12/24/23, 9:47 AM API 577 Sample Questions | Free Test | Welding Inspection and Metallurgy

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12/24/23, 9:47 AM API 577 Sample Questions | Free Test | Welding Inspection and Metallurgy

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Congratulations - you have completed API 577 Bench Mark 20 Questions.

You scored 30 points out of 30 points total.

Your answers are shown below:

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12/24/23, 9:47 AM API 577 Sample Questions | Free Test | Welding Inspection and Metallurgy
1. Welding inspection is a critical part of an overall:

Weld inspection plan

Weld quality assurance program
Quality assurance plan
Inspection program

Reference: Section 4.1 Welding Inspection (General) ; API may check your understandings of basics.
Remember all activities are part of a program.

2. Welding Inspection includes much more than just the non-destructive examination of the completed
weld. Many other issues are important & they include all of the below except:

Review of specs & welding procedures

Review of joint design
Review of cleaning procedures
Review of Material Verification Program

Reference: Section 4.1 Welding Inspection (General) ; API may check your understandings of basics. PMI
is not normally part of welding inspection activities.

3. Welding inspection activities can be separated into three stages corresponding to the welding work
process and include all of the following except:

Prior to welding
During welding
During audits after weld inspections
Upon completion of welding

Reference: Section 4.1 ;Inspection; these are main duties of welding inspector (before, during, after
welding).

4. What is the most important stage of welding to assure that welding problems are avoided and changes
and corrections necessary are made?

In the planning and preparation stage before any welding on the job begins
Just immediately before the planned start of welding on a new job
During the welding of initial production joints
Either during welding or immediately after

Reference: Section 4.2 Tasks prior to Welding. Always be proactive and ensure all elements in place
before welding.

5. Prior to welding, a review of drawings, standards, codes, and specifications is done to:

Understand the requirements for the welding and identify any inconsistencies
Ensure that the welder understands the specification and is qualified
Ensure that the drawings meet the specifications
None of these are correct per API 577

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Reference: Section 4.2.1 Drawings, Codes& Standards

6. All of the following are Quality Control items to assess prior to welding except?

Dimensions are detailed and any potential for distortion has been addressed
Perform Visual Welding to ensure no rejectable defects are present.
Weld maps identify welding procedure specification (WPS) used for specific weld joints
Welding symbols, weld sizes, weld joint designs, & weld dimensions are clearly specified

Reference: Section 4.2.1.1; QC Items to Assess Prior to Welding

7. Inspectors shall review welding procedures (WPS) & qualification records (WPQs) prior to work to
ensure that:

All procedures & qualification records are completed

All procedures & qualification records are completed and acceptable for work
All procedures & qualification records are completed and signed by the Engineer
None of the above are correct

Ref: Sect4.2.3 Procedures & Qualification Records!

8. All below statements are correct except:

Welder performance qualifications (WPQ) support the requirements for PQR

Welder performance qualifications (WPQ) should cover the WPS range of diameter and thickness
and also the welding process.
WPS are properly qualified and meet the applicable codes, standards & specs for the welding work.
Procedure qualification records (PQR) are properly performed & support the WPS.

Ref: Sect. 4.2.3.1 Procedures & Qualification Records Note: WPQ shows welder ability to deposit sound
weld while PQR supports the WPS and validate weld design or WPS.

9. Inspectors reviewing welding procedures & qualification records (prior to work) should address all of
the following actions EXCEPT:

Obtain acceptable WPS(s) and PQR(s) for the work

Qualify WPS(s) where required and witness qualification effort
Qualify or re-qualify welders as required & witness a percentage of welder qualifications
Qualify WPQs where required and any PQRs needed & witness a % of welder qualifications

Ref: Sect. Sect. 4.2.3.2 4.2.3.2 Procedures/Qual records potential inspector action!

10. Inspectors shall review NDE Information prior to inspection to:

Confirm the NDE procedure(s) from inspection organization are acceptable for the work
Confirm the NDE examiner(s) from inspection organization are capable for the work
Confirm the NDE equipment from inspection organization is acceptable for the work
Confirm the NDE examiner(s) are certified to ASNT SNT TC 1A or ASNT CP 189 or ISO 9712.

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Ref: Sect. 4.2.4 ; NDE Information Trick question : NDE examiner shall be qualified as per ASNT SNT TC
1A or ASNT CP 189 or ISO 9712.

11. Inspectors reviewing NDE Information (prior to work) should assess all of the following Quality
Control items except:

NDE examiners are properly certified for the NDE technique

Condition of the equipment is new.
NDE procedures are current and accurate
Calibration of NDE equipment is current

Ref: Sect. 4.2.4.1 NDE Information QC Items to Assess!

12. Inspectors shall check Welding equipment & Instruments prior to work to:

Confirm Welding equipment & Instruments operate properly and are in good condition
Confirm Welding equipment & Instruments operate properly and are calibrated
Confirm Welding equipment & Instruments operate properly
Confirm Welding equipment & Instruments are calibrated

Ref: Sect. 4.2.5.2; Welding equipment & Instruments

13. Inspectors checking welding equipment & instruments prior to work should assess all of the
following Quality Control items except:

Welding machine calibration is current

Instruments (ammeters, voltmeters, contact pyrometers) have current calibrations
Welding cabinets for large quantity storage of hermetically sealed containers exists on job
Welding consumable storage ovens operate (automatic heat control, visible temp indication)

Ref: Sect. 4.2.5.1 Welding Equip & Instruments QC Items to Assess!

14. Inspectors shall check Heat Treatment & Pressure Testing procedures/ associated equipment prior to
work in order to:

Confirm Heat Treatment & Pressure testing procedures/associated equipment are acceptable
Confirm Heat Treatment & Pressure testing associated equipment is acceptable
Confirm Heat Treatment & Pressure testing procedures are acceptable
confirm heating is adequate after welding.

Ref: Sect. Sect. 4.2.6 4 Heat Treatment & Pressure Testing

15. Inspectors checking Heat Treatment & Pressure Testing procedures/associated equipment prior to
work should assess all of the following Quality Control items except:

Heat treatment procedure is available & appropriate & equipment calibrations are current
Pressure testing equipment & gauges calibrated & meet appropriate test requirements

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Pressure testing procedures are available and detail the testing requirements
Trained personnel to perform activities have been approved for the work

Ref: Sect. 4.2.6.1 Heat Treat& Press Testing QC Items to Assess! Note: there is no PMI, PWHT and
Pressure Testing Technician Certificate unlike NDT Certifications. These technicians are normally
trained in house.

16. Inspectors shall check all Materials (for welding) prior to work in order to ensure all of the following
except:

Ensure all filler metals, base materials, and backing ring materials are properly identified
Ensure all filler metals, base materials, and backing ring materials are properly marked
Ensure material traceability is maintained as per mandatory API 578 requirements
Ensure PMI is performed (if required) to verify the material composition

Ref. 4.2.7 Materials. PMI is not mandatory unless specified in spec.

17. Inspectors checking Materials prior to work should assess all of the following Quality Control items
except:

Material test certifications are available & items properly marked (incl. back-up rings if used)
Electrode marking/bare wire flag tags/identification on wire spools as-specified
Filler material markings are visible and known to the welding organization
Base metal markings are traceable to a material certification

Ref: Sec. 4.2.7.1 fillet materials need only be traceable and identifiable only.

18. Inspectors checking Materials prior to work should assess all of the following Quality Control items
except:

Paint striping color code meets requirements of PFI-ES-22

Recording of filler and base metal traceability information is performed
Base metal stampings are low stress and not detrimental to the component
PMI records supplement material traceability/confirm material of construction

Ref: Sect. 4.2.7.1

19. Final tasks upon completion of the weldment and work should include those that assure final weld
quality before placing the weldment in service & they include all of these except:

Document Audit (Perform final audit of Insp dossier to identify inaccuracies/ incomplete info)
Appearance & finish (Verify post-weld acceptance, appearance & finishing of welded joints)
NDE review (Verify NDE is performed at selected locations & review examiner’s findings)
Identify non-conformances and defects and take immediate corrective actions

Cosmetic appearance of weld is not cause for rejection.

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20. If defects or non-conformances to specification are found by the Inspector, this should be handled
when and in what manner (Identify False statement):

Inspector takes actions on these issues at any time during the welding inspection
Inspector takes actions on these issues after his welding inspections by report issuance
Inspector takes steps to ensure correction of the issues before welding proceeds further
Inspector brings issues to attention of those responsible before welding proceeds further

Note: you should be pro active and don't wait until the end result. Intervene if you see something is not
right otherwise the cost and delay would be much more to rectify the issue at hand.

21. Recording on a data sheet of an indication that exceeds the reject flaw size criteria and needs to be
corrected is .....

Recordable indication
Reportable indication
Notable indication
Removable indication

Reportable indications need to be removed, corrected while recordable indications are those that do not
exceed acceptance criteria but still significant enough to be recorded.

22. A sub –surface terrace and step-like crack with basic orientation parallel to the base metal surface
caused by tensile stresses in thickness direction is called ......

Lamination
Plane-breaking crack
Lamellar tearing
D] Stress corrosion crack

23. Slag inclusion” is not found in welding performed by ....

GMAW
SAW
SMAW
FCAW

GMAW is free from slag as no flux coated electrode is used

24. Most applicable method for sub-surface porosity is ...

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12/24/23, 9:47 AM API 577 Sample Questions | Free Test | Welding Inspection and Metallurgy
UT
PT
ET
RT

25. VT is most conveniently performed placing an eye ......

Within 6” – 24” with angle less than 30° with the surface
Within 6’’-24’’ with angle not less than 30° with surface
Beyond 24’’ with angle less than 30°
Beyond 24’’with angle not less than 30°

26. A clear radiography film has density of ....

2
4
0
infinity

0 means all lights pass through.

27. In UT examination,

A- scan shows cross-sectional elevation view

B- scan shows cross-sectional elevation view
C-scan shows cross-sectional elevation view
Planar view

28. Steels with CE greater than 0.55% typically require:

Preheating only
Pre-heating & PWHT
No pre- heating or PWHT
PWHT only

29. A method to assure that PWHT was performed satisfactorily is ...

Hardness testing of weld & HAZ

Radiography of weld &HAZ
PT or MT of weld & HAZ
UT of weld & HAZ

30. Welding process that has very high metal deposition rate is ........

SMAW

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GMAW
GTAW
SAW

There are three definite leads to help you understand what type of questions to expect during
examination. These are:

API 577 and it’s cross references (ASME V & ASME IX),
Body of Knowledge or what you are expected to know
Exam Score Report (showing the areas where you are scored against and the number of questions
from each topic).

API 577 Body of Knowledge

API 577 exam tests the individual’s knowledge and expertise in the field of welding and metallurgy.

You shall be able to:

Know about terms, definitions, vocabulary

Know about popular welding process, advantage and disadvantage
Know about Welding Inspection, common issues encountered and how to handle them.
Know about WPS/PQR and can verify a WPS against the supporting PQR using ASME IX.
Can verify a Welder Qualification against a WPS and welding position requirement using ASME IX.
Know about (NDE) Non-Destructive Examination (Concept, application, examiner qualification, NDE
procedure, report, and equipment); The NDT methods are UT, RT, MT/ACFM, PT, VT and Hardness
testing. Pressure and leak testing.
Have basic knowledge of Metallurgy; Physical & Mech. Properties of metals, PWHT, Mill Test Report,
and Weldability of materials.
Know about common welding defects; welding repair while in service (Hot tapping) and caustic
service,
And finally have sufficient safety awareness in welding and NDE environment.

How the API 577 exam questions developed?

Periodically a question writing session is conducted. Subject Matter Experts (SME’s), or individuals who
specialize in pressure vessels, write questions from specific sections of the Code. Each question is then
checked by three other SME’s.

This validation exercise answers two questions;

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1. Is the question written clearly?
2. Does the question cover knowledge that is important to a vessel inspector?

These questions then go into a question data-bank as non scored exam questions.

Presently there are over 500 questions in the data-bank and are grouped by topics. For each
examination, there are 80 questions on the exam pulled in specified proportion from various categories.
Only 70 Questions are scored. The remaining 10 are pre-test questions and not marked towards your
score, meaning these pre-test questions do not affect your score whether you have answered them
correctly or incorrectly. API does not tell you which ones these questions are.

API needs to ensure that these questions are not significantly challenged by the candidates and also has
been answered by a reasonable number of people before adding them to their question bank as scored
questions.

Our suggestion for you

 API 577 Welding Inspection & Metallurgy | Full Course

 API 577 Mock Exam Package

Scoring area
Percentage of Questions

API 577 70%

ASME V 15%

ASME IX 15%

Area of examination scores

You are scored for your performance in the following areas during the examination:

Metallurgy
Welding Process, Procedure and Qualifications
Definitions, Acronyms and Symbols
Welding Inspection and NDE Examination
Refinery and Petrochemical Plant Welding Issues
Welding Materials

No Negative Marking

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The pass mark is roughly 70% for all the API examinations. No negative marking is applied. Therefore,
make sure that you have answered all the questions. At the end, click the ‘’review all’’ button and peruse
through the list to ensure that you have not skipped any question. You can also check ‘’review
incomplete questions’’ to ensure there is nothing on the list, that is, no question left unanswered.

API 577 Mock Exam Package API 577 Welding Inspection & Metallurgy Online
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