API 577 quiz

577 QUIZ  1. •

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What What are are the the weld weldme ment nt requ requir irem emen ents ts prio priorr to to wel weldi ding ng?  ?  Review the WPS(s) and welder performanc performancee qualification record(s) (WPQ) to assure they are acceptable for the work. onfirm the !"# e$aminer(s)% !"# procedure(s) and !"# equipment of the inspection or&ani'ation or&ani'ation are acceptable for the work. onfirm weldin& equipment and instruments are calibrated and operate. onfirm heat treatment and pressure testin& procedures and associated equipment are acceptable #nsure all filler metals% base material materials% s% and backin& rin& materials are properly marked and identified and if required% perform P to verify the material composition. composition. onfirm weld preparation% *oint fit+up% and dimensions are acceptable acceptable and correct. onfirm the preheat equipment and temperature. onfirm electrode% filler wire% flu$es% and inert &ases are as specified and acceptable.

2.

What What are are the the mate materi rial als s req requi uire reme ment nts s pri prior or to weld weldin ing?  g? 

a. aterial test certifications certifications are are available and and items properly marked marked (includin& back+up back+up rin& if used  b. #lectrode markin&% markin&% bare wire fla& ta&s% ta&s% identification identification on spools of wire% etc. as+specified as+specified (see ,.-). c. iller material markin&s are traceable to a filler material certification. d. /ase metal markin&s are traceable to a material certification. e. Recordin& of filler and base metal traceability information is performed. f. /ase metal stampin&s are low stress and not detrimenta detrimentall to the component. &. Paint stripin& color code is correct for the material of construction. h. P records supplement the material traceability traceability and confirm the material of construction

3. • • •

What What are are the the qua quali lity ty assu assura ran ne e tas tas!s !s duri during ng weld weldin ing?  g?  #stablish a quality assurance and quality control umbrella with the weldin& or&ani'ation. onfirm weldin& parameters and techniques are supported by the WPS and WPQ. omplete physical checks% visual e$amination% and in+process !"#

".

What What are are the the appe appear aran ane e and and #in #inis ish h tas! tas!s s upo upon n om ompl pleti etion on o# weld weldin ing?  g? 

a. Si'e% len&th and location of all welds conform to the drawin&s0specifications0ode. drawin&s0specifications0ode.  b. !o welds added without approval. approval. c. "imensional and visual checks of the weld don1t identify weldin& discontinuities% e$cessive distortion and  poor workmanship. d. 2emporary attachments and attachment welds removed and blended with base metal. e. "iscontinuities reviewed a&ainst acceptance criteria for defect classification. classification. f. P of the weld% if required% and e$aminer1s findin&s indicate they comply with the specificati specification. on. &. Welder stampin&0markin& of welds confirmed. h. Perform field hardness check 

5.

$ame $ame 2 $%& $%& pers person onne nell qua quali li#i #iat atio ions ns spei spei#i #ied ed in '()& '()& (&* (&* + art 1.

a. 3S!2 S!2+2+43  b. 3!S03S!2 P+45,

,.

What What are , re#er e#eren ene ed d weld elding ing pro proes esse ses?  s?  • • • •

shielded metal arc weldin& (S3W) &as tun&sten arc weldin& we ldin& (623 (623W) W) &as metal arc weldin& (63W)

• • •

7.

flu$ cored arc weldin& (3W) submer&ed arc weldin& (S3W) stud arc weldin& (SW)

What are the ad-antages and limitations o# the ()'W welding proess? 

Some commonly accepted advanta&es of the S3W process include7 a. #quipment is relatively simple% ine$pensive% and portable.  b. Process can be used in areas of limited access. c. Process is less sensitive to wind and draft than other weldin& processes. d. Process is suitable for most of the commonly used metals and alloys. 8imitations associated with S3W are7 a. "eposition rates are lower than for other processes such as 63W.  b. Sla& usually must be removed at stops and starts% and before depositin& a weld bead ad*acent to or onto a  previously deposited weld bead.

.

What are the 3 #iller metal trans#er modes in the /)'W welding proess?  • • •

Short ircuitin& 2ransfer (63W+S) 2he &lobular transfer mode 2he spray transfer mode

0. What are at least si types o# essential -ariales that must e shown on the W(?  a. Process.  b. /ase metal. c. iller metal (and0or flu$). d. Weldin& current. e. Weldin& position. f. Shieldin& &as% if used. &. Preparation of base metal. h. ittin& and ali&nment. i. /ackside of *oint.  *. Peenin&.

14.

What are the " tests that an e #ound on the Q?  • • • •

11.

What are the 3 steps used in re-iewing a W(6Q?  •

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they will include tension test to determine the ultimate stren&th of a &roove weld% guided bend  tests to determine the de&ree of soundness and ductility of a &roove weld notch toughness  testin& when tou&hness requirements are imposed% hardness measurements  when hardness restrictions are defined

2he initial step is to verify the WPS has been properly completed and addresses the requirements of Section 9 and the construction0repair code. 2he second step is to verify the PQR has been properly completed and addresses all the requirements of Section 9 and the construction and repair code.  2he third step is to confirm the PQR essential variable values properly support the ran&e specified in the WPS .

12.

Where are the 'W( lassi#iations #ound in (e I? 

3n 3WS classification number identifies electrodes and weldin& rods. 2he 3WS classification numbers are specified in 3S# Section  under their appropriate S3 specification number. 3S# Section 9 Table QW-432 lists the 3WS classification numbers and S3 specification numbers included under each of the + numbers.

13.

8he '9numer applies to whih type o# -essel? 

steel and steel alloy

1". Where an '()& guidelines e #ound #or storage and handling o# #iller  metals?  Weldin& consumable stora&e and handled &uidelines should be in accordance with the consumable manufacturer1s instructions and &uidelines and as &iven in the 3WS 3:.99 series of filler metal specifications . Sec. 9

15.

%iret +8 is onduted when aess is su##iient to plae the eye within? 

"irect visual e$amination is conducted when access is sufficient to place the eye within ; in. < -= in. (4:> mm  < ;>> mm) of the surface to be e$amined and at an an&le not less than ?> de&rees to the surface

1,.

$ame the 5 mehanial aids to +8.

a. Steel ruler@available in a wide selection of si'es and &raduations to suit the needs of the inspector (considered a non+precision measurin& instrument).  b. Aernier scale@a precision instrument% capable of measurin& in decimal units to a precision factor of >.>>>4 in. 2he Aernier system is used on various precision measurin& instruments% such as the caliper% micrometer% hei&ht and depth &a&es% &ear tooth and protractors. c. ombination square set@consistin& of a blade and a set of three heads7 Square% enter and Protractor. Bsed universally in mechanical work for assembly and layout e$amination. d. 2hickness &au&e@commonly called a CeelerD &au&e is used to measure the clearance between ob*ects. e. 8evels@tools desi&ned to prove if a plane or surface is truly hori'ontal or vertical

17.

:or added sensiti-ity using )8 whih tehnique is reommended? 

or added sensitivity% wet fluorescent ma&netic particle (W2) techniques may be used. With this technique% a filtered blackli&ht is used to observe the particles% which requires the area of testin& be darkened

1.

What are the " requirements that apply to 8? 

a. nspection is to be performed in accordance with a procedure as specified by the referencin& code section).  b. 2ype of penetrant materials to be used. c. "etails for pre+e$amination cleanin& includin& minimum dryin& time. d. "well time for the penetrant. e. "etails for removin& e$cess penetrant% applyin& the developer% and time before interpretation. f. #valuation of indications in terms of the acceptance standards of the referencin& code. &. Post e$amination cleanin& requirements. h. inimum required surface illumination (visible or blackli&ht) of the part under e$amination

10.

What are the ommon hole diameters o# hole type IQI;s related to? 

Eole+type Q1s (penetrameters) are placed ne$t to the weld either on the parent material or on a shim havin& a thickness equivalent to the weld build+up. or pipe wall or weld thickness of >.?4- in. (F., mm)% a !o. 4: 3S2 Q (penetrameter) with a thickness of >.>4: in. would be used. See 2able F for Q (penetrameter) numbers for other thicknesses. 2his table illustrates the specified thickness and number of 3S2 # 4=- Q1s (penetrameters) for all thickness ran&es. 1T, 2T & 4T

24. What are the 2 most ommon radioati-e soures used #or 8?  6amma Ray (R4,-) is normally used for performin& radio&raphy on steel with a thickness ran&e of >.-: in. < ?.> in. and obalt (G;>) is used for steel thickness of 4.: in. < F.> in. 21. When using the doule wall tehnique #or 8 how many eposures are required when oth walls are superimposed?  3lternatively% the weld may be radio&raphed with the radiation beam positioned such that both walls are superimposed. When complete covera&e is required% a minimum of three e$posures taken at either ;>H or 4->H to each other should be made for each weld *oint.

22.

What are " items that a #ilm interpreter must possess? 

2he interpreter should know7 a. 2he characteristics of the radiation source and ener&y level(s) with respect to the material bein& e$aminedI  b. 2he characteristics of the recordin& media in response to the selected radiation source and the ener&y level(s)I c. 2he processin& of the recordin& media with respect to the ima&e qualityI d. 2he product form (ob*ect) bein& radio&raphedI e. 2he possible and most probable types of discontinuities that may occur in the test ob*ectI and f. 2he possible variations of the discontinuities1 ima&es as a function of radio&raphic &eometry% and other factors.

23.

What are 3 types o# displays used with U8? 

2he 3+scan% /+scan and +scan

2".

What is the purpose o# %'*? 

2he distance amplitude correction ("3) curve allows a s imple echo evaluation of unknown reflectors by comparison of the echo hei&ht with respect to the "3 (J"3). /ecause of attenuation and beam diver&ence in all materials% the echo amplitude from a &iven si'e reflector decreases as the distance from the probe increases. 2o set up "3% the ma$imum response from a specified reference reflector (e.&.% flat bottom or side drilled hole) is recorded at different depths over the required test ran&e.

25.

What are the 3 types o# 'utomated U8? 

Pulse #cho Raster Scannin&% Pulse #cho Koned nspection% 2ime of li&ht "iffraction (2G")

2,.

8he tip di##ration method is e##eti-e #or si
2ip diffraction methods are very effective for si'in& flaws which are open to the inside or outside diameter surface and are shallow to mid+wall. or " connected flaws% the half CAD path or one and one half CAD path technique is used. or G" connected flaws% two techniques are availableI the time+offli&ht tip diffraction technique and the time measurement technique of the tip diffracted si&nal and the base si&nal.

27.

What is a ommon lea! testing method that is used in hydrotesting? 

Gne of the most common methods used durin& hydrostatic testin& is the direct pressure bubble test. 2his method employs a liquid bubble solution% which is applied to the areas of a closed system under pressure. 3 visual test is then performed to note any bubbles that are formed as the leaka&e &as passes throu&h it. When  performin& the bubble test% some items of concern include the temperature of surface to be inspected% pre+test and post+test cleanin& of the part to be inspected% li&htin&% visual aids and the hold time at a specific pressure  prior to application of the bubble solution.

2.

What items o# inspetion results are to e reported in an inspetion report? 

9.12.1.1 General Information

9.12.1.2 Inspection Information

9.12.1.3 Inspection Results

a. ustomer or pro*ect

a. "ate of inspection.

a. nspection sheet number.

 b. ontract number or site

b. Procedure number.

b. nspection limitations.

c. "ate of inspection.

c. #$aminer.

c. nspection results.

d. omponent0system

d. #$aminer certification information.

d. 3 description of all recordable and reportable indications

e. Subassembly0description.

e. nspection method.

e. or each indication7

f. Weld identification

f. Aisual aids and other equipment used

&. Weld type0material0thickness

&. Weld reference datum point.

20. What e##ets does trae elements o# aron= sul#ur and phosphorous ha-e in a ast struture?  2he properties of the cast structure can also be impaired by compositional variations in the microstructure called se&re&ation. /ecause of the solubility of trace and alloyin& elements% such elements as carbon% sulfur% and phosphorous% can vary in a pure metal% these elements can cause variations in the s olidification temperature of different microstructural phases within the melt. 3s the melt cools% these elements are eventually contained in the micro structural phases that solidify last in spaces between the &rains.

34. What are other terms #or rapid heating and ooling o# a wrought material  within ertain temp ranges?  2he formation of structures such as bainite and martensite may also be the result of rapid or controlled coolin& and reheatin& within certain temperature ran&es often termed Cquenchin&D and Ctemperin&.

31.

What is an important #ator in the seletion o# shielding gases? 

3n important factor in selectin& shieldin& &ases is the type or mi$ture. 3 reactive &as such as carbon dio$ide can break down at arc temperatures into carbon and o$y&en. 2his is not a problem on carbon and low+alloy steels. Eowever% on hi&halloy and reactive metals% this can cause an increase in carbon content and the formation of o$ides that can lower the corrosion resistant properties of the weld. Ei&h+alloy materials welded with &as+shielded processes usually employ inert shieldin& &ases or mi$tures with only sli&ht additions of reactive &ases to promote arc stability.

32. )aterials with high thermal onduti-ity require higher or lower heat inputs to weld?  n &eneral% metals with hi&h electrical conductivity also have hi&h thermal conductivity. aterials with hi&h thermal conductivity require hi&her heat inputs to weld than those with lower thermal conductivity and may require a pre+heat.

33.

What are metals with high oe##iient o# thermal epansion suseptile to? 

Steel is a poor conductor of heat as compared with aluminum or copper. 3s a result it takes less heat to melt steel. 3luminum is a &ood conductor of heat and has the ability to transfer heat very efficiently. 2his ability of aluminum to transfer heat so efficiently also makes it more difficult to weld with low temperature heat sources.

3".

(tress in relation to a tensile test is de#ined as? 

Stress is defined as the force actin& in a &iven re&ion of the metal when an e$ternal load is applied. 2he nominal stress of a metal is equal to the tensile stren&th. 2he ultimate tensile stren&th of a metal is determined  by dividin& the e$ternal load applied by the cross sectional area of the tensile specimen

35. %utility is usually epressed as perentage o# the elongation within a  >>>>>>>>>>gage length?  Bniform elon&ation will continue% and the elon&ation be&ins to concentrate in one locali'ed re&ion within the &a&e len&th% as does the reduction in the diameter of the specimen. 2he test specimen is said to be&in to Cneck  down.D 2he neckin&+down continues until the specimen can no lon&er resist the stress and the specimen separates or fractures. 2he stress at which this occurs is called the ultimate tensile stren&th.

3,. $ame 3 hardness testing methods. rinnell= +i!ers= o!well 37.

What is the meaning o# 55 @*? 

3 letter has been assi&ned to each combination of load and indenter. Scale is indicated by a suffi$ combination of E for Eardness% R for Rockwell and then a letter indicatin& scale employed. or instance% a value of :: on the  scale is e$pressed as :: ER.

3.

What is an eample o# an in9ser-ie degradation that is hardness related? 

2here are often in+service de&radation requirements% which are hardness related. or e$ample% susceptibility to wet E-S crackin& in carbon steel is reduced if hardness levels are maintained below ER --.

30.

What are , reasons #or per#orming pre heating? 

a. /rin& temperature up to preheat or interpass temperatures required by the WPS.  b. Reduce shrinka&e stresses in the weld and base metal% which is especially important in weld *oints with hi&h restraint. c. Reduce the coolin& rate to prevent hardenin& and a reduction in ductility of the weld and base metal E3K. d. aintain weld interpass temperatures. e. #liminate moisture from the weld area. f. eet the requirements of the applicable fabrication code% such as the 3S#  Boiler and Pressure Vessel Code% dependin& on the chemistry and thickness of the alloy to be welded.

"4.

What is the name applied to a nothed ar impat test? 

Gne of the most common is a notched bar impact test called the harpy impact test.

"1.

)aterials are o#ten impat tested at -arious to determine what? 

aterials are often tested at various temperatures to determine the ductile to brittle transition temperature. any codes and standards require impact testin& at minimum desi&n metal temperatures based on service or location temperatures to assure that the material has sufficient tou&hness to resist brittle fracture.

"2.

What is the primary reason #or W@8? 

2he primary reason for post+weld heat treatment is to relieve the residual stresses in a welded fabrication .

"3. Why is hardening o# the weld and ase metal @'Z are important in aron and low alloy steels?  Eardenin& of the weld and base metal E3K are important because of hydro&en assisted crackin& that occurs in carbon and low+alloy steels. 3s the hardness of the base metal E3K increases so does the susceptibility to hydro&en assisted crackin&. 2he hardness limits currently recommended for steels in refinery process service are listed in 2able 44. Eardness values obtained in e$cess of these usually indicate that post+weld heat treatment is necessary% re&ardless of whether specified on the weldin& procedure specification. n those instances where PWE2 is needed% an alternate weldin& procedure qualified with PWE2 is necessary .

"".

@ow is hardenaility determined? 

2he simplest means to determine hardenability is to measure the depth to which a piece of steel hardens durin& quenchin& from an elevated temperature.

"5.

What are 2 types o# )8;s? 

2here are typically two types of test reports% a heat analysis and a product analysis . 3 heat analysis% or mill certificate% is a statement of the chemical analysis and wei&ht percent of the chemical elements present in an in&ot or a billet. 3 product analysis is a statement of the chemical analysis of the end product and is supplied  by the manufacturer of the material.

",.

What are the #ators related to weldaility? 

a. 2he metallur&ical compatibility of the metal or alloy bein& welded% which is related to the chemical composition and microstructure of the metal or alloy% and the weld filler metal used.  b. 2he specific weldin& processes bein& used to *oin the metal. c. 2he mechanical properties of the metal% such as stren&th% ductility and tou&hness. d. 2he ability of the metal to be welded such that the completed weld has sound mechanical properties. e. Weld *oint desi&n.

"7.

What is the primary #ator a##eting weldaility o# metals and alloys? 

3 primary factor affectin& weldability of metals and alloys is their chemical composition.

".

What do steels ha-ing a *& etween 4.35 A 4.55 require? 

2ypically% steels with a # less than >.?: require no preheat. Steels with a # of >.?: < >.:: usually require  preheatin&% and steels with a # &reater than >.:: require both preheatin& and a PWE2

"0.

8he simplest weldaility tests are those that e-aluate what? 

2he simplest weldability tests are those that evaluate the stren&th and ductility of the weld. 2ests that evaluate stren&th include weld tension tests% shear stren&th% and hardness. "uctility and fracture tou&hness tests include  bend tests and impact tests

54.

8he Behigh 8est e-aluates what types o# ra!s? 

Weld restraint induces stresses that can contribute to crackin& of both the weld and base metal in fabrication welds. 2his type of crackin& occurs when the ri&idity of the *oint is so severe that the base metal or weld metal stren&th cannot resist the strains and stresses applied by e$pansion and contraction of the weld *oint.

51. What is the most ommon measure o# weldaility and suseptiility to hot  ra!ing in austeniti stainless steel than #or aron steel?  2he most common measure of weldability and susceptibility to hot crackin& is the  ferrite number of the weld metal. 3ustenitic welds require a minimum amount of delta ferrite to resist crackin&. 2he amount of ferrite in the weld metal is primarily a function of both base metal and weld metal chemistry. or welds made without filler metal% the base metal chemistry should be appropriate to produce the small amounts of ferrite that is needed to prevent crackin&.

52.

Is distortion greater or less #or austeniti stainless steel than aron steel? 

"istortion is more often a problem with weldin& of austenitic stainless steels than carbon or low+alloy steels. 2he thermal conductivity of austenitic stainless steels is about one third that of carbon steel and the coefficient of thermal e$pansion is about ?>J &reater. 2his means that distortion is &reater for austenitic stainless steels than for carbon steels. ore frequent tack welds may be necessary for stainless steels to limit shrinka&e.

53. Is it an ad-antage or disad-antage to apply preheating to ni!el alloys when welding?  2he faster a nickel alloy weld solidifies (free'es)% the less time it spends in the temperature ran&e where it can tear. or this reason pre+heatin&% which slows down the coolin& rate of the weld% is actually harmful% as it  permits more opportunity for hot tearin& to occur.

5". @ot tap and in9ser-ie welding operations should e arried out with what  type o# eletrodes?  Eot tap and in+service weldin& operations should be carried out only with low+hydro&en consumables and electrodes (e.&.% #F>4;% #F>45 and #F>=5). #$tra+low+hydro&en consumables such as #$$$$+E= should be used for weldin& carbon steels with # &reater than >.=?J or where there is potential for hydro&en assisted crackin& (E3) such as cold worked pieces% hi&h stren&th% and hi&hly constrained areas.

55. What is the required liquid #low rates in piping when in9ser-ie welding is  per#ormed?  Bnder most conditions% it is desirable to maintain some product flow inside of any material bein& welded. 2his helps to dissipate the heat and to limit the metal temperature durin& the weldin& operation% thereby reducin& the risk of burnthrou&h. Liquid lo! rates in piping shall be bet!een 1"3 t#sec" and 4"$ t#sec" aster liquid flow rates may cool the weld area too quickly and thereby cause hard 'ones that are susceptible to weld crackin& or low tou&hness properties in the weldment.

5,. 8o minimi
57. What are the inspetion tas!s typially assoiated with hot tapping or  welding on in9ser-ie equipment?  a. Aerifyin& adequate wall thickness alon& the len&ths of the proposed welds typically usin& B2 or R2.  b. Aerifyin& the weldin& procedure. Gften% plants have weldin& procedures qualified specifically for hot taps and in+service weldin&. c. Aerifyin& flow conditions. d. Specifyin& the sequence of weldin& full encirclement sleeves and fittin&s (circumferential and lon&itudinal welds). e. Aerifyin& fit+up of the hot tap fittin&.

f. 3uditin& weldin& to assure the weldin& procedure is bein& followed. &. Perform !"# of completed welds. 2ypically this includes A2% B2 shear wave usin& special procedures for the *oint confi&uration% 2 or P2 as applicable for material and temperature. h. Witness leak testin& of fittin&% if specified.

5. What is the limiting #ator #or ase metal thi!ness when welding with the /)'W9( proess?  2he &as metal arc weldin& (63W) process can utili'e various metal transfer modes. When usin& the low volta&e% short circuitin& mode (desi&nated by the +S e$tension)% the molten weld puddle is able to free'e more quickly. 2his allows the unique ability to weld out of position% to weld thin base metals% and to weld open butt root passes. "ue to this inherent nature of the weldin& process the /PA ode Section 9% restricts this process  by7 a. Requirin& welders qualify with mechanical testin& rather than by radio&raphic e$amination.  b. 8imitin& the base metal thickness qualified by the procedure to 4.4 times the test coupon thickness for coupons less than 40- in. thick (4-.F mm) per variable QW+=>?.4>. c. 8imitin& the deposited weld metal thickness qualified by the procedure to 4.4 times the deposited thickness for coupons less than 40- in. thick (4-.F mm) per variable QW+=>=+?-. d. akin& variable QW+=>,.- an essential variable when qualifyin& a welder for the 63W+S process.

50.

What is the trans#er mode #or /)'W9(? 

63W in the short+circuitin& transfer mode is of particular si&nificance to inspectors in that many specifications% codes and standards impose limitations or special conditions on its use. 2he technique can suffer from incomplete fusion particularly in the sidewall of steep or narrow weld preparations.

,4.

What are 5 types o# weld Coints?  • • • • •

 Butt Joint  Corner Joint  T-Joint   Lap Joint   Edge Joint 

,1. What do the 1st  2 ;s stand #or on the ()'W eletrode identi#iation system?  4st L -nd 91s is for Stren&th% ?rd 9 is for position% =th 9 is for coatin& characteristics #9999

,2. 'n eletrode6#lu identi#iation is :7',9&)12D. What is the identi#iation o#  the #lu? F3;+#4-M is a complete desi&nation. t refers to a flu$ that will produce weld metal which% in the as+ welded condition% will have a tensile stren&th no lower than F>%>>> psi and harpy A+notch impact stren&th of at least -> ft+lb at <;>H when deposited with an #4-M electrode under the conditions called for in this specification.