1- In new Rail as well as second hand rails how much end bends of the rails in vertical are permitted when checked with one meter straight edge before welding?
(i) +0.5mm, -0 mm in vertical
(ii) +0.2mm, -.3 mm in vertical
(iii) +0.3mm, -2 mm in vertical
(iv) 0 mm, +.5 mm in vertical
Answer - (i) +0.5mm, -0 mm in vertical
2- In new Rail as well as second hand rails how much end bends of the rails in lateral direction are permitted when checked with one metre straight edge before welding?
(i) ± 0.2 mm in lateral direction
(ii) ± 0.3 mm in lateral direction
(iii) ± 0.5 mm in lateral direction*
(iv) All are above right
Answer - (iii) ± 0.5 mm in lateral direction
3- What is the life of portion?
(i) 2 years
(ii) No specific life.
(ii) 6 months
(iv) 1 year
4- Life of Portion mainly depend upon?
(i) Quality of packing
(ii) Storage condition
(iii) Quality of packing and storage condition.
(iv) Ingredients of portions
Answer - (iii) Quality of packing and storage condition.
5- How rejected portion are to be disposed-off?
(i) By Igniting 5 Portions at a time in pit away from store?
(ii) By throwing them away
(iii) By dispose off in a pit
(iv) By using it in Branch/Yard lines for welding
Answer - (i) By Igniting 5 Portions at a time in pit away from store?
6- Where Portion sample tests(test piece) should be conducted?
(i) At desire by RDSO
(ii) At Zonal CMT’s organisation or the Flash Butt Welding plant.
(iii) In RDSO campus
(iv) As decided by in charge of the plant
Answer - (ii) At Zonal CMT’s organisation or the Flash Butt Welding plant.
7- The composition of thermit welding team?
(i) 7 Nos.
(ii) 8 Nos.
(iii) 6 Nos.
(iv) 9 Nos
Answer - (ii) 8 Nos.
8- What is the duration for Initial course for welders (TW-1)?
(i) Two weeks
(ii) One week
(iii) As decided by TPP/LKO
(iv) 3 working days
Answer - (i) Two weeks
9- What is the duration for Refresher course for welders (TW-2)?
(i) One week
(ii) Two weeks
(iii) As decided by TPP/LKO
(iv) 3 working days
Answer - (i) One week
10- What is the duration for supervisors course (TW-3)?
(i) One week
(ii) Two weeks
(iii) As decided by TPP/LKO
(iv) 3 working days
Answer - (i) One week
11-Type of competency certificate issued after TW-1 course?
(i) Competency for two years
(ii) Provisional competency.
(iii) Competency for six months
(iv) Competency to do welding independently
Answer - (ii) Provisional competency.
12- What is the validity of Provisional competency certificate?
(i) Valid for executing 50 joints or six months whichever is earlier.
(ii) Valid for executing 100 joints or six months whichever is earlier.
(iii) Valid for executing 50 joints.
(iv) Valid for six months
Answer - (ii) Valid for executing 100 joints or six months whichever is earlier.
13- What is the validity after Refresher course for welders (TW-2)?
(i) Six monyhs
(ii) One year
(iii) Two years.
(iv) All are wrong
Answer - (iii) Two years.
14- What is the validity after supervisors course (TW-3)?
(i) Normally, supervisors shall not be required to undergo the course again. However, they may be sent for course on performance basis.
(ii) 2 years
(iii) 5 Years
(iv) 10 Years
Answer - (i) Normally, supervisors shall not be required to undergo the course again. However, they may be sent for course on performance basis.
15- How much rail ends are cleaned with Kerosene Oil and steel wire brush?
(i) Minimum 100 mm both side
(ii) Minimum 50 mm both side.
(iii) No need
(iv) As decided by site supervisor
Answer - (ii) Minimum 50 mm both side.
16- What is the heating time in OXY & LPG in SPW?
(i) 2.0 - 3.5 minutes.
(ii) 2.0 - 3.0 minutes.
(iii) 2.0 - 2.5 minutes.
(iv) 3.0 - 4.5 minutes.
Answer - (iii) 2.0 - 2.5 minutes.
17- What is the minimum distance between AT Weld and other joint exist in track?
(i) 2 Mt.
(ii) 3 Mt.
(iii) 4 Mt.
(iv) 4.5 Mt.
Answer - (iii) 4 Mt.
18- During AT welding reaction is ?
(i) Exothermic.
(ii) Endothermic
(iii) No Reaction
(iv) Heating
Answer - (i) Exothermic.
19- What is Pre Heating Temperature of rail ends in AT Welding?
(i) 300 ± 20oC
(ii) 400 ± 20oC
(iii) 500 ± 20oC
(iv) 600 ± 20oC
Answer - (iv) 600 ± 20oC
20- What action to be taken if slag is not separated within 20 ± 3 seconds?
(i) Tap inside.
(ii) Tap outside
(iii) Good reaction
(iv) Tap well in time
Answer - (ii) Tap outside
21- Internal diameter of thimble in conventional type of crucible is?
(i) 14-16 mm
(i) 16-18 mm
(iii) 18-20 mm
(iv) 20-22 mm
Answer - (iii) 18-20 mm
22- Name the material which is separated from molten steel during chemical reaction of A.T welding?
(i) Aluminium oxide (slag).
(ii) Ferrous Oxide
(iii) Aluminium
(iv) Ferrous
Answer - (i) Aluminium oxide (slag).
23- Finishing tolerances are measured by?
(i) On 30 cm scale
(ii) 1 MT straightedge or 10 CM straightedge.
(iii) On 15 cm straight edge
(iv) On 30 cm straight edge
Answer - (ii) 1 MT straightedge or 10 CM straightedge.
24- To take care of differential cooling rail ends of 90 UTS rails are lifted by?
(i) 1 mm
(ii) 2 mm
(iii) 2 to 2.2 mm.
(iv) 1 to 2 mm.
Answer - (iii) 2 to 2.2 mm.
25- Which gauge is used to measure finishing tolerances .
(i) Tilted gauge
(ii) Filter gauge
(iii) Meter gauge
(iv) Filler gauge.
Answer - (iv) Filler gauge.
26- Early tapping will cause defect of?
(i) No defect
(ii) Inclusion of slag
(iii) Inclusion of aluminium
(iv) Inclusion of ferrou
Answer - (ii) Inclusion of slag
27- Risers are broken at?
(i) cold.
(ii) Hot
(iii) After 5 mints
(iv) After 3 mints
Answer - (i) cold.
28- Pressure of compressed air is kept during preheating by CAPS?
(i) 1 to 2 kg/cm2
(ii) .1 to .2 kg/cm2
(iii) 2 to 3 kg/cm2
(iv) 0.2 to 0.3 kg/cm2
Answer - (iv) 0.2 to 0.3 kg/cm2
29- Crucible is repaired by?
(i) Magnasite Powder
(ii) Magnasite Powder & Sodium Silicate.
(iii) Sodium Silicate
(iv) Aluminium powder
Answer - (ii) Magnasite Powder & Sodium Silicate.
30- Function of Calcium fluoride/flour spar in portion is?
(i) To separate slag
(ii) To separate aluminum
(iii) To separate ferrous
(iv) No separation
Answer - (i) To separate slag
31- Finished tolerance on 1 Mt. st. edge at the centre on gauge side shall be?
(i) ± 0.2 mm
(ii) ± 0.3 mm
(iii) ± 0.5 mm
(iv) ± 1.0 mm
Answer - (iii) ± 0.5 mm
32- Finished tolerance on 1 Mt. long st. edge on surface of head shall be?
(i) 0 to .1 mm
(ii) 1 to 1.5 mm
(iii) 0 mm
(iv) 0 to 1 mm
Answer - (iv) 0 to 1 mm
33- Finished tolerance on 10 cm long st. edge at the centre on gauge side shall be?
(i) ± 0.4 mm
(ii) ± 0.1 mm
(iii) ± 0.2 mm
(iv) ± 0.3 mm*
Answer - (iv) ± 0.3 mm
34- Finished tolerance on 10 cm. long st. edge on surface of head shall be?
(i) 0 to 0.1 mm
(ii) 0 to 0.2 mm
(iii) 0 to 0.4 mm
(iv) 0 to 0.3 mm
Answer - (iii) 0 to 0.4 mm
35- Minm. deflection during transverse breaking load test is?
(i) 5 mm
(ii) 10 mm
(iii) 15 mm
(iv) 20 mm
Answer - (iii) 15 mm
36- Min. breaking load of 52kg weld during transverse breaking load test is?
(i) 90MT
(ii) 100 MT
(iii) 110 MT
(iv) 120 MT
Answer - (i) 90MT
37- Min. breaking load of 60kg weld during transverse breaking load test is?
(i) 110 MT
(ii) 115 MT
(iii) 90 MT
(iv) 120 MT
Answer - (ii) 115 MT
38- To take care of differential cooling rail ends of 72 UTS rails are lifted by?
(i) 1 to 1.5 mm
(ii) 1 to 2 mm
(iii) 2 to 2.5 mm
(iv) 3 to 4 mm
Answer - (iv) 3 to 4 mm
39- The colour of bag containing Portion for 72 UTS ?
(i) Pink
(ii) Green
(iii) Red
(iv) Black
Answer - (iii) Red
40- The colour of bag containing Portion for 90 UTS ?
(i) Red
(ii) Green
(iii) Pink
(iv) Black
Answer - (ii) Green
41- The colour of bag containing Portion for 110 UTS ?
(i) Red
(ii) Green
(iii) Pink
(iv) Black
Answer - (iv) Black
42- Pressure of LPG during pre-heating shall be?
(i) 2.0 - 2.5 kg/ sq cm
(ii) 2.0 - 2.5 kg/ sq cm
(iii) 2.0 - 2.5 kg/ sq cm
(iv) 2.0 - 2.5 kg/ sq cm
Answer - (iii) 2.0 - 2.5 kg/ sq cm
43- Pressure of Oxygen during pre-heating shall be?
(i) 4.0 – 5.0 kg/ sq cm
(ii) 5.0 – 6.0 kg/ sq cm
(iii) 6.0 – 7.0 kg/ sq cm
(iv) 7.0 – 8.0 kg/ sq cm
Answer - (iv) 7.0 – 8.0 kg/ sq cm
44- Defect of Blow holes is due to?
(i) Slag
(ii) Moisture
(iii) Lack of heating
(iv) Extra heating
Answer - (ii) Moisture
45- Heating time with compressed air and petrol in SPW is ?
(i) 4.0 to 4.5 minutes.
(ii) 4.0 to 5 minutes
(iii) 5.0 to 5.5 minutes
(iv) 5.5 to 6 minutes
Answer - (i) 4.0 to 4.5 minutes.
46 – What is the Shelf life of mould ?
(i) 6 months minimum.
(ii) 8 months minimum
(iii) 9 months minimum*
(iv) 12 months minimum
Answer - (iii) 9 months minimum
47 – What is the Life of luting sand ?
(i) No defined
(ii) 6 months
(iii) 9 months
(iv) 12 months
Answer - (i) No defined
48 –Minimum traffic block required for execution of AT Weld ?
(i) 70 minutes
(ii) 70-75 minute.
(iii) 60 mints
(iv) 1 hrs and 30 mints
Answer - (ii) 70-75 minute.
49-What are the recognized systems for pre heating of rails ends for AT Welding?
(i) Oxygen –LPG & Compressed air petrol both
(ii) Only Oxygen –LPG
(iii) Only Compressed air petrol both
(iv) both are correct
Answer - (i) Oxygen –LPG & Compressed air petrol both
51-Weather protection of track is required during block for execution of AT Welding?
(i) Yes.
(ii) No
(iii) As decided by site supervisor
(iv) As per site condition
Answer - (i) Yes.
52-Weather traffic block is required for execution of AT Welding?
(i) Yes.
(ii) No
(iii) As decided by site supervisor
(iv) As per site condition
Answer - (i) Yes.
53- After AT Welding First train is to be passed after ?
(i) 20 Minutes from pouring of weld metal.
(ii) 35 Minutes from pouring of weld metal.
(iii) 30 Minutes from pouring of weld metal.*
(iv) 25 Minutes from pouring of weld metal.
Answer - (iii) 30 Minutes from pouring of weld metal.
54- What is the speed restriction to be observed for train passing?
(i) Necessary speed restriction shall be observed until the grinding operation is over.*
(ii) 30KMPH
(iii) 45 KMPH
(iv) Not required.
Answer - (i) Necessary speed restriction shall be observed until the grinding operation is over.
55- Normal Reaction time in SPW technique?
(i) 17 ± 3 seconds.
(ii) 15 ± 3 seconds
(iii) 23 ± 3 seconds
(iv) 20 ± 3 seconds*
Answer - (iv) 20 ± 3 seconds
56- Colour of rail ends becomes after preheating ?
(i) Golden
(ii) Pink Red
(iii) Red
(iv) Yellow
Answer - (i) Golden
57- How many nos. of sleepers should be loosened either side of the proposed weld?
(i) 3 sleepers
(ii) 5 sleepers.
(iii) 2 sleepers
(iv) 4 sleepers
Answer - (ii) 5 sleepers.
58- No of Ingredient of Portion are?
(i) Five.
(ii) Six
(iii) Seven
(iv) Eight
Answer - (iii) Seven
59- Height of crucible is kept from top surface of mould?
(i) 30 mm
(ii) 40 mm
(iii) 50 mm
(iv) 60 mm
Answer - (iii) 50 mm
60- Torch is kept at height from top surface of rail head?
(i) 30 to 55 mm
(ii) 35 to 40 mm
(iii) 40 to 45 mm
(iv) 45 to 50 mm
Answer - (iii) 40 to 45 mm
61- Which gauge is used to measure the height of rail at the time of aligning of rails for AT welding?
(i) Height gauge.
(ii) Vertical gauge
(iii) Horizontal gauge
(iv) As decided by site supervisor
Answer - (i) Height gauge.
62- Full form of SPW?
(i) Special pre heated weld
(ii) Short preheated weld.*
(iii) Short post heated weld
(iv) None of above
Answer - (ii) Short preheated weld.
63- Grade of 90 UTS rail is?
(i) 880
(ii) 1080
(iii) 710
(iv) None of above
Answer - (i) 880
64 – Grade of 110 UTS rail is?
(i) 880
(ii) 1080
(iii) 710
(iv) None of above
Answer - (ii) 1080
65- Grade of 72 UTS rail is?
(i) 880
(ii) 1080
(iii) 710
(iv) None of above
Answer - (iii) 710
66- Defect of cracks in weld is mainly due to?
(i) Early opening of mould.
(ii) Early trimming of weld
(iii) Early grinding of weld
(iv) None of above
Answer - (i) Early opening of mould.
67- Defect of short of metal is mainly due to?
(i) Less gap
(ii) Excessive gap*
(iii) Less weight of position
(iv) None of above
Answer - (ii) Excessive gap
68- Defect of low joint is due to?
(i) Excess height
(ii) Early trimming of weld
(iii) Early grinding of weld
(iv) Nil/Less provision of height during alignment.
Answer - (iv) Nil/Less provision of height during alignment.
69- Defect of High joint is due to ?
(i) Early trimming of weld
(ii) Excess provision of height during alignment.
(iii) Early grinding of weld
(iv) None of above
Answer - (ii) Excess provision of height during alignment.
70 -Defect of lack of fusion is mainly due to?
(i) Improper heating.
(ii) Improper Gap
(iii) Improper grinding
(iv) None of above
Answer - (i) Improper heating.
71- Late tapping will cause defect of?
(i) Lack of fusion (Heat losses)*
(ii) Piping defect
(iii) Half moon defect
(iv) None of above
Answer - (i) Lack of fusion (Heat losses)
72- Thickness of Lining/Charge is kept?
(i) 20 mm.
(ii) 25 mm
(iii) 30 mm
(iv) As decided by the site supervisor
Answer - (ii) 25 mm
73- Head of closing pin is covered with
(i) Asbestos powder
(ii) Slag Powder
(iii) Asbestos powder than slag
(iv) None of above
Answer - (iii) Asbestos powder than slag
74- How many grams asbestos powder is used to cover head of closing pin ?
(i) 2 grams
(ii) 3 grams
(iii) 4 grams
(iv) 5 grams
Answer - (iv) 5 grams
75- What will happen if slag is not used above the layer of asbestos powder?
(i) Auto tapping*
(ii) High welding
(iii) Low welding
(iv) Nothing will happen
Answer - Answer - (iv) 5 grams
76- What is mould waiting time?
(i) 3 to 5 minutes.
(ii) 4 to 6 minutes*
(iii) 3.5 to 5.5 minutes
(iv) 4.5 to 6.5 minutes
Answer - (ii) 4 to 6 minutes
77- Late tapping will cause defect of?
(i) Lack of fusion (Heat losses)
(ii) Piping defect
(iii) kidney defect
(iv) All above are correct
Answer - (i) Lack of fusion (Heat losses)
78- What is the function of Zircon wash?
(i) To maintain good quality of weld
(ii)To achieve good finish of the weld surface.
(ii) Both above are correct
(iv) Both are incorrect
Answer - (ii)To achieve good finish of the weld surface.
79 Main advantage of 3-piece P F Mould is?
(i) To overcome fin defect.*
(ii) To prevent the flaw of molten metal
(iii) To make proper weld size
(iv) None to the above
Answer - (i) To overcome fin defect.
80 What is the time of removal the tensor from the newly executed A T Weld?
(i) 15 minutes after pouring.
(ii) 20 minutes after pouring*
(iii) 25 minutes after pouring.
(iv) 30 minutes after pouring.
Answer - (ii) 20 minutes after pouring
81 Last flag man is deputed at which distance from last detonator during protection of welding site .
(i) 30 mts
(ii) 50 mts
(iii) 45 mts
(iv) 60 mts
Answer - (iii) 45 mts
82 When was the collar painting done ?
(i) After the welding
(ii) after one week of welding
(iii) After 15 days of welding
(iv) None of the above
Answer - (i) After the welding
83 Second coat of paint is done after minim. of
(i) 2 Hrs after first coat
(ii) 4 Hrs after first coat
(i) 6 Hrs after first coat
(iv) 8 Hrs. after first coat .
Answer - (iv) 8 Hrs. after first coat
84 Painting of weld is done up to
(i) 10 CM minimum both side of weld & on welded surface .
(ii) 15 CM minimum both side of weld & on welded surface
(iii) 20 CM minimum both side of weld & on welded surface
(iv) None of the above
Answer - (i) 10 CM minimum both side of weld & on welded surface .
85 Name the paint used in A.T. Welding painting?
(i) Black Paint
(ii) Bituminous black IS:9862-1981.*
(iii) Any type of black paint
(iv) None of the above
Answer - (ii) Bituminous black IS:9862-1981.
86 Rails used for A T Welding shall not normally be welded?
(i) 20 years old .
(ii) 30 years old
(iii) 40 years old
(iv) 50 years old
Answer - (iv) 50 years old
87. Marking on weld should be done which side?
(i) Non gauge face side of A.T. weld
(ii) Gauge face side of A.T. weld
(iii) On web of non gauge face side of A.T. weld
(iv) On web of gauge face side of A.T. weld
Answer - (i) Non gauge face side of A.T. weld
88. Marking on weld should be done
(i) On centre of the rail head
(ii) 10 mm below the top surface of rail head.*
(iii) 10 mm above the bottom surface of rail head.
(iv) None of the above
Answer - (ii) 10 mm below the top surface of rail head.
89. Weather date of welding is marked on weld?
(i) Yes
(ii) As decided by the site supervisor
(iii) No*
(iv) None of the above
Answer - (iii) No
90. Banner flag is planted at a distance of
(i) At the site of work
(ii) At 1200 mtrs from welding site
(iii) At 30 mtrs from welding site
(iv) 600 Mt. from welding site .*
Answer - (iv) 600 Mt. from welding site .
91. Ist detonator is planted at a distance of
(i) 1200 Mt. from welding site .
(ii) 600 mtrs from welding site
(iii) 30 mtrs from welding site
(iv) None of the above
Answer - (i) 1200 Mt. from welding site .
92. Distance between the two detonators should be
(i) 15 Mt.
(ii) 10 Mt.
(iii) 20 Mt
(iv) None of the above
Answer - (ii) 10 Mt.
93. How many detonators are planted during protection of track for welding site ?
(i) One
(ii) Two
(iii) Three
(iv) None of the above
Answer - (iii) Three
94. New AT weld should be entered in TMS by ?
(i) Sectional JE/SSE*
(ii) Incharge SSE
(iii) Welder
(iv) None of the above
Answer - (i) Sectional JE/SSE
94. In how many time rough riding should be done of new AT weld ?
(i) Just after the welding
(ii) After 8 hrs of welding
(iii) After 24 hrs
(iv) None of the above
Answer - (i) Just after the welding
95 In how many time final grinding should be done of new AT weld ?
(i) Just after the welding
(ii) After 8 hrs of welding
(iii) With in 24 hrs*
(iv) None of the above
Answer - (iii) With in 24 hrs
96. Till USFD testing of new AT weld what is criteria for joggling ?
(i) Joggling with two far end bold
(ii) Joggling with two tight clamps*
(iii) Leave without joggling till its testing
(iv) None of the above
Answer - (ii) Joggling with two tight clamps*
97. What is the testing frequency of new AT weld ?
(i) Just after the welding
(ii) After 7 days of welding
(iii) With in the one month of welding*
(iv) None of the above
Answer - (iii) With in the one month of welding
97. After declare good in USFD testing what is the joggling criteria ?
(i) Joggle will be open from the AT weld
(ii) Joggling with two far end bolting
(iii) joggling with four tight bold
(iv) None of the above
Answer - (i) Joggle will be open from the AT weld
98. USFD testing of new AT weld will be done by ?
(i) JE/SSE sectional
(ii) Incharge SSE
(iii) USFD machine operator
(iv) None of the above
Answer - (iii) USFD machine operator
99. Testing of AT weld shall be done from ?
(i) SRT
(ii) DRT
(iii) Digital weld tester
(iv) None of the above
Answer - (iii) Digital weld tester
100. After how much time lining of crucible should be changed ?
(i) After every weld
(ii) After 7 welds
(iii) After every 10 welds
(iv) None of the above
Answer - (iii) After every 10 welds
101. Trimming of AT weld should be done by ?
(i) Chisel
(ii) Trimmer
(iii) Both
(iv) None of the above
Answer - (ii) Trimmer
102. What is the app. Weight of 52 kg portion?
(i) 10 kg
(ii) 11 kg
(iii) 12 kg
(iv) None of the above
Answer - (ii) 11 kg
103. What is the app weight of 60 kg portion ?
(i) 11 kg
(ii) 12 kg
(iii) 13 kg
(iv) None of the above
Answer - (iii) 13 kg
104. What is the dia of thimble ?
(i) 14-16 mm
(ii) 16-18 mm
(iii) 18-20 mm
(iv) None of the above
Answer - (ii) 16-18 mm
105 . Ignition rod can be ignited from ?
(i) Match box
(ii) Ignition match
(iii) From fire
(iv) None of the above
Answer - (ii) Ignition match
106 . In AT welding process what is the role of closing pin ?
(i) To hold the portion before melt
(ii) To hold the asbestos powder & slag
(iii) Both above are correct
(iv) None of the above
Answer - (iii) Both above are correct
107. In AT welding process what is the role of asbestos powder & slag ?
(i) To separate closing pin from portion*
(ii) To hold the portion
(iii) Both above are correct
(iv) None of the above
Answer - (i) To separate closing pin from portion
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