577 Exercise

RP 577 Welding Inspection and Metallurgy 2nd Edition October 2006

Rev. 2 10/06 DTM Enterprises Technical Training Division Page 1 of 35 281-330-9542 www.DTM-Enterprises.org

Welding Inspection

TASKS PRIOR TO WELDING

4.2.1 Drawings, Codes and Standards

1. Which of the following should be assessed as part of the welding quality control?

A. Welder performance in a qualified laboratory. B. Welding equipment manufacturer is recognized by the Code of construction. C. Welding symbols and weld sizes.

2. Before welding starts the inspector should review______________________.

A. AWS D1.1 B. Codes and Standards C. Welders work histories

3. List the four potential inspector actions associated with tasks prior to welding.

A._________________________________________________

B._________________________________________________

C._________________________________________________

D._________________________________________________

4.2.2 Weldment Requirements

4. As part of a welding review the inspector must determine the competency of the

welding organization and the competency of the __________________________.

A. design engineer B. welding foreman C. inspection organization

4.2.4 NDE Information

5. Name three items that the inspector must assure are in order before accepting NDE

procedures.

A.___________________________________________________________

B.___________________________________________________________

C.___________________________________________________________



4.2.5.1 Welding Equipment and Instruments 6. As regards storage ovens for welding consumables the inspector should confirm that

the ovens have ______________________________.

A. current calibration stickers B. a window for viewing the contents of the oven. C. automatic heat controls

4.2.6 Heat Treatment and Pressure Testing

7. List the four issues that must be addressed when reviewing proposed heat treatment

and pressure tests.

A. _____________________________________________________________

B. _____________________________________________________________

C. _____________________________________________________________

D. _____________________________________________________________

4.2.7 Materials

8. All filler metals, base materials, and backing rings materials should be properly

marked and identified. What additional step might be required to insure proper materials?

Ans. ____________________________________________________________

4.2.8 Weld Preparation

9. Preheat is often applied prior to welding; sometimes it may also be needed for

_____________.

A. bending pipe B. thermal cutting C. popping off scale in single vee welds

4.2.10 Welding Consumables

10. One item often forgotten during the review of welding consumables is looking for the

_______________.

A. name of the manufacturer of the consumable on the Welding Procedure B. type of water cooling used for a GTAW torch C. gas composition and purity requirements



4.3 TASKS DURING WELDING OPERATIONS 11. Normally quality assurance and quality control measures include such things as

welder responsibility, welder qualification, and the welder understanding the requirements of the WPS and inspection hold points. What else might be required to help the welder perform the weld?

Ans. ____________________________________________________________

4.3.3 Weldment Examination

12 During the inspection of a weldment, tack welds, weld root penetration, cleaning between passes, in-process rework, in process ferrite measurement if required and final weld sizes will be required. What else might be necessary?

Ans. ________________________________________________________

4.4 TASKS UPON COMPLETION OF WELDING

4.4.1.1 Quality Control Items

13. Which of the following items should be assessed after completion of a weldment?

A. All welding equipment is verified as in current calibration. B. Welders stamps have been applied to each weld in the weld increment. C. All inspection steps have been verified by the welding foreman or contractors

representative.

4.4.2 NDE Review 4.4.2.1 Quality Control Items

14. If performing NDE on a weldment that will receive PWHT the order of operation

is________________.

A. After final PWHT B. Before and after final PWHT C. Either before or after PWHT



4.4.3 Post-weld Heat Treatment

4.4.3.1 Quality Control Items

15. The inspector should inspect the following after PWHT.

A. Temporary attachments have been removed. B. Equipment supported to prevent distortion. C. Temperature monitoring system was calibrated.

4.7 Safety Precautions

16. The hazards associated with welding that the inspector must be aware of

are_______________________________.

A. _____________________________________________________________

B. _____________________________________________________________

C. _____________________________________________________________

D. _____________________________________________________________

5 Welding Processes

5.2 SHEILDED METAL ARC WELDING (SMAW)

17. Which of the following is a true statement about SMAW?

A. It often uses pressure in combination with the welding arc to complete fusion and assure complete penetration of the base material.

B. Only DC current can be used with the SMAW process. C. A gas for shielding of the molten metal is generated by the decomposition of the

electrode covering.

5.2.1 Electrode Covering

18. The covering for and SMAW electrode provides a way to add alloys to change the mechanical properties of the weld metal.

A. True B. False



5.2.2 Advantages of SMAW

19. List the 4 advantages of the SMAW process.

A. ______________________________________________________________

B. ______________________________________________________________

C. ______________________________________________________________

D. ______________________________________________________________

5.2.3 Limitations of SMAW

20. Name the two major limitations when using the SMAW process.

A. ______________________________________________________________

B. ______________________________________________________________

5.3 GAS TUNGSTEN ARC WELDING (GTAW)

21. When using GTAW in DC current mode typically it will be set to DCEN polarity.

DCEN stands for________ and provides ____________________.

A. Direct Current Electrode Neutral and deeper penetration B. Differential Current Electrode Negative and deeper penetration C. Direct Current Electrode Negative and deeper penetration.

5.3.1 Advantages of GTAW

22. Which of the following is not an advantage of GTAW?

A. Allows excellent control for root pass weld penetration B. Only minor post-weld cleaning may be required C. Has a low tolerance for contamination on base material or filler metals

5.4 GAS METAL ARC WELDING (GMAW)

23. GMAW uses a ___________ power supply.

A. Continuous voltage B. Constant voltage C. Consistent voltage



5.4.1 Short Circuiting Transfer (GMAW-S)

24. The danger in using the short circuiting mode of arc transfer is _______________?

A. It will cause excessive distortion in thin materials B. It can lead to lack of fusion in thin materials C. It can lead to lack of fusion in thicker materials

5.4.2 Globular Transfer

25. This arc transfer mode is suitable for _____________________________?

A. All position welding B. Flat position welds C. Vertical and horizontal welds

5.4.3 Spray Transfer

26. The following is true about this arc transfer mode.

A. Spatter is minor B. Spatter is a major concern. C. It cannot be used in any mode for thin sheet material.

5.4.4 Advantages of GMAW

27. GMAW process has the advantage of ___________________________.

A. being highly portable B. high deposition rates C. not being subject loss of shielding gas due to air drafts

5.5 FLUX CORED ARC WELDING (FCAW)

28. FCAW is normally a _________________________________.

A. fully automated welding process B. semi-automatic welding process C. process used with a DC constant-current power supply.



5.5.1 Advantages of FCAW

29. The slag generated by the FCAW process has the advantage of _________.

A. supporting and shaping the weld bead B. being only a minor issue for removal between passes C. allowing the weld metal to be exposed to the atmosphere

5.6 SUMERGED ARC WELDING (SAW)

30. Major use of SAW is found in_______________________________.

A. Field welding of large bore piping B. Field welding of large vessel components C. Shop fabrication of vessels and manufacturing of piping

5.6.1 Advantages of SAW

31. List the two advantages that SAW has over other processes.

A. ______________________________________________________________

B. ______________________________________________________________

5.6.2 Limitations of SAW

32. Which of following is not a limitation of the SAW welding process?

A. Low deposition rates B. The weld is not visible during the welding process C. Welding is limited to the flat position only

5.7 STUD ARC WELDING (SW)

33. _____ current is normally used with SW and its positions allowed are______.

A. ACEN - flat only B. DCEN - all positions C. ACEN or DCEN - horizontal and overhead



5.7.2 Limitations of SW

34. This process is limited to use with_______________________________.

A. Carbon and Stainless Steels only B. Carbon steels only C. Carbon and low alloy steels only

5 Welding Processes Equipment Identification

Identify the following equipment by the welding process.

35. The process



36. The process

37. The process



38. The process

39. The process



40. The process



9 NON-DESTRUCTIVE EXAMINATIONS

9.1 DISCONTINUITES

41. The _________________ should choose the NDE method based on the type of

discontinuity and weld joint.

A. NDE Examiner B. Welding foreman C. Inspector

Table 2 - Common Types of Discontinuities

42. Piping is a type of ________ normally found in the ____________________.

A. crack - base metal B. lack of fusion - heat affected zone C. porosity - weld metal

43. Convexity is found in the _____________.

A. weld face of groove welds B. weld face of a fillet weld C. weld faces of groove and fillet welds

Table 4 - Capability of the Applicable Inspection Method for Weld Type Joints

44. Which method of the following NDE methods is applicable to all weld type joints?

A. RT B. UT C. PT

45. The abbreviation LT applies to __________________.

A. Leak Testing B. Longitudinal ACFM C. Laser Testing



Table 5 - Capability of the Applicable Inspection Method vs. Discontinuity

46. RT has a marginal capability for detecting cracks in welds.

A. True B. False

Table - 6 Discontinuities Commonly Encountered with Welding Processes

47. Which of the following welding processes does not promote hydrogen cracking in

carbon steel welds?

A. SMAW B. FCAW C. SAW D. GTAW

48. If a weld is found to have excessive undercut at the toe the best way to detect it is

by ______ or _______, and the best way to correct undercut is to _________ during welding.

A. RT - VT - Increase travel speed B. UT - VT - decrease travel speed C. VT - ACFM - decrease travel speed

49. Which welding processes are subject to Arc Strike?

A. SMAW and GMAW B. GTAW and SAW C. All welding processes

50. The GMAW -S (short circuiting mode) is subject to the discontinuity Lack of

Sidewall Fusion. Which of the following might help with this problem?

A. Slow down travel speed. B. Increase travel speed. C. Vertical downhill welding D. Vertical uphill welding.



Use Table 2 from RP577 and answer the following questions. 51. The discontinuity labeled number 10 is________________________.

52. Number 12d is ___________________________________________.

53. Number 7 represents______________________________________.

54. 1d depicts ______________________________________________.

55. Number 3 is known as _____________________________________.

9.2 MATERIALS IDENTIFICATION 56. Who is responsible for establishing a written material verification program?

A. The inspector B. The product manufacturer C. The owner/user



9.3 VISUAL EXAMINATION (VT)

57. Visual examination personnel are required to pass a vision test _________ and it

shall be of the __________________ eye vision test.

A. biannually - J - 2 Jaeger - type B. triennially - J - 1 Joiner - type C. annually - J - 1 Jaeger - type D. semi- annually - J - 1 Jaeger - type

9.3.2.3 Weld Examination Devices

58. A bridge cam gauge cannot measure ___________________________.

A. weld preparation angle B. depth of undercut C. excess reinforcement on a butt weld D. Internal misalignment of pipe welds

9.4 Magnetic Particle Examination (MT)

9.4.2 Magnetic Flux Direction indicator

59. On of the most common and popular flux direction indicator for MT is known as the

________.

A. Cake gauge B. Pie gauge C. Donut gauge

9.4.3 Demagnetization

60. If residual magnetism is not eliminated after MT examination it may cause

___________________.

A. deflection of the welding arc during the welding of subsequent passes B. false readings when performing the next phase of MT C. reduction of sensitivity by follow up ACFM testing



9.5 ALTERNATING CURRENT FIELD MEASUREMENT (ACFM) 61. The maximum temperature that the ACFM method can be used at is _________.

A. 900 oF B. 600 oF C. 482 oF

62. ACFM does not require the use of a calibration piece with artificial flaws.

A. True B. False

9.7 EDDY CURRENT INSPECTION (ET)

63. List below the uses for eddy current testing in welding inspection.

A. ____________________________________________________

B. ____________________________________________________

C. ____________________________________________________

D. ____________________________________________________

9.8 RADIOGRAPHIC INSPECTION (RT)

9.8.3 Radiographic Film

64. The acceptable class of radiographic films are______________________.

A. Class I, II and III B. Class I and II C. Class II and III

65. The minimum coverage area of radiographic film for a weld is

______________________.

A. 3/4 on consecutive circumferential exposures and 1 on either side of the weld. B. 1 on consecutive circumferential exposures and 3/4 on either side of the weld.



9.8.4 Radioactive Source Selection

66. Which weld thickness below is best suited for use with Iridium 192 source?

A. 0.500 B. 3.5

9.8.5 Film Processing

67. As regards film processing, the normal development time is listed as 5 to 8 minutes

at ________.

A. 82 oF B. 70 oF C. 68 oF

9.8.8 Radiographic Techniques

68. A reliable radiographic technique is one where the radiation passes

_________________________.

A. at right angles to the part being examined B. at an angle of 30 degrees or less C. through a single thickness D. through a double thickness

9.8.8.2 Single-wall Viewing 69. Describe the Single-wall viewing method.

Ans. _______________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

__________________________________________________________________



9.8.8.2 Single-wall Viewing 70. The minimum number of radiographic exposures when using the single-wall viewing

on circumferential welds is ______.

A. 2 B. 3 C. 1

9.8.8.3 Double-wall Technique

71. The double-wall technique is suitable for pipe outside diameters up to 6.

A. True B. False

9.8.9 Evaluations of Radiographs

72. Rounded indications on a radiograph will be more apparent than

__________________.

A. cracks B. cracks, lack of fusion C. cracks, lack of fusion or overlap

9.8.9.1 Facilities for Viewing Radiographs

73. Magnification is allowed for viewing and interpreting radiographs,

however______________________________________________.

A. too high a magnification will distort the size of an indication and may cause undue rejection

B. too high a magnification will enhance the graininess of the film

9.8.9.3 Radiographic Density

74. Clear film has a density of 0, a film that allows 10% of the incident light pass through has a density of 1.0. A film that allows 1% pass through has a density of ___________.

A. 3.0 B. 2.0



75. The radiograph above indicates that this weld has____________________.

A. LOP B. centerline cracking

76. This radiograph exhibits ______________ porosity.

A. random B. cluster



77. This radiograph indicates burn through. According to Table 6 of RP 577 this was probably not welded using the _______________process.

A. SMAW B. GMAW C. GTAW D. FCAW

9.9 ULTRASONIC INSPECTION (UT)

78. Of the ultrasonic display types the________ is the most common.

A. B-scan B. C-scan C. A-scan D. D-scan

79. The B-scan display shows a ______________ view of the object.

A. cross-sectional B. planner C. half thickness



80. Ultrasonic display screen above represents the _____________ method.

A. C-scan B. B-scan C. A-scan

9.9 ULTRASONIC INSPECTION (UT)

81. ____________ or ___________ are used for detecting discontinuities in welds.

A. skip beam - angle beam B. angle beam - back-wall C. shear wave - angle beam

9.9.1 Ultrasonic Inspection System Calibration

82. Some requirements are placed on the condition of a calibration block for use with UT. List those requirements below.

A. ______________________________________________________________

B. ______________________________________________________________

C. ______________________________________________________________

D. ______________________________________________________________

E. ______________________________________________________________



9.9.1 Ultrasonic Inspection System Calibration

83. Calibration checks should be performed _____________________________.

A. before the examination B. after the examination C. before and after the examination

9.9.7.1, 9.9.7.2, 9.9.7.3 and 9.9.7.4

84. Match the following descriptions with the method it applies to.

1. Very effective for sizing flaws which are open to the inside or outside diameter surface and are shallow to mid-wall. ____

2. Uses the effects of multiple sound modes, such as longitudinal waves and shear

waves to qualitatively size flaws. ____ 3. A dual element tandem probe with the transducers crystals located one in front of

the other. ____ 4. Wave method that is very effective for very deep flaws. _____ A. The ID Creeping Wave Method B. The Tip Diffraction Method C. The High Angle Longitudinal Method D. Bimodal Method

9.10 Hardness Testing

85. Hardness tests on welds are meant to verify that acceptable softness has been

maintained after welding and often is applied after any required heat treatment. The places where the hardness tests are performed are ______________________.

A. Base metal, HAZ and weld metal B. HAZ and weld metal C. HAZ only



10 Metallurgy

10.2 THE STRUCTURE OF METALS AND ALLOYS

86. Welding can be considered to be like making a ___________.

A. solid sheet of metal B. casting

10.2.1 The Structure of Castings

87. _______________ largely responsible for the physical and mechanical properties

of metal.

A. Smaller grains are B. Larger grains are C. Microstructure is

10.2.2 The Structure of Wrought Materials

88. Wrought materials are those which have been worked by ____________________.

A. rolling B. forging C. extrusion D. All of the above

10.2.3 Welding Metallurgy

89. Weld metal does not have the same uniform makeup as the base metal, because

________________________________________.

A. it is normally not the same type of metal as the base metal B. of the flux used during welding C. of the mixing of filler metal with melted base metal

90. The heat affected zone (HAZ) of a weldment is an area that has not been melted but

has been affected by the pre-heat and heat of welding. For carbon steels this occurs at temperatures _____________________.

A. greater than 1350 oF B. less than 1350 oF



10.3 Physical Properties

10.3.1 Melting Temperature

91. A pure metal has a fixed melting temperature that is just above its solidification temperature. However, complete melting of _________occurs over a range of temperatures.

A. non-ferrous metals B. alloyed materials C. ferrous metals

10.3.2, 10.3.3, 10.3.4, 10.3.5

92. Which property below affects the heat input required to weld a metal?

A. Coefficient of Thermal Expansion B. Density C. Thermal Conductivity

93. Steel requires less heat input to weld than aluminum. What property determines

this?

A. Thermal Conductivity B. Electrical Conductivity C. Density

94. Some metals are more subject to distortion than others during welding. This is

because of a physical property know as _______________________

A. Electrical Conductivity B. Coefficient of Thermal Expansion C. Thermal Conductivity

95. Casting and welds are usually _______dense than wrought materials.

A. more B. less

96. _____________ is an important factor in RT.

A. Thermal Conductivity B. Density C. Melting Temperature



10.4 MECHANICAL PROPERTIES

10.4.1, 10.4.2, 10.4.3, and 10.4.4

97. The mechanical property of a metal that defines its amount of deformation and

elongation is referred to as _____.

A. ultimate strength B. tensile strength C. strain

98. Knowing how ductile a metal is helps to determine _______________.

A. tensile strength B. the extent to which a metal can be worked without fracture during fabrication

operations C. how often a metal can be stressed before failure

99. Which of the following is hardness test for metals?

A. Vickery C B. Knoop C. Donnell Scale

100. Which hardness test uses a minor and major load to determine hardness?

A. Rockwell B. Vickers C. Brinell

101. The ability for a metal to absorb energy and deform plastically before fracture is

known as its ___________________.

A. Ductility B. Yield C. Toughness

102. Toughness is required a lower metal temperatures to resist_____________.

A. spider cracking B. planer breaking flaws C. brittle fracture



10.5 PREHEATING

103. Which of the following is the primary reason for pre-heating when welding carbon and low alloy steels?

A. Reduce shrinkage stresses B. Reduce hydrogen induced delayed cracking C. Eliminate moisture from the weld area

10.6 POST-WELD HEAT TREATMENT

104. Post-weld heat treatment is mostly done to bring about_____________.

A. a reduction of locked in stresses due to the welding process B. a softening of the metal to prevent environmental cracking C. a change in the chemistry of the weld metal and heat affected zone

10.7 HARDENING

105. Which of the following is a typical test for the hardenability of metals?

A. Johnson Freeman Plate Test B. Jominy Bar Test C. Everson and Ives Flattening Bar Test

10.8 MATERIAL TEST REPORTS

106. Which of the following is not a true statement about the MTR?

A. The chemical analysis given in the test report can be used to calculate the carbon equivalent for that material.

B. The inspector should review the material test report. C. The material test report is automatically provided by the manufacturer even if not

requested.



10.9 WELDABILITY OF STEELS 107. List below 5 factors related to the weldability of a metal.

A. ______________________________________________________________ B. ______________________________________________________________ C. ______________________________________________________________ D.______________________________________________________________ E. ______________________________________________________________

10.9.1 Metallurgy and Weldability

108. The addition of carbon to a metal generally makes it________________.

A. easier to weld B. more difficult to weld

109. Which of the following is considered a tramp element in carbon steel?

A. sulfur B. phosphorus C. arsenic D. all of the above

110. The equation below is referred to as the ______________equation.

A. Schaffer B. Dilution C. Carbon Equivalent



10.9.2 Weldability Testing

111. The restraint tests that determine possibility of weld metal cracking for the following locations and types are ____________________.

Solidification cracks Root & Toe Micro cracks A. Lehigh and RRC B. Lehigh and Circular Weld C. Tekken and Slot

10.10.1 Austenitic Stainless Steel

112. List the most important considerations when welding Stainless Steels.

A. _______________________________

B. _______________________________

C. _______________________________

D. _______________________________

113. Austenitic stainless steels are iron-based alloys that typically contain low carbon,

chromium between ________ and nickel between _________.

A. 10 % - 22% and 5% - 27% B. 19 % - 42% and 5% - 27% C. 15% - 32% and 8% - 37%

114. Stainless Steels which are subject to hot cracking may be evaluated for this

problem by using the __________________________.

A. Carbon Equivalent of the base metal B. ferrite number of the weld metal C. Slot test

115. Austenitic Stainless Steels distort more easily than carbon steels due to their lower

__________ and higher_____________.

A. solubility - coefficient of heat transfer B. thermal conductivity - thermal expansion C. thermal expansion - thermal conductivity



10.10.2 Nickel Alloys 116. Nickel alloys weld in a sluggish manner, meaning the weld metal does not move

easily during the welding process and this tends to create a lack of sidewall fusion as a result. A proper technique is to use a weave or oscillation during welding. One indication that proper weave/oscillation has not occurred is ______________________.

A. the weld contour will be concave or flat B. the weld contour will have a convex profile C. the weld contour will have a high convex profile

117. Nickel alloys are subject to ___________________.

A. short cracks B. hot cracking C. cold cracking

11 Refinery and Petrochemical Plant Welding Issues

11.2 HOT TAPPING AND IN-SERVICE WELDING

118. The two primary concerns when welding on in-service piping and equipment are

____________ and __________.

A. burn through - cracking B. rupture - cracking C. burn through - rupture



11.2.1 Electrode Considerations 119. Hot tap and in-service welding should be carried out only with low - hydrogen

consumables, the reasoning for this when welding carbon steel is to prevent___________.

A. hydrogen centerline cracks (HCC) B. hydrogen cracks (HC) C. hydrogen assisted cracks (HAC)

11.2.2 Flow Rates

120. The flow rate of liquids in a piping system may affect the possibility of a failure during in-service welding. A low flow rate may cause____________.

A. hard zones and cracks B. burn through C. lack of fusion

11.2.3 Other Considerations

121. When hot tapping a piping system that contains Wet Hydrogen Sulfide the

possibility of __________________ is a concern.

A. explosion B. pyrophoric scale C. metal burning

11.2.4 Inspection

122. Briefly list the duties of the inspector associated with hot tapping or welding on in-

service equipment. A. ______________________________________________________________

B. ______________________________________________________________

C. ______________________________________________________________

D. ______________________________________________________________

E. ______________________________________________________________

F. ______________________________________________________________

G. ______________________________________________________________

H. ______________________________________________________________



APPENDIX A

A.1 Weld Joint Types

123. In the Edge Joint depicted above which of the following types of welds

unacceptable?

A. Bevel Groove B. U - Groove C. Plug

Figure A-2 Symbols for Various Weld Joints

124. The weld symbol shown above is for a _______________________.

A. Double Bevel Weld B. V Weld C. Compression Weld



125. The symbol above is for the use of a _________________________.



Figure A-4 Standard Weld Symbols

126. Using Figure A-4 label the element of the drawing above.

127. Fill in the name of weld joint parts above.



AWS

Filler Metal Classifications

128. The T in the designation above stands for _______________________.

A. Tubular B. Position C. Trailing gas required.

APPENDIX B - ACTIONS TO ADDRESS IMPROPERLY MADE WELDS

129. What action is missing in the chart above? ____________________



APPENDIX DGUIDE TO COMMON FILLER METAL SELECTION 130. A good choice of filler metal for the SMAW welding of carbon steel to carbon

molybdenum steel might be _______ and ________.

A. Classification E7018 and Classification E7018-A1 B. E7018-B2L or E8018-B2, low hydrogen

131. List below the common welding consumables to weld 304L Stainless Steel to

Carbon Steel.

A. __________ B. __________

132. A common filler metal in the past for welding 1Cr -1/2 Molybdenum was E8018-

B2L, that AWS classification has been changed to _________________.

RP 577 Welding Inspection and Metallurgy Answer Key


1. C 2. B 3. A. Identify and clarify missing details and information.

B. Identify and clarify missing weld sizes, dimensions, tests, and any additional requirements. C. Identify and clarify inconsistencies with standards, codes and specification requirements. D. Highlight potential weld problems not addressed in the design.

4. C 5. A. NDE examiners are properly certified for the NDE technique (see 4.6)

B. NDE procedures are current and accurate. C. Calibration of NDE equipment is current.

6. C 7. A. Heat treatment procedure is available and appropriate (see 10.6).

B. Pressure testing procedures are available and detail test requirements. C. PWHT equipment calibration is current. D. Pressure testing equipment and gauges calibrated and meet appropriate test

requirements. 8. Ans. If required, perform PMI to verify the material composition 9. B 10. C 11. Ans. Special training and mock-up weldments performed if required. 12. Ans. - Additional NDE performed between weld passes and on back-gouged

surfaces. 13. B 14. A 15. A 16. A. Arc radiation

B. Air contamination C. Airborne debris D. Heat

17. C 18. A 19. A. Equipment is relatively simple, inexpensive, and portable.

B. Process can be used in areas of limited access. C. Process is less sensitive to wind and draft than other welding processes. D. Process is suitable for most of the commonly used metals and alloys

20. A. Deposition rates are lower than for other processes such as GMAW. B. Slag usually must be removed at stops and starts, and before depositing a weld

bead adjacent to or onto a previously deposited weld bead. 21. C 22. C 23. B 24. C 25. B



26. A 27. B 28. B 29. A 30. C 31. A. Provides very high metal deposition rates.

B. Produces repeatable high quality welds for large weldments and repetitive short welds.

32. A 33. B 34. C 35. SMAW 36. GTAW 37. GMAW 38. FCAW 39. FCAW self-shielding 40. SAW 41. C 42. C 43. B 44. C 45. A 46. A 47. D 48. C 49. C 50. D 51. Seam or Lap 52. Throat Crack 53. Overlap 54. Aligned Porosity 55. Incomplete Fusion 56. C 57. C 58. D 59. B 60. A 61. A 62. A 63. A. Eddy current can be used as a quick test to ensure that the components being

joined during welding have the same material properties. B. As a quick check for defects of the weld joint faces. C. Measure the thickness of protective, nonconductive surface coatings. D. Measure cladding thickness.

64. B



65. B 66. A 67. C 68. C 69. Ans. For materials, and for welds in components, a technique may be used in

which the radiation passes through two walls and only the weld (material) on the film sidewall is viewed for acceptance. An adequate number of exposures should be made to demonstrate that the required coverage is met for circumferential welds (materials). A minimum of three exposures taken at 120 to each other should be made.

70. B 71. B 72. C 73. B 74. B 75. A 76. B 77. C 78. C 79. A 80. A 81. C 82. A. (calibration block) should be of the same nominal diameter

B. Same thickness. C. Same composition. D. Same heat treatment condition as the product that is being examined. E. It should also have the same surface condition as the part being examined.

83. C 84. 1. B

2. A 3. D 4. C

85. B 86. B 87. C 88. D 89. C 90. A 91. B 92. C 93. B 94. B 95. B 96. B 97. C



98. B 99. B 100. A 101. C 102. C 103. B 104. A 105. B 106. C 107. A. The metallurgical compatibility of the metal or alloy being welded, which is

related to the chemical composition and microstructure of the metal or alloy, and the weld filler metal used.

B. The specific welding processes being used to join the metal. C. The mechanical properties of the metal, such as strength, ductility and

toughness. D. The ability of the metal to be welded such that the completed weld has sound

mechanical properties. E. Weld joint design.

108. B 109. D 110. C 111. A 112. The most important considerations to welding austenitic stainless steels are;

A. solidification cracking B. hot cracking C. distortion D. maintaining corrosion resistance

113. C 114. B 115. B 116. C 117. B 118. A 119. C 120. B 121. B 122. Inspection tasks typically associated with hot tapping or welding on in-service

equipment should include: A. Verifying adequate wall thickness along the lengths of the proposed welds

typically using UT or RT. B. Verifying the welding procedure. Often, plants have welding procedures

qualified specifically for hot taps and in-service welding. C. Verifying flow conditions. D. Specifying the sequence of welding full encirclement sleeves and fittings



(circumferential and longitudinal welds). E. Verifying fit-up of the hot tap fitting. F. Auditing welding to assure the welding procedure is being followed. G. Perform NDE of completed welds. Typically this includes VT, UT shear wave

using special procedures for the joint configuration, MT or PT as applicable for material and temperature.

H. Witness leak testing of fitting, if specified. 123. C 124. B 125. Answer Consumable Insert - Square 126. See Figure A-4 127. See Figure A-5 128. B 129. Answer: Test Welder to Qualify Appendix B Fig. B-1 130. A Appendix D Table D-1 131. Table D-2 E309-XX or EniCrFe -2 or -3 132. Table D-4 E7018-B2L

577 Exercise

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