Industrial Quality Concepts E r MODEL QUESTIONS - API 1104 CODE BOOK (20" Edition) Read each question carefully, and select the one best answer. It is very helpful for you to write down the Section number(s) and page number(s) where you found the answer. 1, Automatic welding without filler metal additions shalt be done using: a GTAW b | OFW © the flash butt welding process a SMAW & none of the above 2. Atmospheres for shielding an are may cousist of: ® inert gases, active gases, or mixtures of inert and active gases b. only inert gases are permitted & only active gases are permitted & ——_ogases are permitted for welding © none of the above 3 For welder qualification, the specimens shalt be prepared for teusile-strength, nick-break, aud bend tests. Whew tensile-strength tests are omitted: 2. the welder is not qualified b. the weld must be redone ©, _ this is not covered im APE 1104 4. —_tensile-strength specimens shail be subject to the nick-break test © extra face bends must be tested 4 For pipe ends of the sanre nominal wail thickmess, the alignment ofiset requirement is: not more than 1/4 inch nof more than 1/8 inck not more than 1/16 inck not more than 1/32 inck none of the above ae me 5. For procedure quifction, the exposed surfaces of each nick-break specimen shall show: no slag inelusions over 1/4 inch Ke stleast 3/4 inches of sound weld metst between inclusions © complete penctration and fusion &._ «the tensile strength of the sample & none of the above Page tof 1612, BB. 14, 16. com Industrial Quality Concepis Eb 2 Welding inspection personnel shall be qualified by: Pee ep Sense ‘American Welding Society American Society for Nondestructive Testing American Petroleum Institute American Society of Mechanical Engineers experience and training for the specified inspection task they perform Welding may be done by whick of the following processes: SAW SMAW GTAW GMAW alt of the above Inadequate penetration without bigh-ow (IP) found by NDF shall be unacceptable wher: Peo ee the aggregate length of IP indications exceeds 3” in any continuous 12 inch length of weld the aggregate length of IP indications exceeds 2” in any continuous 12 inch length of weld the aggregate length of IP indications exceeds 1” in any continuous 12 inch length of weld the aggregate length of IP indications exceeds 1/2" in any continuous 12 inch lengtir of weld the aggregate length of IP indications exceeds 1/4" in any continuous 12 inch length of weld Incompicte fusion due to cold lap (IFD) is defined as = oo weld metal not melted in the joint reot weld metal not melted om the joint face + discontinuity between two adjacent weld beads or between the weld metal aud base metal that is not open to the surface ‘2 discontinuity aleng the weld toe noue of the above beveling of pipe ends by manual oxygen cutting is acceptable if authorized by the company fale = this statement is true only if the cutting operator is certified by API this statement is true only if the cutting operator is a certified welder mone of the shove Avy length of internal concavity (IC) found by NDT is acceptable provided; Pan the density ofthe radiograph image ofthe TC dow ot exceed hat of the thinnest adjacent base metat the density of the radiographic image of the IC must exceed that of the thinnest adjacent base metal IC is never acceptable ultrasonic inspection does not reveal the IC none of the above Page 3 of 10.24, 25. 26. 27. 29. Industrial Quality Concepts E 3 Whee found by NDT, inadequate penetration due to high-low (EPD) shall be unacceptable when: 2, the lengtt of an individual IPD indication exceeds 1 inch b. the length of an individual IPD indication exceeds 2 inches & _ the aggregate length of IPD indications exceeds 3 inches in any continuous 12 inck weld length d wand cabove & band cabove Cracks in welds may be repaired provided the following criteria are met : the length of the crack is less tham 8% of the weld lengtlr 2 b. the erater crack must be ground smooth © x complete repair procedure has been developed and documented 4° sande above & band cabove For pipe with an outside diameter greater than or equal to 2 3/8 inches, isolated slag inclusions (ISI) found by NDF shall be unacceptable when: 2, _ the aggregate length of ISI indications exceeds 4” in any continuows 12 inch weld length b. the aggregate length of ISI indications excceds 3” in any continuous 12 inch weld length © _ the aggregate lengti of ISI indications exceeds 2” in any continous 12 inch weld length ¢. _ the aggregate length of ISI indications exceeds 1” in any continuous 12 inch weld length © . the aggregate length of IST indications exceeds 1/2" in any continuous 12 inch weld lengtit SWESWY i is the abbreviation for: swage welded and extruded/swage welded and visually inspected b side wall examined/side wall visually inspected a b. _the flange rating of the piping system © the type of radiographic film used d. _ the curie strength of the radiographic source used & — noneof the above &. b & the welder may select any location for the samples d. the inspector may select suy location for the samples € none of the above Page Sof 1°36. 37. at Industrial Quality Concepts EL 4 Mechanised welding shall be done using which of the folowing processes? a b. © a e. SAW GMAW GTAW FCAW with or without external shielding all of the above When a radiographic sources is centered imside the pipe for exposing a butt weld: three exposures are adequate for the radiographic inspection of the completed weld two exposures are adequate for the radiographic inspection of the completed weld ‘one exposure is adequate for the radiographic inspection of the completed weld (SWESWV) double filo must be loaded im the fitm cassette none of the above Each automatic welding unit end each operator shail be qualified by producing ax acceptable weld using the qualified welding procedure. a trae b. false © _-eutomatie welding is not permitted in APE 1104 & band cabove e none of the abpve. A welder who successfally completes the qualification in Section 6.2.1 -0u 8 inch, schedule 40 pipe (0.322” wall) must be requalified if; Pane the welding process is changed from SMAW to GMAW the welder elranges the welding direction from horizontal left to horizontal right there is « change in filler metal classification from Group 1 or 2 to Group 3 the welder welds on 6 inch, schedule 40 (0.280” wall) pipe aand cabove For mechanised welding, which of the following statements are truc? , a be © flux cored arc welding without external shielding may not be used in automatic welding qualified procedures for awiomatic welding need mot be recorded the welding position need not be specified as to roll or position welding for automatic welding all of the above are false none of the above Which of the following represent changes in essential variables for manual welding procedure? Peo ep a change in the pipe material group a change of welding position # change in the vertical direction of welding a-change im the shielding gas or a major change in shielding gus flow rate all of the above Page 7 of 1049, 51. 52. 54, Industrial Quality Concepts E é For the above weld, what is the allowable height for a buried imperfection ? (Refer Figure A-5) 0.20” a b, 0.40” cs 036” a 0.72” © — Noneof the above API Standard 1104 does not cover the welding of steel piping of the following a carbon steel b. low alloy stect a stainless steel 4... .new construction e. in-serviee welding The primary concerns with welding onto in-service pipelines are a ing through b. c. safety of the welder & ‘a and “b? above & —- Allof the above For lyrogen erecking to oor the Stlowing conditions ores be ents ied stmttencovsly hydrogen in the weld. b crack-susceptible microstructure © tensile stress acting om the weld dé. allof the above none of the above Burning through is unlikely during in-service welding of pipelines, if % the wall thickness is 0.25” or greater b. if low hydrogen electrodes and normal welding practices are used © preheating is done 2. allofthe above € ‘a orb’ above « Hydrogen cracking during in-service welding cam be prevented by ~ a. use of low hydrogen electrodes b. low heat input & preheating d__allof the above & ‘a or ‘e’ above ‘The procsture sjefication Sor in-service welding of pipes shall inched the foBowing the minimum yield strength of the pipe material b. —_carbom equivalent level & —_weld deposition sequence d..... allof the above © ‘a and §e? above Page 9 of 1055, *™, Industrial Quality Concepts L ‘The macro-section tests of branch and sleeve welds for in-service welding involve the following 2. etching of at least onc cross section face to reveal the weld structure b. _ visual examination to evaluate the soundness c hardness testing a all of the above e woue of the above ‘The hardness testing of the macro test specimens of branch and sleeve welds shall be done 4%. st HAZ, using Vickers indentor and 2 103 load at HAZ, using Vickers indentor and a 10kg load at HAZ, using Brinell indentor and a 10kg load at weld metal, using Vickers indentor and 2 10kg load ~ at the base metal, using Vickers indentor and 2 10kg load pene ‘The risk of hydrogen cracking shall be evaluated for in-service welding of branch and sleeve welds when the concavity or convexity is more than 1/16 “ when the depth of undercutting exceeds 1/32 “ ‘when the HAZ, harduess values are greater than 350 HV when the HAZ, hardness values are lower than 350 HV. when the weld metal hardness values are greater than 350 HV Reo ep ‘The face-bend test for in-service welding of branch and sleeve welds skal be conducted 2. - immediately after completion of the weld b. not less than 24 hours after the welding © not less than 48 hours after the welding d. using the guided-bend test jig © ‘brand “€? above ‘Before welding onto in-service pipeline, the following factors are to be considered. & aspects that affect safety such as operating pressure, flow conditions and wall thickness b. freedom: from imperfections at the areas to be welded c adequate wall thickness at the areas to be welded a all of the above e mone of the above Cantion is advised whew using ultrasonic methods for in-service weld inspection, because the equipment is difficult to operate im the field test results are-often unrepeatable test results vary from test unit fo test unit surface imperfections cam interfere with ifs use surfaces must be coated prior to testing PRP re Page 10.0f 1042, 41, Industrial Quality Concepts y The acceptance standards given in Appendix A can be followed for inspection and acceptance Purposes. This is done a. based on the decision of CWI b. "based om the decision of welder € based on the option o the fabricator 4. e at the option of the company none of the above a b. environment at the erack tip ©... cycles of Inading & i ion size & — allof the above For qualification of welding procedures, as per Appendix A, the tensile test shall meet the following requirements the tensile strength of the weld including fusion zone shall be greater than or equal to the specified minimum tensile strength of the pipe material e 1b. the tensile strength of the weld including fesion zone shall be greater than or equal to the actual tensite strength of the pipe material © the tensile test specimen shall not fail in the weld 4... all of the above © none of the above As per Appendix A, the fractare tonghuess of the weid shall be determined by conducting which of the following test? = Charpy V notek test b Drop weight test © CTOD test~ @. Plane strain fracture test @ None o the above Consider s weld of pipe OD 36” and wall thickness 0.812”, The acceptance Standards are as per Appendix A. ‘The qualified minimum CTOD is 0.016”. The maximum applied axial strain is 0.062in per in. The allowance for inspection error is 0.050”, For this'weld, what is the allowable surface imperfection height ? (Refer Figure A-5) a 0.20” b 0.36" « 0.005” 4. 0.010" e 0.10 Page 8 of 1036, 34. 35. Industrial Quality Concepts E API 1104 applies to the welding of pipe and fittings that conform to: API Specification SL API Specification 620 AWS Specification 5.19 Applicable ASTM specifications aandd above farre per APE 1404, pipes shall be welded by: ified welders pipeline welders using qualified procedures a and eabove Nowe of the above ABA RD © true, but the exposed arez of the fracture must be at least 3/4 incl . trae, but the exposed area of the fracture must be no more than 3/4 inch e Bone of the above there are no cracks or other defects b. the bend sample does not break into several pieces & the defects in the weld or fasion zone do not exceed 1/16 inch in any direction d. the defects in the weld or fasion zone do not exceed 3/32 inch in any direction © the defects in the weld or fusion zone do not excced 1/8 inch or one-half the nominal walt thickness, whichever is smaller, in any direction Film or other imaging media shall be processed, handled, and stored so that the images are Be is required by APE b. generally accepted as the best thing to do © every good thing to do a. ouly when requested by the company © none of the above A record of certified nondestructive testing persounet shall be kept by the company, Levet T and Level IE NDT persovinel shall be recertified at least every: = Lyear bo 2 years Gos. 3 years d. 4 years eS ycars Page 6 of 10-19; 20. 24. industrial Quality Concepts E Parallel clongated slag inclusion (ESI) indications separated by approximately the width of the root bead shall be considered 2 single indication unless the width of either of the indications exceeds 1/1¢ inch. a true b false e true if no other indications exist a true if SMAW was used for the welding e none of the above A welding procedure qualification test is being performed om 3 inch schedule 80 pipe (0,300” wall). What is the totst number of specimens required for testing? a 4. be 6 © 8 & 2 e 16 Hollow-bend porosity (HB) found by NDF shall be unaceepiable whos: the length of an individual indication of HB exceeds finch the length of am individual indication of HB exceeds 7/8 inch cS the length of su individual indication of HB exceeds 3/4 inch ¢. _the length of am individual indication of HB exceeds 1/2 inck € the length of air individual indication of HB exceeds 1/4 inch’ re NDF operators may, by API 1104, be required to: a pass the AWS CWI exam b. only pass the ASNT Level I exam for all test method interpretations & _berecertified if sny question arises about their ability a. demonstrate at least two different methods of NDT e demonstrate at least three different methods of NDT To test fillet-welded joints for qualification of a welding procedare: & at least 4 spetimens shalt be prepared b, _the specimens may be machine cut or oxygen cut © the specimens shall be air cooled to ambient temperature before testing d. the speeimens should be at least I inch wide 6 — altof the above the repaired areas to be reradiogruphed or inspected by the sanre means previously used a. b « all repairs be magnetic particle inspected a. © none of the above Page 4 of 10Hh. 7 Industrial Quality Concepts E Lineup clamps shall be used for butt welds in accordance with the procedure specification. When it is permissible to remove the lincup clamp before the root bead is completed: 2. the completed part of the bead shall be in approximately equal segments spaced approximately equally around the circumference of the joint b. the completed part of the bead shall be removed and rewelded after removing the clamp & the completed part of the bead shall be peened before removing the clamp 4. the completed part of the bead shall be at least 4 inches long for all pipe sizes € none of the above the entire pipe must be used for bend testing one full-section teusile specimen may be substituted for the root-bend aud nick-break specimens Pipe of this diameter may not be destructively tested none of the above 12 inches 46 inches 20 inches 24 inches 2 b « a e When pipe'is welded above ground, the working clearance around the pipe at the weld should be at east: a b « a e 30 inches - bat least 3/4 inches sound metal between adjacent inclusions © complete penetration and fusion 4 the tensile strength of the specimen e none of the above = b bead starts c high points all of the above © —_moue of the above b. not be more than 1/32 inch or 12.5% of the pipe wall thickness, whichever is smaller © not be more than 1/8 inch or 6% of the pipe wall thickness, whichever is smaller d. always be acceptable if the inspector does nat see it & none of the above ‘Page 2 of 10