size of IQI would be used? a) No. 12 ASTM IQI with a thickness of 0.012 in, (0.30 mm) b) No, 15 ASTM IQI with a thickness of 0.015 in, (0.88 mm) ¢) No, 17 ASTM IQI with a thickness of 0.017 in. 10.48 mm) 4) No, 20 ASTM IQI with a thickness of 0.020 in. (0.51 mm) When a surface condition that could mask a defect is visually detected by a vadiographer prior to radiography, what should be done? 8) surface condition should be noted on the radiographer's report b) surface condition should be remedied prior to the exposure: ©) a radiograph should be taken to confirm if the surface condition really does exist @)_ the area should be cut-out for immediate repair What type of NDE technique is used for identification of discontinuities in welds? a) UT (straight beam) b) SWUT (angle beam) o RP a) Pr What commonly used UT sizing technique uses the beam spread to determine the edges of the reflector? a) intensity drop technique ) intensity increase technique ©) gain drop technique 4) gain increase technique Page 13 of 1776. 18, 80. 81 API 577 : Practice Exam Questions ‘When hardness testing production welds and HAZ, how should the test area be prepared to accommodate the hardness testing instrument? 8) should always be done on metal as-is b) may be done on metal as-is, provided surface scale is not thicker than 1/16 in, (1.6 mm) ©) test areas should very lightly grounded 4) test areas should be ground flat or even flush with the base matal ‘What are examples of physical properties of a metal? a} melting temperature b} thermal conductivity ©) electrical conductivity a) allof the above ‘What are examples of physical propertios of a metal? a) density bi) fatigue endurance ©) coefficient of compression 4d) all of the above |. Which physical property would influence distortion during welding? ) coefficient of thermal expansion b} melting temperature ©) electrical conductivity a) density ‘Metals with a high coefficient of thermal expansion are much more susceptible to what type of ‘welding problem? a) lack of fusion b) undercutting ©) warping and distortion )_ porosity ‘Which of the following is an example of a mechanical property of metals and alloys? a) coefficient of thermal conductivity b) thermal expansion ©) electrical conductivity 4) toughness Page 14 of 1783, 84 86. 86. API 577 : Practice Exam Questions . What is the definition of strain? a) the amount of deformation, change in shape, a specimen has experienced when stressed bi the amount of deformation, change in shape, a specimen has experienced when strained €) the fatigue endurance limit divided by the tensile strength 4). the yield strength divided by the tensile strength How does a Rockwell hardness test differ from Brinell hardness testing? 1a) based on the penetration diameter rather than impression size bi based on the speed of penetration rather than impression size ©) based on the depth of penetration rather than impression size 4d) Rockwell is an American test, where Brinnel is a British test ‘What is the primary purpose for preheating carbon and low-alloy steels? a) to reduce the tonsile strength, b) to increase the tensile strength ©) to reduce the tendency for hydrogen induced delayed cracking ) to increase the tendency for hydrogen absorption How should PWHT temperatures be monitored and recorded? )_ by calibrated IR gun on the part being heated b)_ by thermocouples attached to the part being heated ©) by themography of the part being heated 4) all of the above What is the maximum hardness limit for carbon steels in refinery service? a) 200 HBW >) 225 HBW ©) 237 HBW @) 241 HBW ‘What information is included on a mill certificate? a) a statement of the chemical analysis present in an ingot or a billet b)_astatement of the chemical analysis present in finished product ©) astatement of the product analysis )_ a statement of all welding specification requirements Page 15 of 1788, 89, 20. 91. 92. API 577 : Practice Exam Questions Are materials test reports generally supplied to the purchaser? 4) yes, generally supplied to the purchaser ») yes, iferdered to 2 material specification ©) no, not generally supplied to the purchaser unless requested 4) no, not generally supplied to the purchaser unless an addltional cost is paid What type of test is the Lehigh test? a) lamination test b)_ externally loaded test ©) restraint test 4) underbead cracking test When welding a type 304 stainless steel, what precaution should be taken to prevent a loss in corrosion resistance? a). the root of the weld should always be completed with GTAW b) the root of the weld should be protected by using an inert backing gas ©) the heat input of welding should always be maximized 4) 1100°F (570°C) PWHT should always be performed In general, what location within the weldment does solidification cracking occur? a) in partially melted zone b) in the fusion zone ©) at the weld interface 4) in the HAZ What is one of the main differences between welding nickel alloys and austenitic stainless steels? 1) there tendeney for the nickel alloy to be hotter during welding b) there tendency for the nickel alloy to have more weld spatter during welding ©) there tendeney for the nickel alloy to be sluggish during welding 4) there tendency for the austentie stainless steel to be sluggish during welding What may happen during hot tapping or in-service welding on carbon steel systems containing chlorine? a) carbon stee! will burn in the presence of chlorine and high heat b) an implosion may occur ©) adeadly vacuum may oceur which would smother the welder 44). carbon steel would brittle fracture in the presence of chlorine Page 16 of 17API 577 : Practice Exam Questions 94, How does the BPV Code Section IX restrict the welder qualification when using GMAW-S process? a) reguiring welders qualify with mechanical testing rather thaa by radiographic examination bi requiring welders qualify with radiographic examination rather than by mechanical testing 1 limit the welder to globular transfer method only d) limit the welder to maximum 6 in. O.D. pipe welding Page 17 of 17