Closed Book Practice Questions

API RP 577 PRACTICE QUESTIONS

1. The level of learning and training offered by RP 577 is __________________.

a.
b.
c.
d.

consistent with an AWS CWI

the same as required for an AWS CWI
not a replacement for AWS CWI training
automatically makes one a welding inspector

2. DCEN means.
a.
b.
c.
d.

direct current, electrode none

direct current, electrode negative
dont come easy, Norman
direct current, electrode normal

3. Another name or abbreviation for a penetrameter is:

a.
b.
c.
d.

O.C.T.
D.E.Q.
B.E.P.
I.Q.I.

4. A theoretical throat dimension is based on the assumption that the root opening is equal to:
a.
b.
c.
d.

zero
1/16
1/8
1/32 1/16

5. Welding inspection is a critical part of any ____________ program.

a.
b.
c.
d.

Quality Assurance
Quality Process
ISO 9000
ISO 11000

6. Welding inspection can be separated into 3 distinct stages:

a.
b.
c.
d.

welding, NDE, hardness testing

pre-welding, NDE, heat treatment
visual, NDE, RT
before welding, during welding, after welding

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7. One of the items that should be checked prior to welding is:

a.
b.
c.
d.

confirm NDE examiners qualifications

confirm acceptability of heat treatment procedures
review WPS, PQR, and WPQs
All of the above should be checked prior to welding

8. When discovered, welding defects should be:

a.
b.
c.
d.

radiographed to determine extent

removed and re-inspected
shearwave tested
evaluated to API 580 acceptance criteria

9. NDE examiners should be qualified to ______ when specified by the referencing code.
a.
b.
c.
d.

ASME XII
API 570
SNT-TC-1A
API 510

10. As a minimum, each Inspector should review the ______________ prior to starting each job.
a.
b.
c.
d.

OSHA regulations
EPA regulations
site safety rules
HAZWOPER Guidelines

11. An advantage of SMAW is:

a.
b.
c.
d.

equipment is very expensive

slag must be removed from weld passes
can be used on almost all commonly-used metal or alloy
deposition rates are much higher than for other processes

12. GTAW and SMAW can be distinguished from other processes as they are both used with _______.
a.
b.
c.
d.

cc power supplies
cv power supplies
external gas shielding
flux cored electrodes

13. When welding aluminum, and magnesium with GTAW, ______ is normally used.
a.
b.
c.
d.

DCEN
CCPO
DCEP
AC

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14. GMAW can be used in 3 distinct modes of transfer. The coolest or fastest freezing of these transfers is:
a.
b.
c.
d.

spray
short circuiting
pulse-spray
globular

15. A limitation of the FCAW process is:

a.
b.
c.
d.

slag removal
slower than GTAW or SMAW
lower deposition than GTAW
lack of fusion problems because of short arcing

16. One of the unusual aspects of SAW is that:

a.
b.
c.
d.

it is not an arc welding process

it can be automated
the arc is not visible during welding
a gas is used for shielding

17. The three welding documents required to make a production weld (as required by ASME IX) are:
a.
b.
c.
d.

WPS, PQR, WPL

PSW, QPR, WPQ
WPQ, PQR, WPS
POR, PQR, WOR

18. F numbers are assigned to electrodes based on their ______________.

a.
b.
c.
d.

alloy
chemistry
usability characteristics
flux coating

19. What type of electrodes should be stored in a heated oven after initial removal from the package?
a.
b.
c.
d.

low hydrogen
cellulose coated
GMAW rod
high nickel

20. Slightly damp low hydrogen electrodes should be:

a.
b.
c.
d.

discarded
rebaked in special ovens
used as is
rebaked in the storage oven

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21. A welder continuity log should be maintained to allow verification that each welder has utilized each welding
process within a _______ period.
a.
b.
c.
d.

one yea
3 month
2 year
six month

22. Undercut is normally found_______________.

a.
b.
c.
d.

in the weld metal

in the base metal
at the weld interface
at the root of the weld, only

23. Weld underbead cracking is normally found _______________________.

a.
b.
c.
d.

in the HAZ
in the throat of the weld
in the weld root
in the weld face

24. The best NDE method used to inspect butt joints volumetrically (through the entire weld) would be:
a.
b.
c.
d.

PT
VT
RT
LT

25. Hydrogen cracking may occur in all of the following welding processes, except:
a.
b.
c.
d.

SMAW
FCAW
SAW
GMAW

26. In austenitic stainless steel, incomplete penetration is normally corrected by:

a.
b.
c.
d.

reducing travel speed

proper heat input
controlling ferrite content
all of the above

27. Optical aids include which of the following:

a.
b.
c.
d.

levels
thickness gauge
mirrors
fillet weld gauge

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28. A typical fillet weld gauge would include which of the following:
a.
b.
c.
d.

skew-T
Bridge Cam
Hi-Lo
Vernier Caliper

29. ACFM is an NDE technique that is applied to detect:

a.
b.
c.
d.

sub-surface indications, in carbon steel

surface and sub-surface indications in stainless steel
surface indications in carbon, alloy and stainless steel
surface indications in carbon steel only

30. One of the best features of ACFM is that it:

a.
b.
c.
d.

requires not calibration standards

does not require a skilled operator
requires no electricity
is a low temperature technique

31. Eddy Current (ET) has limited use in welding inspection, but is often used in____________.
a.
b.
c.
d.

heavy wall volumetric testing

coating thickness measurement
measuring cladding thickness
both b and c, above

32. The NDE Examiner that performs the radiographic film interpretation should be qualified, as a minimum, to
a _____.
a.
b.
c.
d.

ASNT Level I
ASNT Level II
ASNT Level III
ASNT Level IV

33. Cobalt is normally used for radiographing thicknesses of _________.

a.
b.
c.
d.

0.25 3.0
1.5 7.0
8.0 10.0
0.50 2.0

34. A film density of 1.0 will allow _______% of light through to the film.
a.
b.
c.
d.

1%
10%
0.01%
0.001%

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35. Ultrasonic examination that shows a plan view of the test object would be _____________.
a.
b.
c.
d.

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

36. Each pass of the UT transducer should overlap the previous pass by _____% of the transducer dimension.
a.
b.
c.
d.

1%
5%
10%
15%

37. Because of the similarities in the shape of the grains and cooling characteristics, a weld can be considered
to be a small_______________.
a.
b.
c.
d.

casting
forging
extrusion
ingot

38. A defect is also considered to be a (an):

a.
b.
c.
d.

imperfection
rejectable flaw
acceptable flaw
non-relevant indication

39. The vast majority of metallic materials used in refineries or chemical plants are ___________.
a.
b.
c.
d.

cast materials
killed materials
stainless steel materials
wrought materials

40. Hydrogen in welding may come from various sources, such as:
a.
b.
c.
d.

lubricants
moisture
net electrodes
all of the above

41. Materials with high thermal conductivity will require ___________________.

a.
b.
c.
d.

higher heat input to weld

lower heat input to weld
preheating
post-weld heating

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42. Metals with a high coefficient of thermal expansion are more susceptible to:
a.
b.
c.
d.

transverse cracking
lack of fusion
warpage and distortion
linear porosity

43. The three hardness tests normally used are the:

a.
b.
c.
d.

Schindler, Johnson, Williams

Rockwell, Vickes, Brinell
Rockwell, UT, Shearwave
Brinell, Vicky, Rockdale

44. In Rockwell hardness testing, the minor load is always____________________

a.
b.
c.
d.

10 psi
150 psi
150 kg
10 kg

45. One of the most common types of fracture toughness tests is the _________ test.
a.
b.
c.
d.

Rockwell
Tensile
Charpy
Stress-strain

46. How does preheating carbon steel tend to reduce hydrogen-induced delayed cracking?
a.
b.
c.
d.

eliminates SCC
prevents carbon migration
slows the cooling rate prevents martensite formation
makes the grains grow so they wont crack

47. Preheat is usually monitored by________________

a.
b.
c.
d.

thermocouples
crayons
contact pyrometer
any or all of the above

48. The primary reason for PWHT is:

a.
b.
c.
d.

relieve residual stresses

complete phase transformations
de-sensitize steel
drive off excess moisture

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49. Hardness and hardenability are two terms that:

a.
b.
c.
d.

mean the same thing

indicate the carbon content of a material
mean two different properties
indicate the alloying content of a material

50. A typical test for hardenability is the ___________.

a.
b.
c.
d.

bend test
Rockwell test
Jominy Bar test
Charpy V-notch test

51. The general Brinell Hardness limit for 5CR-Mo steels is:
a.
b.
c.
d.

200
225
241
250

52. Which of the following elements influences the mechanical properties of weldments more than any other?
a.
b.
c.
d.

carbon
silicon
nitrogen
nickel

53. OPEN BOOK QUESTION: A material Test Report shows the following chemistries:
carbon 0.15%
manganese 0.20%
nickel 0.35%

chrome 1.25%
molybdenum 1.00%
copper 0.01%

vanadium 0.02%
silicon 0.53%

What is the approximate CE of this material using the formula supplied in RP 577?
a.
b.
c.
d.

0.35
0.7
0.9
0.55

54. From the above CE number, what should typically be done after welding this steel?
a.
b.
c.
d.

no PWHT
preheating
PWHT
preheat and PWHT

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55. A very specialized external loading weld test is the _________ test.
a.
b.
c.
d.

bend
Schindlerini
gleeble
rrc

56. Austenitic stainless steels typically contain chrome and nickel, and are used for:
a.
b.
c.
d.

corrosion resistance
resistance to high temperature degradation
sulfur resistance
both a and b, above

57. The most common measure of weldability and hot cracking of stainless steel is the _________.
a.
b.
c.
d.

bend test
ferrite number
Charpy V-notch number
hydrogen number

58. An extra-low hydrogen electrode (H4) should be used when hot tapping carbon steels with a CE greater
than _____________(%)
a.
b.
c.
d.

0.50
0.43
0.25
0.35

59. To reduce burn-through potential, liquid flow rates should be between _________ and _________ when
hot-tapping.
a.
b.
c.
d.

0.4 1.3 m/sec

1.5 4.0 ft/sec
0.4 1.2 m/sec
40 70 ft/sec

60. A common weld defect encountered with the GMAW-S welding process is:
a.
b.
c.
d.

LOP
slag
LOF
cracking

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ANSWER SHEET
FOR API RP 577 PRACTICE QUESTIONS
1. c, Para. 1

31. d, 9.7

2. b, 3.17

32. b, 9.8.1

3. d, 3.33

33. b, 9.8.4

4. a, 3.58

34. b, 9.8.9.3

5. a, 4.1

35. c, 9.9

6. d, 4.1

36. c, 9.9.3

7. d, 4.2

37. a, 10.2

8. b, 4.5

38. b, Table 10

9. c, 4.6

39. d, 10.2.2

10. c, 4.7

40. d, 10.2.3

11. c, 5.2.2

41. a, 10.3.2

12. a, 5.2 and 5.3

42. c, 10.3.4

13. d, 5.3

43. b, 10.4.3

14. b, 5.4.1

44. d, 10.4.3

15. a, 5.5.2

45. c, 10.4.4

16. c, 5.6.2

46. c, 10.5

17. c, 6.1

47. d, 10.5

18. c, 7.3

48. a, 10.6

19. a, 7.7

49. c, 10.7

20. b, 7.7

50. c, 10.7

21. d, 8.2

51. c, 10.7

22. c, Table 2

52. a, 10.9.1

23. a, Table 2

53. b, Calculated 0.68 10.9.1

24. c, Table 4 5

54. d, 10.9.1

25. d, Table 6

55. a, Table 12

26. b, Table 6

56. d, 10.10.1

27. c, 9.3.2.1

57. b, 10.10.1

28. a, 9.3.2.3

58. b, 11.2.1

29. c, 9.5

59. c, 11.2.2 Last paragraph

30. a, 9.5

60. c, 11.3

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