understanding api icp653 reading 15-worksheet-11a revision1

8/19/2019 Understanding API ICP653 Reading 15-Worksheet-11a revision1

1/180

Charlie Chong/ Fion Zhang


2/180



3/180


Expert at Works


4/180Charlie Chong/ Fion Zhang

Expert at Works


5/180

Expert at Works


7/180

Fion Zhang at Shanghai

22nd March 2016



8/180

http://independent.academia.edu/CharlieChong1http://www.yumpu.com/zh/browse/user/charliechong

http://issuu.com/charlieccchong




The Magical Book of Tank Inspection ICP


10/180

API 653 Exam Administration -- Publications

Effectivity Sheet FOR: November 2015, March2016 and July 2016Listed below are the effective editions of the publications required for thisexam for the date(s) shown above.

API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment inthe Refining Industry, Second Edition, April 2011



11/180

API 653 Exam Administration -- Publications

Effectivity Sheet FOR: November 2015, March2016 and July 2016Listed below are the effective editions of the publications required for thisexam for the date(s) shown above.

API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment inthe Refining Industry, Second Edition, April 2011



12/180

ATTENTION: Only the following sections / mechanisms from RP 571 areincluded on the exam:

Section 3, DefinitionsPar. 4.2.7 Brittle Fracture4.2.16 Mechanical Fatigue4.3.2 Atmospheric Corrosion

4.3.3 Corrosion Under insulation (CUI)4.3.8 Microbiologically Induced Corrosion (MIC)4.3.9 Soil Corrosion4.3.10 Caustic Corrosion4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC)4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement)5.1.1.10 Sour Water Corrosion (Acidic)5.1.1.11 Sulfuric Acid Corrosion



13/180


API Recommended Practice 575, Inspection of Atmospheric and Low-Pressure Storage Tanks, Third Edition, April 2014

API Recommended Practice 577 – Welding Inspection and Metallurgy,Second Edition, December 2013

API Standard 650, Welded Tanks for Oil Storage, Twelfth Edition, March2013 with Addendum 1 (September 2014), Errata 1 (July 2013), and

Errata 2 (December 2014). API Recommended Practice 651, Cathodic Protection of Aboveground

Petroleum Storage Tanks, Fourth Edition, September 2014. API Recommended Practice 652, Lining of Aboveground Petroleum

Storage Tank Bottoms, Fourth Edition, September 2014 API Standard 653, Tank Inspection, Repair, Alteration, and

Reconstruction, Fifth Edition, November 2014.


14/180


American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2013 Edition

i. ASME Section V, Nondestructive Examination, Articles 1, 2, 6, 7 and 23(section SE-797 only)

ii. Section IX, Welding and Brazing Qualifications (Welding Only)

See end of this study note for API Official BOK


15/180



16/180

练功闭


17/180


ASME SECTION IX EXERCISES


18/180


#1


19/180


TASK# 1

Read the following paragraphs then answer the questions.

General Requirements QW-100 thru QW-195

Q1. The cut surfaces of guided-bend test specimens is designated as the:

(a) sides.

(b) face.

(c) root.

Q2. What is the angular deviation for groove weld tests from the specified

inclined plane?(a) None/

(b) ±5°

(c)±10°


20/180


21/180


Q5. Where are notch-toughness requirements for the specimen, orientation

and acceptance criteria found?

(a) ASTM E208(b) SA-370

(c) Construction Code

ANS: b

Q6. The radiographic acceptance criteria for welders qualified in accordance

with QW-142 is found in:

(a) The Construction Code

(b) QW-191.2.2(c) QW-192.2

ANS:


22/180


Q7. The qualification of a new WPS or there-qualification of an existing WPS

shall be in accordance with the:

(a) component contract date.(b) current Edition and Addenda of Section IX.

(c) 1962 or later Edition of Section IX.

ANS: b

Q8. In relation to the surface of the plate or pipe, what is the required test

position orientation of a stud during welding?

(a) Perpendicular to the surface.

(b)±

15°

from the specified horizontal plane(c) ± 15 ° from the specified vertical plane.

ANS:


23/180


Q9. How is the minimum specimen curvature of guided-bend jig specimens

verified'?

(a) A 1/8" diameter wire cannot be inserted between the specimen and thedie.

(b) A 1/8" diameter wire cannot be inserted between the specimen and the

plunger.

(c) The specimen is bottomed ejected.

Q10. How is the tensile strength of a tension test specimen computed?

(a) Dividing the maximum load by the least cross-sectional area of the

specimen as measured before the load is applied.(b) Dividing the maximum load by the least cross-sectional area of the

specimen as measured after the load is applied.

(c) Measuring the percent of outer fiber elongation as required by the

construction Code . ANS: b


24/180


Q11.What pipe fillet weld test positions are not to be rotated during welding?

(a) 2F-3F-4F-5F

(b) 1 F-3F-5F(c) 2F-4F-5F

ANS: a

Q12. What pipe fillet weld test positions are allowed to be rotated duringwelding?

(a) 1F-2F-2FR

(b) 1F-2FR-3F

(c) 1F-2FR ANS:


25/180


Q13. Procedure and performance macro-examination specimens are etched

to give clear definition of: ·

(a) weld metal and heat affected zone.(b) inclusions and porosity.

(c) root of the weld.

ANS: a

Q14. Under what conditions are tension tests considered acceptable if the

specimen breaks in the base metal outside the weld or fusion line?

(a) Lf there are no open defects exceeding 1/16" measured In any direction.

(b) If the strength is not more than 5% below the specified minimum tensilestrength of the base metal.

(c) Lf there are no open defects exceeding 1/8” in the bond line.

ANS: a


26/180


Task# I Ref Para

1. A QW-161

2. B QW-1203. C QW-100.1

4. B QW-151.2

5. C QW-171.2, 171.3

6. B QW-191.2.27. B QW-100.3

8. QW-123.1

9. A QW-162.1

10. A QW-15211. C QW-132.2, 132.3,132.4

12. C QW-132.1, 132.2

13. A QW-183

14. B QW-153.l (d)


27/180


#2


28/180


Q1. Under what conditions may a WPS, PQR or WPQ qualified in accordance

with the 1957 Edition be used?

(a) When they meet the requirements of the 1962 or any later Edition.(b) After they have been revised to reflect the latest Edition of Section IX.

(c) Not permitted.

ANS: a

Q2: The methodology for the qualification of welders and welding operators

by radiography are given in:

(a) QW-191.2

(b) Article 2, Section V(c) The construction Code

ANS: b


29/180


QW-191.1 Radiographic Examination

QW-191.1.1 Method. The radiographic examination

in QW-142 for welders and in QW-143 for welding operatorsshall meet the requirements of Article 2, Section V,

except as follows:

(a) a written radiographic examination procedure is not

required. Demonstration of density and image qualityrequirements on production or technique radiographs shall

be considered satisfactory evidence of compliance with

Article 2 of Section V

(b) final acceptance of radiographs shall be based onthe ability to see the prescribed image and the specified

hole of a hole-type image quality indicator (IQI) or the

designated wire of a wire-type IQI. The acceptance standards

of QW-191.1.2 shall be met.


30/180


QW-191.2 Ultrasonic Examination

QW-191.2.1 Method

(a) The ultrasonic examination in QW-142 for weldersand in QW-143 for welding operators may be conducted

on test welds in material 1 ⁄ 2 in. (13 mm) thick or greater.

(b) Ultrasonic examinations shall be performed using a

written procedure verified by the manufacturer to be incompliance with paragraph T-150, Article 1, Section V

and the requirements of Article 4, Section V for methods,

procedures, and qualifications.

(c) Ultrasonic examination personnel shall meet therequirements of QW-191.2.2.


31/180


Q3. When may longitudinal-bend tests be used in lieu of transverse guided

bend tests to qualify a WPS?

(a) When the axis of the weld is transverse to the longitudinal axis of thespecimen.

(b) When the weld metal or base metal combinations differ markedly in

bending properties between the two base metals or the weld metal and

base metal.(c) When the axis of the weld is parallel to the longitudinal axis of the

specimen.

ANS: b

Q4. The dimensioning requirements for reduced-section tension specimens

for pipe having an O.D. less than 3 in. are found in;

(a) QW-462.1 (a)

(b) QW-462.1 (b)

(c) QW-462.1 (c)

ANS: c

Q5 W ldi d lifi d i d ith th 1974 Editi d


32/180


Q5. Welding procedures qualified in accordance with the 1974 Edition needs

to be amended or revised to the Edition mandated for construction.

(a) True(b) False

ANS: b

Welding Procedure Specifications and Welder/Welding Operator Performance Qualification records meeting the above

requirements do not need to be amended to include any variables required by later Editions and Addenda except as specified in

QW-420

Q6. What is the angular deviation in groove weld test positions from the

specified horizontal and vertical planes during welding?

(a) ± 5°

(b) ±10°

(c) ±15° ANS: a

Q7. Tension tests and Guided-Bend tests are two mechanical weld tests

which employ ____type weld joint configurations.

(a) stud

(b) groove

(c) fillet ANS: b

QW 100 3 W ldi P d S ifi ti (WPS) itt d lifi d i


33/180


QW-100.3 Welding Procedure Specifications (WPS) written and qualified in

accordance with the rules of this Section, and welders and welding operators

of automatic and machine welding equipment also qualified in accordancewith these rules may be used in any construction built to the requirements of

the ASME Boiler and Pressure Vessel Code or the ASME B31 Code for

Pressure Piping. However, other Sections of the Code state the rules under

which Section IX requirements are mandatory, in whole or in part, and giveadditional requirements. The reader is advised to take these provisions into

consideration when using this Section.

Welding Procedure Specifications, Procedure Qualification Records, andWelder/Welding Operator Performance Qualification made in accordance with

the requirements of the 1962 Edition or any later Edition of Section IX may be

used in any construction built to the ASME Boiler and Pressure Vessel Code

or the ASME B31 Code for Pressure Piping.

W ldi P d S ifi ti P d Q lifi ti R d d


34/180


Welding Procedure Specifications, Procedure Qualification Records, and

Welder/Welding Operator Performance Qualification made in accordance with

the requirements of the Editions of Section IX prior to 1962, in which all of therequirements of the 1962 Edition or later Editions are met, may also be used.

Welding Procedure Specifications and Welder/Welding Operator

Performance Qualification records meeting the above requirements do notneed to be amended to include any variables required by later Editions and

Addenda except as specified in QW-420.

Qualification of new Welding Procedure Specifications or Welders/WeldingOperators and requalification of existing Welding Procedure Specifications or

Welders/ Welding Operators shall be in accordance with the current Edition

(see Foreword) and Addenda of Section IX.


35/180

Q10 What dimensional requirement is there for the guided bend test jig


36/180


Q10. What dimensional requirement is there for the guided-bend test jig

mandrel being used on specimens wider than 1-1/2"?

(a) At least ½" wider than the specimen width ..(b) At least 1/8" wider than the specimen width.

(c) At least 1/4 “ wider than the specimen width.

ANS: c

Q11. The substitution of radiography for mechanical testing is permitted forwelder and welding operator performance qualifications except as restricted

by QW-304 & 305.

(a) True

(b) False ANS: a

Q12. At what base metal thickness shall the multiple turned tension

specimens be used? The specimens are cut through the full thickness of the

weld with their centers parallel to the metal surface and not over 1" apart.(a) 5/8"

(b) > 1"

(c)


37/180


Task#2 Ref Para.

1. A QW-10()3

2. B QW-191.13. B QW-161.5

4. C QW-151.2

5. B QW-100.3

6. A QW-1207. B QW-141.1, 141.2

8. A QW-122

9. B QW-100.2

10. C QW-162.1

11. A QW-142, 143

12. B QW-151.3 (b)


38/180


#3

Reading: General Requirements


39/180


Reading: General Requirements

QW-100 thru QW-195

Q1. The qualifications of welders and welding operators by radiography are

documented on Form QW-484 that is only a suggested form.

(a) True

(b) False

ANS: a

Q2. What is the minimum tensile strength for tension tests if the base metals

have different minimum tensile strengths?

(a) The specified minimum tensile strength of the stronger of the two.

(b) The specified minimum tensile strength of the weld metal.

(c) The specified minimum tensile strength of the weaker of the two.

ANS: c

Q3: The open defects for guided-bend test specimen of the convex surface of


40/180


Q3: The open defects for guided bend test specimen of the convex surface of

the weld or heat affected zone shall not exceed ____

(a) 1/16".(b) 1/8"

(c) 3/16“

ANS: b

Q4. The PQR qualification test determines the ___ of the___ but not the ___

of the welder or welding operator.

(a) properties-weldment-skill

(b) skill-welder-qualification

(c) qualification-welder-skill

ANS: a

Q5. What constitutes a "set" of reduced multiple section specimens for plate


41/180


Q5. What constitutes a set of reduced multiple section specimens for plate

or pipe tension tests?

(a) Strips of equal size that can be tested in the available equipment.(b) All specimens representing the full thickness of the weld at one location.

(c) All specimens representing half the thickness ofthe weld at one location.

ANS: a

Q6. What is the purpose of the welder's performance qualification?

(a) To determine the welder's ability to operate the equipment.

(b) To determine the mechanical properties of the weldment.

(c) To determine the welder's ability to deposit sound weld metal.

ANS: c

QW-151-1(c)


42/180


Q ( )

(c) When multiple specimens are used, in lieu of full

thickness specimens, each set shall represent a single tensiontest of the full plate thickness. Collectively, all of the

specimens required to represent the full thickness of the

weld at one location shall comprise a set.

(d) When multiple specimens are necessary, the entire

thickness shall be mechanically cut into a minimum number

of approximately equal strips of a size that can be

tested in the available equipment. Each specimen of the

set shall be tested and meet the requirements of QW-153.

T, full plate

thickness1/3T x 3 plate thickness

Q7. The WPS must list variables, while the PQR must list


43/180


___ , __ _

(a) essential, nonessential, I essential, supplementary essential

(b) essential, nonessential and acceptable ranges, supplementary (whenrequired) / essential, supplementary (when required)

(c) essential/ nonessential, supplementary essential

ANS: b

Q8. The cut surfaces of guided-bend test specimens are designated____of

the specimen, while the other two surfaces are called the ____and ____

surfaces.

(a) sides-face-root

(b) face-root-side

(c) root-side-face

ANS: a

Q9. Guided-bend tests require that the surface being examined becomes


44/180


q g

the_____surface bent specimen.

(a) concave(b) convex

(c) Transverse

ANS: b

Task#3 Ref Para


45/180


1. A QW-484

2. C QW-153.1 (b)

3. B QW-163

4. A QW-100.1

5. B QW-151.1 (c)

6. C QW-100.2

7. B QW-100.1

8. A QW-161

9. B QW-161


46/180


#4

Reading: Procedure Qualif ications


47/180


g

QW-200 thru QW-283

Q1. Qualification of the WPS using test coupons made of plate also qualifiesfor pipe and vice versa.

(a) True

(b) False

ANS: a

Q2. How does the Manufacturer attest that the information in the PQR is a

true record of the variables that were used during the welding of the test

coupons and that the resulting tensile, bend, or macro-etch test results are incompliance with Section IX?

(a) By having the Manufacturer certify and notarize the PQR .

(b) By having the welder certify the PQR

(c) By having the Manufacturer certify the PQR. ANS: c

Q3. A SMAW WPS was qualified with a 3” pipe, the pipe diameter range on


48/180


the WPS permitted by Code shall be:

{a) 2 7/8" 0.0. or over.

(b) All diameters and all thickness.

(c) All diameters within the base metal thickness range.

ANS: c

Q4. In general, what mechanical test is mandated for P-No. 11 quenched and

tempered metals, for low temperature applications of other metals as applied

to Section VIII?

(a) Notch-toughness tests.

(b) Guided bend tests.

(c) Tension tests.

ANS: a ?

Q5. The qualification of the ___is the welding of test coupons, the testing of

i d di th d t d t t lt i


49/180


specimens, and recording the data and test results in a ____

(a)WPS-PQR

(b)PQR-WPS

(c)WPS-WPQ

ANS: b

Q6. Under what conditions may changes be made to the PQR?

(a) Editorial or Addenda.

(b) To suit production requirements.

(c) None.

ANS: a

Q7. A PQR is a record of the welding data used to weld a test coupon and the

t t lt


50/180


test results.

(a) True.

(b) False.

ANS: a

Q8. When qualifying a separate procedure in SAW process for root deposits

only, what is the minimum coupon thickness?

(a) ½ "

(b) ¾ "

(c) 1-½ "

(d) ¼ “

ANS: a

QW-200.4

(b) F GTAW SMAW GMAW PAW d SAW


51/180


(b) For GTAW, SMAW, GMAW, PAW, and SAW,

or combinations of these processes, a PQR for a process

recording a test coupon that was at least ½ in. (13 mm)

thick may be combined with one or more other PQRs

recording another welding process and any greater base

metal thickness. In this case, the process recorded on the

first PQR may be used to deposit the root layers using

the process(es) recorded on that PQR up to 2t (for short circuiting

type of GMAW, see QW-404.32) in thickness

on base metal of the maximum thickness qualified by the

other PQR(s) used to support the WPS. The requirements

of Note (1) of tables QW-451.1 and QW-451.2 shall apply.

Task#4 Ref Para.

1 A QW 211


52/180


1. A QW-211

2. C QW-201

3. C QW-203

4. A QW-200.3

5. A QW-201

6. A QW-200.2 (c)

7. A QW-200.2 (a)

8. A QW-200.4 (b)


53/180


#5

TASK#5

R di P d Q lif i ti


54/180


Reading: Procedure Qualif ications

QW-200 thru QW-283Q1. A Manufacturer may not subcontract the preparation of test materials for

welding and subsequent work on preparation of test specimens from the

completed weldment, performance of NDE, and mechanical tests.

(a) True(b) False

ANS: b

Q2. A shop wishes to combine two existing PQR's to write a new compositeWPS. PQR No.1 was in GTAW process with a 1/4" coupon, PQR No.2 was in

SMAW process with 1/2" coupon. The WPS specifies GTAW process will only

be used for the root passes with maximum deposit not to exceed 1/4". The

base metal thickness range on the WPS should be;(a) 1/16" min 1" max.

(b) 1/16" min, 1/2" max.

(c) 3/16" min. 1" max.

(d) 3/16" min, 1/2" max. ANS: b

QW-200.4 Combination of Welding Procedures

(a) More than one WPS having different essential supplementary essential


55/180


(a) More than one WPS having different essential, supplementary essential,

or nonessential variables may be used in a single production joint. Each WPS

may include one or a combination of processes, filler metals, or other

variables. Where more than one WPS specifying different processes, filler

metals, or other essential or supplementary essential variables is used in a

joint, QW-451 shall be used to determine the range of base metal thickness

and maximum weld metal thickness qualified for each process, filler metal, or

set of variables, and those limits shall be observed. Alternatively, qualification

of WPSs for root deposits only may be made in accordance with QW-200.4(b).

When following a WPS that has more than one welding process, filler metal,

or set of variables, each process, filler metal, or set of variables may be used

individually or in different combinations, provided

(1) the essential, nonessential, and required supplementary essential

variables associated with the process filler metal or set of variables are


56/180


variables associated with the process, filler metal, or set of variables are

applied

(2) the base metal and deposited weld metal thickness limits of QW-451 for

each process, filler metal, or set of variables are applied

(b) For GTAW, SMAW, GMAW, PAW, and SAW, or combinations of these

processes, a PQR for a process recording a test coupon that was at least

½ in. (13 mm) thick may be combined with one or more other PQRs

recording another welding process and any greater base metal thickness.

In this case, the process recorded on the first PQR may be used to

deposit the root layers using the process(es) recorded on that PQR up to

2t (for shortcircuiting type of GMAW, see QW-404.32) in thickness on

base metal of the maximum thickness qualified by the other PQR(s) used

to support the WPS. The requirements of Note (1) of tables QW-451.1 and

QW-451.2 shall apply.

Discussion:GTAW PQR variables: T=1/4” t=1/4”


57/180


GTAW PQR variables: T=1/4 t=1/4

qualified range: T = 1/16 ~ ½”, t max = ½”

The GTAW can not used for welding T> ½”

Answer: 3/16" min. 1" max. incorrect!

Q3. Why should precaution be taken if Form QW-483 is used to document the

essential variables that were used during the welding of the test coupons?


58/180


essential variables that were used during the welding of the test coupons?

(a) The Form does not easily lend itself to cover multiple processes or more

than one No. in one test coupon.

(b) Revisions are not permitted except as defined in QW-200.2 (c).

(c) Form QW-483 is only a suggested format for procedure qualifications.

ANS: a

Q4. Why have P-No's. been assigned for different base metals?

(a) They are unique identifiers assigned by Section IX.

(b) P-No's. simplify the identification of various ASTM materials.

(c) To reduce the number of welding procedure qualifications, dependent on

characteristics such as composition, weldability, and mechanical

properties.

ANS: c


59/180

Q7. For vessels or parts of vessels constructed with P-No. 11 base metals,

weld grooves for thickness' shall be prepared by thermal processes,


60/180


g ____ p p y p ,

when used in fabrication.

(a) 5/8“

ANS: b QW-213(?)

Q8. A butt welded coupon consisted of 1-1/2" carbon steel and ¼” stainless

steel base metals, what base metal thickness range does this coupon qualify?

(Notch toughness is not a requirement).

(a) 1/16" to 8" for both metals,

(b) 1/16" to 1/2" for stainless steel 3/16" to 8" for carbon steel.(c) 1/16" to 1/2" for stainless steel3/16" to unlimited thickness for carbon steel.

ANS: b

Q9: An organization's operational control of welding procedure qualification

for two or more companies of different names shall be defined in their __ .


61/180


p __

(a) Manufacturing Procedures

(b) Quality Control System

(c) Qualified Supplier's List

ANS: b

Q10. What is the purpose of assigning Group Numbers to base metals?

(a) To classify the different base metal Grades.


62/180


(b) To classify the metals within P-No's. for the purpose of procedure

qualification where notch-toughness requirements are specified.

(c) To simplify the identification of ASTM materials.

ANS: b

Q11. In procedure qualification on groove weld qualifications on 1/2" plate

qualify fillet welds for___ in base metal thicknesses and ___in diameters on

pipe and tube.

(a) 1/16"to 1", 2 7/8" O.D. and over

(b) All, All(c) All, 2 7/8" O.D. and over

(d) 1/16" to 1 ", all

ANS: b

Q12. The ____ is a true record of the variables that were used during the

welding of the test coupon and that the resulting tensile, bend or macro-etch


63/180


(as required) test results are in compliance with Section IX

(a) WPS

(b) PQR

(c) WPQ

(d) All of the above

ANS: b

Task#5 Ref Para.

1. B QW-201


64/180


2. C QW-200.4, 451.1

3. A QW-200.(d)

4. C QW-200.3

5. C QW-203

6. C QW-200.1 (b)

7. A QW-2138. B QW-451.1

9. B QW-201

10. B QW-200.3

11. B QW-202.2 (c)12. B QW-200.2 (a)


65/180

Task#6 Ref Para.

1. B QW-321.4

2 C QW 304 1


66/180


2. C QW-304.1

3. C QW-302.2

4. A QW-301.3

5. B QW-306

6. A QW-306

7. A QW-461.98. A QW-302, 304

9. B QW-302.3

10. B QW-321

11. C QW-~0412. B QW-361.1

13. B QW-322.1

Reading:

Performance Qualifications


67/180


QW-300 thru QW-383Q1. What are the retest requirements for a welder who has failed his renewal

qualification

test after he has received additional training or practice?

(a) Complete requalification in accordance with QW-301.2.(b) A new test shall be made for each position he failed.

(c) Weld a single test coupon of either plate or pipe.

ANS: b

Q2. What is the length of a welder's first production weld that needs to be

radiographed for qualification?

(a) 3'

(b) 3"(c) 6“

ANS: c

Q3. What is the extent of radiography for a welder who is qualified by

radiography?

( ) 3' d h ll i l d th ld i f f i


68/180


(a) 3' and shall include the weld circumference for pipe.

(b) 3" and shall include 1/2" either side of the weld on plate.

(c) 6" and shall include the weld circumference for pipe.

ANS: c

Q4. By what method does a Manufacturer identify the work of a welder orwelding operator?

(a) By assigning an identification number, letter, or symbol.

(b) By having the welder or welding operator initial the traveler or process

sheet(c) This is no longer required

ANS: a

Q5. How are the thickness limits determined for a welder when qualified using

multiprocess procedure?

(a) By the thickness of the weld he deposits with each welding process in


69/180


(a) By the thickness of the weld he deposits with each welding process in

which this thickness shall be considered the test coupon thickness asgiven in QW.451

(b) By the thickness of the weld he deposits with each welding process, in

which this thickness shall be considered the test coupon thickness as

given in QW.452 ANS: b

Q6. Using a combination procedure a welder may be qualified with each

individual welding process in separate test coupons, or with a combinationof welding processes in a single test coupon.

(a) True

(b) False.

ANS: a

Q7. Welder's and welding operators who pass the tests for groove welds are

qualified for what groove and fillet weld positions?

(a) The positions of groove and fillet welds shown in QW 461 9


70/180


(a) The positions of groove and fillet welds shown in QW-461.9.

(b) In all thicknesses of material, sizes of fillet welds, and diameters of pipeand tube 2 7/8" and less.

(c) In all thicknesses of material sizes of fillet welds, and diameters of pipe

and tube 2-7/8" and over.

ANS: A

Q8. The three methods by which a welder or welding operator may be

qualified are __ of initial production weld, radiography of____ or____

taken from a test coupon.(a) radiography-test coupon-bend tests

(b) bend tests -test coupon-tension tests

(c) tension tests-test coupon-bend tests

ANS: A

Q9. What welding positions on pipe test coupons omit the specimens in the

upper right and lower left quadrants, and replaces the root bend specimen in

the upper left quadrant with a face bend?


71/180


the upper left quadrant with a face-bend?

(a) 2G or 5G(b) 1G or 2G

(c) 5G or 6G

ANS:

Q10. What are the immediate retests required if a welder fails the mechanical

tests of QW-302.1 or radiography examination of QW-302.2? .

(a) Mechanical tests.

(b) Mechanical tests and radiographic examination respectively.(c) Radiographic examination.

ANS: b

Q11. With the exception of GTAW, what P-Nos. are prohibited in the

qualification of welders by radiography?

(a) P-2X P-4X and P-5X


72/180


(a) P-2X, P-4X, and P-5X

(b) P-2X, P-3X, and P-5X(c) P-2X, P-5X, and P-6X

ANS: c

QW-361.1

Q12. Machine welding is classified as a ____ category.

(a) manual

(b) welding operator

(c) semi-automatic ANS: b

Q13. A welder who welds in only one position for more than six months loses

his qualification in other positions for which he is qualified in a given process.(a) True

(b) False

ANS: b

QW-304 Welders

Except for the special requirements of QW-380, each welder who welds

under the rules of the Code shall have passed the mechanical and visual


73/180


under the rules of the Code shall have passed the mechanical and visual

examinations prescribed in QW-302.1 and QW-302.4 respectively.

Alternatively, welders may be qualified by volumetric NDE per QW-191 when

making a groove weld using SMAW, SAW, GTAW, PAW, and GMAW (except

short-circuiting mode for radiographic examination) or a combination of theseprocesses, except for P-No. 21 through P-No. 26, P-No. 51 through P-No. 53,

and P-No. 61 through P-No. 62 metals.

Welders making groove welds in P- o. 21 through P-No. 26 and P-No. 51through P-No. 53 metals with the GTAW process may also be qualified by

volumetric NDE per QW-191.

The volumetric NDE shall be in accordance with QW-302.2. A welderqualified to weld in accordance with one qualified WPS is also qualified to

weld in accordance with other qualified WPSs, using the same welding

process, within the limits of the essential variables of QW-350.


74/180


#7

TASK#7

Reading:


75/180


Performance Qualif ications QW-300 thru QW-384Q1. Performance qualifications conducted in special orientations are valid forthe special position actually tested and the_____, except that an angular

deviation of_____ is permitted in the inclination of the____ and the rotation of

the______ (a) vertical position, ±5°, weld axis, production piece

(b) flat position, ±5°, production piece, weld fixture

(c) flat position, ±15°, weld axis, weld face.

ANS: b

Q2. What option does a Manufacturer have if a welder fails the production

weld alternative of QW-304.1?

(a) Radiograph an additional 6" of the same production weld.(b) Radiograph an additional12" of the same production weld.

(c) Radiograph an additional12" of the same production weld.

ANS: c

Q3. If the radiograph of the alternative production weld used for qualification

does not meet the radiographic standards:

(a) Radiograph an additional 6" of the same production weld.


76/180


(a) Radiograph an additional 6 of the same production weld.

(b) The welder shall be retested by mechanical tests.(c) The welder has failed the test, requiring RT of all his production welds and

repaired by a qualified welder.

ANS: c

Q4. What is the intent of performance qualification tests?

(a) To determine the ability of welders and welding operators to make sound

welds.

(b) Provide direction to the welder or welding operator.(c) To prove the mechanical properties of the weldment.

ANS: a

Q5. Why is the Manufacturer responsible for conducting tests to qualify

welders and welding operators in accordance with a qualified WPS which

his organization employs in construction? ·


77/180


g p y

(a) The welder's performance is not transferable from employer to employer,(b) To assure that they are capable of developing the minimum requirements

specified.

(c) The responsibility of the qualifying welders can not be delegated to

another organization.(d) All of the above.

ANS: d

Q6. A welder shall be re-qualified whenever a change is made in one or moreof the ___ variables listed for each welding process

(a) essential

(b) supplemental essential

(c) essential and nonessential ANS: a


78/180

Q9. When performance qualification is done in accordance with a WPS that

requires preheat or post weld heat treatment, these may be omitted.

(a) True


79/180


( )

(b) False ANS: a

Q10. What are the requalification requirements for a welder who has had his

qualifications revoked because there was a specific reason to question hisability to make sound welds?

(a) Weld a single test coupon of either pipe or plate, of any material, thickness

or diameter, in any position.

(b) Weld a test coupon appropriate to qualify him for the production work hewill do and tested in accordance with QW-301 and QW-302.

(c) May be extended when welding with another process.

ANS: b

Q11. What position limitations are placed on the welder if he prepares the

WPS qualification test coupons?

(a) Qualification of the WPS in any position qualifies for all positions.


80/180


(b) Qualified only within the limits for positions specified in QW-303.(c) Qualified only for the position(s) used during the welding of the test

coupon.

ANS: c

Q12. For performance qualification, how are the deposited weld metal

thickness limitations determined if a single test coupon is used for a

combination welding process?

(a) They are considered individually for each welder and each process used.(b) In accordance with QW-451.

(c) In accordance with QW-452.

ANS: a

Q13. Failure of any portion of a combination test in a single test coupon

constitutes failure of the entire combination.

(a) True


81/180


(b) False ANS: a

QW-306

Task#7 Ref Para.

1. C QW-303.3

2. C QW-321.3 (b)


82/180


3. C QW-304.24. A QW-301.1

5. D QW-300.2

6. A QW-351

7. B QW-3048. B QW-301.4

9. A QW-301.2

10. B QW -322.2 (b)

11. B QW-301.212. C QW-306

13. A QW-306


83/180


#8

Task#8 Ref Para.

1. B QW-403.10

2. C QW-401.3


84/180


3. A QW-420.14. A QW-401

5. A QW-451.1

6. B QW-401.1

7. B QW-424.18. B QW-431

9. A QW-423.1

10. C QW-355

TASK#8

Welding Data


85/180


QW-400 thru QW-450Q1. A manufacturer is qualifying a WPS in GMAW process in short circuit arctransfer mode. The test coupon is ½" thick the maximum thickness qualified

for the WPS would be,

(a) 0.5"(b) 0.275"

(c) 0.25"

ANS: 1”

QW-403.10 For the short-circuiting transfer mode of

the gas metal-arc process, when the qualification test coupon

thickness is less than 1 ⁄ 2 in. (13 mm), an increase in

thickness beyond 1.1 times that of the qualification test coupon. Forthicknesses of 1 ⁄ 2 in. (13 mm) and greater, use

table QW-451.1 or table QW-451.2, as applicable.


86/180


Q2. Under what conditions may a WPS that has been qualified without notch

toughness may be used for applications where they are applicable?

(a) Qualification without notch toughness qualifies the procedure with notch

t h i t


87/180


toughness requirements.(b) After the procedure has been requalified to include the notch toughness

requirements.

(c) After preparing an additional test coupon using the same essential

variables, but additionally with all the required supplementary essentialvariables, in a coupon long enough to provide the necessary specimens.

ANS: c

Q3. What effect did the 1974 Edition have on material in the 1971 Editionwhen new PNo.’s, or the assignment to different subgroups within a P-No.

were given?

(a) Procedure and performance qualifications continued to be valid based on

the new P-No. designations.(b) Required re-quafification of those welding procedures.

(c) Required re-qualification of welders and welding operators.

ANS: a

Q4. As a convenience, variables for procedure and performance

qualifications are summarized in and respectively.

(a) QW-250- QW-350

(b) QW 451 QW 452


88/180


(b) QW-451 - QW-452(c) QW-252- QW-265

ANS:

Q5. A SMAW WPS was written with notch-toughness test. The test couponon the supporting PQR is 3/8" in thickness. What would be the base metal

thickness qualified range for the WPS?

(a) 1/16" thru 3/4"

(b) 3/8" thru 3/4"(c) 3/16"thru 3/4“

ANS: a

Q6. A change in a welding condition which will affect the mechanical

properties of a weldment or the ability of a welder to deposit sound weld metal

is dependent upon which type of variable?

( ) N ti l


89/180


(a) Nonessential(b) Essential

(c) Supplemental Essential

ANS: b

Q7. The test coupon for a PQR consisted P5A to P4 materials when notch

toughness is not a factor, the base metals qualified would be;

(a) P-No.5A to P-No.4 only

(b) P-No.5A to P-No.4, P-No.3, and P-No.1(c) P-No.5A to P-No.5A and P-No.4 to P-No.4

(d) None of the above

ANS: b

QW-424.1

QW-424 Base Metals Used for Procedure

QualificationQW-424.1 Base metals are assigned P-Numbers in table QW/QB-422; Metals that do

not appear in table QW/QB 422 are considered to be unassigned metals except as


90/180


not appear in table QW/QB-422 are considered to be unassigned metals except asotherwise defined for base metals having the same UNS numbers. Unassigned metals

shall be identified in the WPS and on the PQR by specification, type and grade, or by

chemical analysis and mechanical properties. The minimum tensile strength shall be

defined by the organization that specified the unassigned metal if the tensile strength

of that metal is not defined by the material specification.


91/180

Q10. What welding process addresses the essential performance variables

for the flux cored arc welding process?

(a) SAW

(b) PAW


92/180


(b) PAW(c)GMAW

ANS: c


93/180


#9


94/180

TASK#9

Welding Data

QW-451 thru QW-492Q1 Wh lif i ld t 6G iti i 6" h d l 40 (0 280")


95/180


QW-451 thru QW-492Q1 . When qualifying a welder at 6G position using a 6" schedule 40 (0.280")pipe test coupon, the required type and number of tests are:

(a) One face bend test and one root bend test

(b) Two side bend tests(c) Either two face and two root bend tests or four side bent tests

(d) Two face and two root bend tests

ANS: a

NOTES:

(1) To qualify using positions 5G or 6G, a total of four bend specimens are

required. To qualify using a combination of 2G and 5G in a single test coupon,

a total of six bend specimens are required. See QW-302.3. The type of bend

test shall be based on weld metal thickness.

Q2. A welder has been qualified by a 2" nominal schedule. 40 pipe in the 5G

position. Is he qualified to weld a groove weld of a 3/4" nominal, 3000 lb.

coupling in the overhead position in the field?

(a) yes


96/180


(a) yes(b) No

ANS: b

Q3. In reviewing the form QW-483 (PQR form) in a Code shop, the

Authorized Inspector noticed the thickness of test coupon was

documented as 3/4" SA-285C plate. However on the back of the form

thickness of the specimen was recorded as 0.725". The difference in


97/180


thickness of the specimen was recorded as 0.725 . The difference inthickness is most likely because.

(a) A mistake in the testing laboratory, they documented a different set of

coupon on this PQR.

(b) The thickness of the specimen is approximate.(c) The test coupon has been machined down to 0.725" to offset the heat

distortion due to welding.

ANS: c

Q4. A welder was qualified by a plate at 4G (overhead) position in the lab. He

will be qualified to weld pipe 2 7/8" O.D. and over, but under 24" O.D. in

the field in the overhead position.

(a) True(b) False

ANS: b correct answer

QW-461.9 Performance Qualification — Position And Diameter Limitations

(Within The Other Limitations Of Qw-303)


98/180


Q5. The SAW process is commonly classified as a process in _____ and

GMAW as a process for______ welding.

(a) Automatic, semi-automatic

(b) Semi-automatic, manual


99/180


( ) ,(c) Machine1 semi-automatic welding

ANS: a

Q6. A welder is qualified in 6G position on a 2" schedule 160 pipe (2-3/8"O.D.). What is the diameter range and position the welder is qualified to weld?

(a) 2.375" O.D. and over, 6G position

(b) 2" NPS and over, all positions

(c) 1.00” O.D. and over, all positions ANS: c

#10


100/180


#10


101/180

Q3. The PQR must list:

A. essential variables

B. qualification test & examination results

C. supplementary essential variables (when notch toughness is required)D ll f th b


102/180


pp y ( g q )D. all of the above

ANS: a

Q4. What is the earliest Edition of Section IX recognized by the current edition? A. 1958

B. 1992

C. 1987

D. 1962 ANS: d

Q5. New Welding Procedure Specifications must meet the _______ Edition

and Addenda of Section IX.

A.1962

B. currentC 1986


103/180


C. 1986

D. 1995

ANS: b

Q6. Each____ shall conduct the tests required by Section IX to qualify the

WPS's used during the construction, alteration, or repair.

A. Welder or welding operator

B. Manufacturer or contractor C. Inspector

D. All of the above

ANS: b

Q7. The records of procedure, welder and welding operator qualification must

be available to the

A. Manufacturer

B.Welder C Authorized Inspector


104/180


C. Authorized Inspector

D. Foreman

ANS: c

Q8. A welder qualifying with a groove weld in plate in the 4G position is

qualified to weld groove welds in plate and pipe over 24"0.D. in at least the

________positions.

A Vertical

B. Flat & horizontal

C. Flat & overhead

D. Horizontal

ANS: c

Q9. A welder qualifying with plate fillet welds in the 3F and 4F positions is

qualified to weld groove welds in plate in the positions.

A. Flat only

B. Flat and horizontalC Flat and vertical


105/180


C. Flat and vertical

D. None of the above

ANS: d

Q10. A welder qualifying by making a groove weld on pipe with an O.D. of

3/4" in the 5G position is qualified to weld groove welds in:

A. 1/2" O.D. Pipe in the overhead position

B. 6" O.D. Pipe in the vertical positionC 3/4" O D Pipe in the horizontal position


106/180


C. 3/4 O.D. Pipe in the horizontal position


ANS: b

Q11. In general, qualification on groove welds also qualifies a welder to make:

A. Stud welds

B. Overhand welds

C. Fillet weldsD. All of the above

ANS: c

Q12. Charpy V-notch tests are performed to determine a weldment's

A. Tensile strength

B. Ductility

C. Notch toughnessD All of above


107/180


D. All of above

ANS: c

Q13. A welder making a groove weld using the SAW process on P1 materials

may be qualified using radiography. A. True

B. False

ANS: a

Q14. When a tensile specimen breaks in the base metal outside of the weldor fusion line, the strength recorded may be at most_____ below the specified

tensile and be accepted.

A. 3.5%

B. .5%C. 5%

D. All of the above

ANS: c


108/180

Q17. A WPS must describe:

A. Essential variables

B. Nonessential variables

C. Supplementary essential variables when required for notch toughnessD. All of the above


109/180


D. All of the above

ANS: d

Q18. A PQR must describe A Nonessential variables

B. Essential variables

C. Results of Welder Qualification tests

D. Project description & NDE methods ANS: b

Q19. The ___ must certify the PQR as accurate.

A. Inspector

B. Manufacturer or contractor

C. Welder D. All of the above


110/180


D. All of the above

ANS: b

Q20. For the SMAW process _______ is an essential variable for the WPS. A. Groove design

B. Post Weld Heat Treatment

C. Root spacing

D. Method of cleaning ANS: b

Q21. For the SAW process ______ is an essential variable for the WPS.

A. Supplemental powdered filler metal (if used)

B. Filler metal diameter

C. Preheat maintenanceD. Addition or deletion of peening


111/180


p g

ANS: a

404.10 Alloy flux X

Q22. The basic purpose of testing a welder is to establish the welder;s -------·

A. Knowledge of welding requirements

B. Ability to deposit sound weld metal

C. mechanical ability to operate equipmentD. General attitude toward welding inspectors

ANS: b

Q23. The record of a welder's performance test is called a ______

A. PQR

B. WOR

C. WPSd. WPQ


112/180


ANS: d

Q24. If a welder qualified with the SMAW process on Jan. 1. 1994 and last

welded with SMAW on March 15, 1994, would he still be qualified onOctober 7, 1994?

A. Yes

B. No

ANS: bQ25. A welder qualifying with a groove weld welded from both sides is

qualified to weld_____

A. Without backing

B. With all base metalsC. With backing only

D. With P1 backing only

ANS: c

Q26. Immediate retests of welders qualifications coupons

A. Must use the same method

B. May use any method

C. Are not allowedD. Require Inspector approval


113/180


q p pp

ANS: a

Q27. Welder performance qualification records must describe all the ______variables specified.

A. Essential & nonessential

B. Nonessential

C EssentialD. Brazing

ANS: c


114/180

QW-452 Performance Qualification Thickness

Limits and Test Specimens


115/180


Q30. A welder qualifying by welding P-No. 21 to P-No. 21- is qualified to weld

A. P-1- P-11 to P-1- P-11

B. P-8- P8

C. P-21 - P-25 to P-21 - P-25D. P21 to P21 only


116/180


ANS: c

Q31. Welding electrodes are grouped in Section IX by A. AWS class

B. ASME specification

C. SFA

D. "F" number ANS: c

QW-430 F-NUMBERS

QW-431 General

The following F-Number grouping of electrodes and

welding rods in table QW-432 is based essentially on their usability characteristics, which fundamentally determine

h bili f ld k i f ld i h


117/180


the ability of welders to make satisfactory welds with a

given filler metal. This grouping is made to reduce the

number of welding procedure and performance qualifications,where this can logically be done. The grouping does

not imply that base metals or filler metals within a group

may be indiscriminately substituted for a metal that was

used in the qualification test without consideration of thecompatibility of the base and filler metals from the standpoint

of metallurgical properties, postweld heat treatment

design and service requirements, and mechanical

properties.

QW-432

F-NUMBERS

Grouping of Electrodes and Welding Rods for Qualification


118/180


Q32. Ferrous weld metal chemical composition may be designated using

A. "P" Number

B. Welder I. D.

C. "A" number D. page number

ANS


119/180


ANS: c

Q33. For welder qualification with the SMAW process ____ is an essentialvariable.

A. Base metal thickness

B Peening

C. P-number D. Electrode diameter

ANS: c

Q34. Each welder must be assigned a(n)

A. P number

B. Unique identifier

C. Hood & glovesD. Inspector

ANS: b


120/180


ANS: b

Q35. May a welder, qualified in the 2G position on 1/4 inch thick plate, weld a1 inch outside diameter pipe, 1/4 inch thick in the horizontal position without

requalification?

A. Yes

B. NoC. Not enough information provided

D. Yes, provided pipe is carbon steel, P#1

ANS: b

Q36. What is the basic difference between gas metal arc welding and gas

tungsten arc welding processes?

A. How they are produced

B. The.SFA specification of the filler metalC. The F# of the filler metal

D GTAW is run with gas; gas is optional with GMAW


121/180


D. GTAW is run with gas; gas is optional with GMAW

ANS: a

Q37. A welder has been tested in the 6-G position, using an E-7018 F-4

electrode, on 6" sch 160 (.718" nom) SA 1068 pipe. Is this welder qualified to

weld a 2" 300# ANSI schedule 80 bore flange to a 2" schedule 80 SA 106 B

nozzle neck? A. Yes

B. No

C. Not enough information provided

D. Yes, provided a backing strip is provided in the 2" weld. ANS: b

Q38. May a welder who is qualified using a double-groove weld, make a

single V-groove weld without backing?

A. Yes

B. NoC. Not enough information provided

D Yes because backing is not an essential variable for a welder


122/180


D. Yes, because backing is not an essential variable for a welder

ANS: b

Q39. May a GTAW welder be qualified by radiography, in lieu of bend tests?

The test coupon will be P-22 material and the production welds will be P-22

also.

A. YesB. No

C. Not enough information provided

D. Yes, provided the P-22 is welded with F-22 fillers

ANS: b


123/180

P2/5/6

SA-240 Type 310Cb S31040 75 (515) 8 2 102 8.2 25Cr–20Ni –Cb Plate, strip

SA-182 F22, Cl. 1 K21590 60 (415) 5A 1 102 5.2 2.25Cr–1Mo Forging

SA-182 F6a, Cl. 1 S41000 70 (485) 6 1 102 7.2 13Cr Forgings


124/180


Q40. Who is responsible for qualification of welding procedures, welders and

welding operators?

A. The Inspector

B. The A.I.C. The Shop Foreman

D: The Manufacturer of Contractor


125/180


D: The Manufacturer of Contractor

ANS: d

Q41. A welding electrode has the marking E-6010. The "1" marking indicates:

A. Flat position only

B. Harizantal position only

C. All positionsD. Only goad for heat treated welds

ANS: c

Q42. May a FCAW welder qualified using UT, be used to weld in production?

A. Yes, welder can be used

B. No welder cannot be used

C. Yes, if welder is using GMAW (Short Arc)D. Yes, if welder is qualified with backing

ANS: b


126/180


ANS: b

Q43. A wefder may deviate from the parameters specified in a WPS if theyare a nonessential variable. (True or False)

A. True

B. False

ANS: b

Q44. A repair organization has a WPS which states it is qualified for P-6 to P-

8 material welded with either E308, E308L, E309, E316, electrodes (SMAW

process).

The PQR, supporting this WPS, states the weld test coupons were SA-240Type 304L material, welded with E308 electrodes. Is the WPS properly

lifi d f th b t i l li t d?


127/180


qualified for the base material listed?

A. Yes

B. NoC. Nat enough information given

D. Yes, if properly heat treated

ANS: b

Q44. A repair organization has a WPS which states it is qualified far P-6

(Martensitic/Ferritic SS) to P-8 material (Austenitic SS) welded with either

E308, E308L, E309, E316, electrodes (SMAW process).

The PQR, supporting this WPS, states the weld test coupons were SA-240Type 304L material (P8, γ SS), welded with E308 electrodes. Is the WPS

l lifi d f th b t i l li t d?


128/180


properly qualified for the base material listed?

A. Yes

B. NoC. Nat enough information given

D. Yes, if properly heat treated

ANS: b? P8-P8 coupons

QW-424 Base Metals Used for Procedure

Qualification

QW-424.1 Base metals are assigned P-Numbers in table QW/QB-422; Metals

that do not appear in table QW/QB-422 are considered to be unassignedmetals except as otherwise defined for base metals having the same UNS

numbers. Unassigned metals shall be identified in the WPS and on the PQR


129/180


g

by specification, type and grade, or by chemical analysis and mechanical

properties. The minimum tensile strength shall be defined by the organizationthat specified the unassigned metal if the tensile strength of that metal is not

defined by the material specification.


130/180


Q45. What positions are necessary to qualify a welder far all position pipe

welding?

A. 3G and 4G

B. 2G and 5GC. 3G and 1G

D. 4G and 5G


131/180


ANS: b

Q46. What ASME Code Section has welding electrode storage requirements?

A ASME IX

B. ASMEVIII

C. ASME B31.1D. ASME II Part C

ANS: d


132/180


Q47. What are the number of transverse guided bend tests required forPerformance Qualification in a 6G position?

A. 2

B. 4

C. 6D. 3

ANS: b

Q48. May a GMAW, short circuit transfer, welding procedure be qualified

using real-time utrasonics?

A. Yes

B. NoC. No t enough information given

D. Yes, provided bend tests are done


133/180


ANS: b

Q49. Three arc welding processes are:

A. BMAW, SMAW, EFGAW

B. FCAW, SAW, ESW

C. SMAW, GTAW, PAWD. PTAW, SLAW, PEAW

ANS: b

Q50. You are reviewing a WPQ (QW-484) for a welder testing in the 6-G

position; on SA-53 grade B pipe (TS-60,000 psi). The test results indicate the

following:

#1 Tensile developed 51,000 psi, broke in the weld#2 Tensile developed 56,900 psi, broke in base metal

#1 Transverse root bend satisfactory


134/180


#2 Transverse face bend satisfactory

Will these test qualify the welder?

A. Yes

B. No

C. Not enough information given

D. Tension test is acceptable but #1 is unacceptable

ANS: A

ESW

Electroslag welding (ESW) is a highly

productive, single pass welding process

for thick (greater than 25 mm up toabout 300 mm) materials in a vertical or

close to vertical position. (ESW) is

similar to electrogas elding b t the


135/180


similar to electrogas welding, but the

main difference is the arc starts in a

different location. An electric arc isinitially struck by wire that is fed into the

desired weld location and then flux is

added. Additional flux is added until the

molten slag, reaching the tip of theelectrode, extinguishes the arc. The

wire is then continually fed through a

consumable guide tube (can oscillate if

desired) into the surfaces of the metal

work pieces and the filler metal are thenmelted using the electrical resistance of

the molten slag to cause coalescence.


136/180

#11


137/180


Q51. Is a welding procedure qualified under the 1965 ASME Code Section IX

still applicable?

A. Yes

B. No, must be requalifiedC. Is only applicable for 1965 pressure vessels

D. Cannot be used for new construction - repairs only

ANS: a


138/180


ANS: a

Q52. A nonessential variable must be documented on: A. The WPQ

B. The PQR

C. The WPS

D. All of the above

ANS: c

Q53. What are the various positions in which a welder may qualify for plate

groove welds?

A. 1G

B. 3G

C. 4G

D. All of the above

ANS: d

Q54. A welder was qualified with a P-1 test coupon using SMAW E7018

electrodes. May the welder weld P-4 material using E8028 electrodes with

backing in production? (Assume the P-4 procedure using E8028 electrodes

has been qualified.) A. Yes

B. No

C Not enough infomnation provided


139/180


C. Not enough infomnation provided

D. None of the above ANS: a


140/180



141/180


QW-423.1 Base metal used for welder qualification may be substituted for the

metal specified in the WPS in accordance with the following table. When a

base metal shown in the left column is used for welder qualification, the

welder is qualified to weld all combinations of base metals shown in the rightcolumn, including unassigned metals of similar chemical composition to these

metals.


142/180


Q55. What are the primary classifications of guided-bend tests pemnitted by

the Code?

A. Side and Transverse

B. Face and RootC. Transverse and Longitudinal

D. Side and Face

ANS: b


143/180


ANS: b

Comment:

Transverse include side bend/ root bend & face bend

Longitudinal is all weld metal

Q56. A welder qualified by welding in the 5G position is qualified for what

position on plate?

A. F, H, OH

B. F, V, OH

C. V, OH, SP

D. H,V, OH

ANS: b


144/180


ANS: b

Q57. Which of the following is a covered electrode?

A. E6010

B. E 7018

C. E 9028

D. All of the above

ANS: d

Q58. Applicable essential variables must be documented on which of the

following?

A. The WPS

B. The PQR

C. The WPQ

D. All of the above

ANS: d


145/180


Q59. In performance qualification of pipe welds to ASME Section IX, which

positions require more than two guided bend specimens for qualification?

A. 5G and 6G

B. 2G and 4F

C. 4G and SG


ANS: a

Q60. Name two defects that would cause visual rejection of a welder's test

pipe or plate?

A. Porosity, underfill

B. Lack of penetration/ fusion

C. Slag, overlap

D. Any of the above

ANS: d


146/180


Q61. A variable that, when changed will cause a change in the mechanical

properties of the weldment is called a:

A. Essential variable

B. Non-essential variable

C. Supplementary essential variable

D. All of the above

ANS:a

Q62. The test that determines the ultimate strength of groove-weld joints is a:

A. Notch Tough ness Test

B. Tension Test

C. Fillet Weld Test

D. Guided-Bend Test

ANS: b


147/180


Q63. The procedure qualification test is used to determine:

A. The skill of the welder

B. That the proposed production weldment is capable of having the required

properties

C. The corrosion -resistance of the proposed weldment


ANS: b

Q64. A change in a supplementary essential variable requires requalification,

when notch- toughness is a consideration.

A. True

B. False (circle one)

ANS: A

Q65. When using Macro-examination of fillet weld tests, the weld and the


148/180


HAZ must not reveal cracks when magnified at:

A. 5X

B. 2X

C. 10X

D. No magnification is required - visual examination is required, only.

ANS: d

Q66. A non-essential variable may be changed without re-qualification

because:

A. Nobody cares about non-essential variables

B. The welder is allowed to change variables at his discretion

C. Non-essential variables do not affect the mechanical or notch-toughness

properties

D. Non-essential variables cannot be changed without re-qualification


149/180


ANS: c

Q67. The data recorded on a PQR (non-editorial) may be changed provided:

A. The AI approves

B. The test data on a PQR is a record of what occurred and should never be

changed. Only editorial information can be changed on a PQR

C. The API 510 Inspector approves

D. The date of the WPS is changed

ANS: b

Q68. A WPS must only address essential and, if applicable, supplementary

essential variables.

A: True

B. False

ANS: b

Q69. Tension tests may be used in lieu of bend tests to qualify welders or


150/180


welding operators.

A: True

B. False

ANS: b

70. A groove weld bend test reveals a linear indication on the face of the bend

surface that measures exactly 1/8" long. No other indications are seen. does

this coupon pass or fail?

A. Pass

B. Fail

ANS: A

Q71. Unless notch-toughness is a consideration, a qualification in any

position qualifies a welding procedure for all positions.

A: True

B. False

ANS: a

Q72. The purpose of a WPS and PQR is to determine if a welder has the skill


151/180


necessary to make sound production welds.

A: True

B. False

ANS: b

73. Welders can be qualified by radiograph when using P6X materials?

A: True

B. False

ANS: b

QW-304 Welders

Q74. It is permissible to sub-contract welding of coupons as well as other

work to prepare coupons.

A: True

B. False

ANS: a

Q75. Variable QW 402.4 for SMAW procedure qualification is a ______

i bl


152/180


variable

A. Essential

B. Non-essential

C. Supplemental essential


ANS: b

Q76. Variable QW 404.24 for SAW procedure qualification is an _____

variable

A. Essential

B. Non-essential



ANS: d


153/180


Q77. Each manufacturer must certify the PQR (by signature) indicating that

the information given is

A: True

B. False

ANS: a

Q78. Welder variable OW- 405.1 (for welders qualifying with the SMAW

process) is a ___ variable.

A. Essential

B. Non-essential



ANS: a


154/180


Q79. The purpose of a. WPS and PQR is to determine if a proposed

weldment to be used in construction is capable of providing the required

properties for the intended application.

A: True

B. False

ANS: a

Q80. A qualification in a 4G position qualifies a welder for all groove weld

positions. A: True

B. False

ANS: b

Q81. A WPS must address all applicable non-essential variables.

A: True

B. False

ANS: a

Q82. Groove weld coupons shall be tested by macro-examination when

qualifying a welding procedure.

A: True


155/180


A: True

B. False

ANS: b

Q83. A welding procedure must be qualified with impact tests only when

required by the applicable constrction code, such as ASME VIII Div. 1.

A: True

B. False

ANS: a

Q84. A welder qualified to weld in the 2G position on pipe would have to be

qualified in which of the addiiional positions to qualify for all position groove

welding on pipe?

A. 1G

B. 2G

C. 5G

D. 6G

E All of the above


156/180


E All of the above

ANS: C

Q85. The maximum preheat temperature decrease allowed without

requalification of a GMAW groove weld procedure is:

A. 50°F

B. 100oF

C. 125oF

D. 150oF

E. None of the above ANS: b

Q86. A welder is qualified to weld all thicknesses of material when:

A. The test is any thickness above 3/8 inch

B. The test thickness was 1/2 inch

C. The test thickness was 3/4 inch or over

D. The test pipe wall thickness was 5/8 inch and nominal pipe size was over

½ inches

E. None of the above

ANS: b?


157/180


ANS: b?

87. What is the maximum defect permitted on the convex surface of a welder

qualification bend test after bending , except for corner cracks and

corrosion resistant weld overlay?

A. ¼ inchB. 1/8 inch

C. 1/16 inch

D. 3/16 inch

E. No defects are allowed ANS: b


158/180


Q88. What period of inactivity from a given welding process requires the

welder to requalify in that process?

A. 3 months

B. 6 months

C 9 months

D. 12 months

E. As stated by the AI

ANS: b


159/180


ANS: b

Q89. Notch-toughness requirements are mandatory

A. For heat treated metels

8. For quenched and tempered metals

C. For hardened and tempered metalsD. For annealed and tempered metels

E. When specified as required by the referencing Code section

ANS: e

Q90. A welder qualified for SMAW using an E7018 electrode is also qualified

to weld with:

A. E7015

B. E6011

C. E6010

D. E7024

E. All of the above

ANS: e


160/180


ANS: e

Q91. Macro examination of an etched fillet weld section for performance

qualification is acceptable if the examination shows:

A. Complete fusion and freedom from cracks, excepting linear indications not

exceeding 1/32 inch at the root.B. Concavity or convexity no greater than 1/16 inch

C. Not more than 1/8 inch difference in leg lengths

D. All of the above

E. Both B and C above ANS: d

Q92. Each manufacturer or contractor is responsible for the welding or

brazing done by his organization. Whenever these words are used in Section

IX, they shall include:

A. Designer or architect

B. Designer or insteller

C. Architect or insteller

D. lnstaller or assembler

E. Assembler or designer


161/180


E. Assembler or designer

ANS:

Q93. For P-11 materials, weld grooves for thicknesses_____ shall be

prepared by thermalprocesses, when such processes are to be employed

during fabrication. A. Less than 5/8 inch

B. 5/8 inch

C. 1 inch

D. 1-114 inchesE. None of the above

ANS: a

Q94. A welder using SMAW must be requalified if there is a change in which

of the following conditions?

A. A#'s

B. 6 NPS to 2 NPS

C. uphill to downhill in the groove

D. both B & C, above

ANS: a


162/180


Q95. A change in a non-ess.ential variable requires re-certification of thePQR.

A: True

B. False

ANS: b

8/19/2019 Understanding API ICP653 Reading 15-Worksheet

understanding api icp653 reading 15-worksheet-11a revision1

Documents