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Open Book API 510 Practice Exam A: Questions 1 To 35 Are OPEN BOOK and Simulate The First Half of The Actual Exam
Open Book API 510 Practice Exam A: Questions 1 To 35 Are OPEN BOOK and Simulate The First Half of The Actual Exam
Questions 1 to 35 are OPEN BOOK and simulate the first half of the actual exam. 1. A vessel is to under go a hydrostatic test after a repair. The vessels stress allowable at the test temperature is 15,000 psi and its stress allowable at its operating temperature is 13,800 psi. The vessels MAWP at its design temperature is 125 psi. What will be the required test pressure at the top of the vessel? 1. 2. 3. 4. 203.8 psi 169.6 psi 176.6 psi 143.7 psi
2. A cylindrical shell contains a welded long joint that is made using a backing strip that remains in place. All of the radiography requirements of UW 12 (a) have been met. For purposes of calculating circumferential stress on the cylinder, what will be the value of the joint E used in the calculation? 1. 2. 3. 4. 1.0 .85 .80 .90
3. A small exchanger has experienced internal corrosion of its tubes. The tubes are required to withstand an external pressure of 350 psi. The tubes have and O. D. of 2.0 inch and are 60 inches in length with a wall thickness of .025 inch. What would be the approximate Factor A value for this combination of length diameter and thickness of tube is? 1. 2. 3. 4. .0056 .00055 .057 .10
4. An additional 4 inch nozzle was added to a pressure vessel and is similar to the one in Fig UW-16.1(i). The minimum thickness of the nozzle is .377 inch and the shell minimum thickness is .750 inch. What is the decimal value of the minimum throat required for each of two equal leg size fillet welds on this attachment? 1. 2. 3. 4. .235 .267 .250 .750
5. A cylindrical shell has a seamless hemispherical head on one end and a seamless ellipsoidal head on the other end. The elliptical head is attached by a type 2 weld meeting the spot radiography requirements of UW-11(a)(5)(b). The shell has a single longitudinal joint. All category A butt welds are type 1 with full radiography applied. The vessel will require an MAWP of 50 psi . The material of the shell and head is SA-515-Gr. 60. The allowable stress at the operating temperature is 15,000 psi. The heads inside diameter is 10'-0". What is the required thickness of the 2 to 1 ellipsoidal head? 1. 2. 3. 4. .250 .235 .200 .1003
7. An engineer is evaluating a pressure vessels head for impact testing requirements based on an MDMT to be marked on the vessel of 40oF. As part of the calculations required it has been determined that this head will have a coincident ratio of 0.60, this will allow a further reduction of the MDMT exemption given by figure UCS-66 of __oF. 1. 2. 3. 4. 30 50 40 35
Answer the following questions about the WPS and PQR (pages 3 to 6) from Captain Bobs Welding. Consider both the WPS and its supporting PQR when answering the questions . 8. (WPS) In the JOINTS (QW-402) section, the following statement is true; 1. 2. 3. 4. There must be a sketch of the joint configuration to be used in production. Any groove design is allowed in production. The box is properly addressed and contains no mistakes. Flux dam retaining is permitted.
9. (WPS) In the BASE METAL (QW-403) there is a mistake because the; 1. 2. 3. 4. Pipe diameter is not addressed. Group number is not addressed and it is a supplemental essential variable. Fillet welds are addressed as ALL. There is no mistake; none of the above is true, 1 &3 are for information only, number 2 is not needed for this procedure because no impact tests are required of the weldment.
10. (WPS) In the TECHNIQUE (QW-410) should have addressed the following; 1. 2. 3. 4. Travel speed. Method of back gouging. Nothing, it is perfect. The length of groove.
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11. Which types of butt-welded joints are allowed to be used to construct vessels in lethal service? 1. 2. 3. 4. A and D only. A, B, C and D are permitted 1 and 2 dependent upon Category. Butt welds are not permitted in lethal service.
12. After rolling a plate into a cylinder designed for internal pressure it is measured for out of roundness; 1. 2. 3. 4. It is acceptable if it is no more than 1% out of roundness. It is acceptable if it is no more than 10% out of roundness. It is acceptable if it is no more than % out of roundness. It is acceptable if it is no more than 2% out of roundness.
13. During the internal inspection of a vertical vessel a minimum thickness reading of 1.270" was found on a shell course. The Data Report reflects an original thickness of 1.50", and allowable stress at 600 degrees of 14,500 psi, full RT, and a MAWP of 650 psi. The MAWP was based on retirement diameter of 49.02 inches after the corrosion allowance was expended; this yields a retirement thickness of 1.129 inches. Inspection records indicate a corrosion rate of 0.025 inches a year. If the corrosion rate does not change what is the maximum time before the next on-stream or internal inspection? 1. 2. 3. 4. 5 years 5.6 years 10 years 2.8 years
14. The inspection of bend tests for a welding procedure revealed an opening in the concave side of the specimen, its greatest dimension was 3/32 of an inch and does not show any sign of a welding flaw. This opening is not cause for rejection because: 1. 2. 3. 4. It is less than 1/8 inch. The opening is not caused by a flaw and it is less than 1/8 inch. The code does not address this issue. The welder had faulty equipment provided at the testing lab.
15. What is the lowest metal temperature permitted to pneumatically test a vessel per Section VIII Div. 1? 1. 2. 3. 4. 30 oF. 30 oF above MDMT. 30 oF below MDMT. There is no such requirement, it is only a recommendation.
17. Regarding corrosion evaluation, for the purposes of determining whether a weld joint efficiency or the surface remote from the weld governs in calculations the following must be true for this to be a consideration; 1. 2. 3. 4. The joints efficiency must be 1.0. The joints efficiency must be less than 1.0. The joints efficiency must be exactly .90. The joint efficiency has no bearing on corrosion evaluations.
18. The following describes the location of corrosion as measured in a vessel shell with the following dimensions and minimums:
.700 inch thickness minimum for shell from original calculations Longitudinal joint E = .85. The thickness of the shell in the welded joint is .701 inch. The thickness 3 inches remote from the welded joint is .698 inch.
Using the rules for corrosion evaluation in API 510, the following conclusion can be made about the evaluation of the vessel for its continued service with out repair; 1. 2. 3. 4. The thickness at the weld governs calculations. The thickness remote from the weld governs calculations. No such rule exits in API 510. Separate calculations will be required to determine which thickness governs.
19. A 2 to 1 ellipsoidal head has experienced uniform corrosion on its inner surface. To determine the governing thickness and evaluate the head for continued service or the need for repair or derating we would; 1. 2. 3. 4. Calculate the required thickness of the knuckle region using the formula given in UG-32 of Section VIII Div. 1. Calculate the thickness required of the spherical portion of the head using the formula from UG 27 of Section VIII Div. 1 for a spherical shell. Calculate the equivalent shell based on the heads inside diameter. Calculate both 1 and 2 above to determine the need for repair or derating.
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21. For calculating the required thickness of a standard torispherical head which has a corroded area in its central portion, the head must be evaluated using a spherical shell calculation. What shall be used as the radius of the dished portion in the calculation? 1. 2. 3. 4. One half the shells inside diameter. 80 % of the shells inside diameter. The shells diameter. The measured central portion of the head taken from its center and based on 80 % of the shells diameter.
22. An ellipsoidal head has experienced corrosion at a radius 31 inches above the center of the head. The head is attached to a shell that is 8 in diameter using a type 2 weld that has been fully radiographed. This corroded area may be considered within the spherical portion because the greatest distance allowed for this calculation from the heads center is; 1. 2. 3. 4. 76.8 inches 38.4 inches 80.0 inches 40.0 inches.
23. A vessel shell has scattered corrosive pits caused by hydrochloric acid. The greatest pit depth found excluding corrosion allowance is 0.333 inch deep in the shell, which has minimum required thickness of 0.521 inch. The sum of pits areas within an 8 inch diameter circle does not exceed 7 sq. inches. This pit must be repaired because the limit of the pit depth in this situation is; 1. 2. 3. 4. .1302 .2605 .3000 .3250
24. While inspecting a vessel you notice that there is corrosion that is general, but varies over an area of the affected shell course, the vessel has an inside diameter of 88 inches. You wish to average this corrosion for purposes of evaluation. Circumferential stress governs in this vessel, in inches what is the greatest length that can be used to average this corrosion? 1. 2. 3. 4. 40 inches 39 inches 29.33 inches 88 inches
26. A hemispherical head formed from solid plate is 48.0 inches in inside diameter this head is attached to a seamless shell and has not had radiography on the Category A Type 1 weld that attaches the head to the shell. The vessel is horizontal and operates at 500 PSI water pressure with an allowable stress on the head's material of 15,000 PSI. The head's thickness required is? 1. 2. 3. 4. .5741 .577 1.1432 .2356
27. A 3 thick plate weld procedure test coupon must be tensile tested. This will require the cutting of the test coupon into smaller pieces. The tensile testing machine is capable of pulling up to 1 thick specimens. How many pieces will be required to for a complete test per Section IX ? 1. 2. 3. 4. 6 8 2 12
28. A round weld tensile specimen is tested and found to fail in the base metal at a load of 14,876 lb. The specimen was measured before the test to have a diameter of .503 inches, the ultimate tensile strength of this specimen is: 1. 2. 3. 4. 74,878 pounds per square inch. 18,829 pounds per square inch. 235,185 pounds per square inch. 74,380 pounds per square inch.
(Hint: The area of a circle is equal to 3.141 (Pi) times its radius squared)
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30. During an internal inspection the following minimum thickness readings were taken on a vertical vessel Top Head Present = .235 Shell Course Present = .225 Bottom Head Present = .195" This vessel has been in service for 6.5 years and all components had an original thickness of .250 inch. The engineer calculated a minimum thickness of the top head to be .145" and the bottom head minimum thickness to be .155" and the shell's minimum thickness to be .205". Based on the readings what is the Corrosion Rate for the shell element? 1. 2. 3. 4. .025 / year .0023 / year .020 / year .00384 /year
31. Pitting has been discovered to be localized in a small area of an ellipsoidal head. The depth of the pits does not exceed half of the required wall thickness. A circle is drawn that takes in all the pits and its diameter is 8 inches. The maximum area of all the pits in square inches to allow averaging is; 1. 2. 3. 4. 8 square inches. 6 square inches. 7 square inches. 5 square inches.
32. A cylindrical shell has been discovered to have uniform external corrosion. The shells original thickness was 7/8 inch; it is presently .745 inch in thickness. The original O.D. of the shell was 30 inches. The vessel operates at 650 0F with a stress allowable on the material of 15,000 psi. 100 % RT was performed on the vessel. All joints are types 1. What is the vessel's present MAWP? 1. 2. 3. 4. 760 psi 772.13 psi 766.88 psi 382.10 psi
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34. A standard ellipsoidal head with a 1 flange is attached to the bottom of a vertical vessel. The heads inside diameter is 56 inches. The vessel has a total elevation of 100 feet. The elevation at this head to shell joint is 5 feet. What amount of hydrostatic head must be considered for use in this heads required thickness calculation? 1. 2. 3. 4. 41.135 psi 41.909 psi 41 psi 41.69 psi
35. A torispherical head which can be calculated using UG-32 of Section VIII Div. 1 has an outside skirt diameter of 84 inches and an inside knuckle radius of 6 % of its O. D. this means that the inside crown radius must be; 1. 2. 3. 4. 42 inches. 5.04 inches. 84 inches. 2.52 inches
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ANSWER
(Example) 1. 3 2. 4 3. 2 4. 3 5. 3 6. 3 7. 3 8. 3 9. 4 10. 2 11. 3 12. 1 13. 4 14. 3 15. 2 16. 3 17. 2 18. 4 19. 4 20. 2 21. 3 22. 2 23. 2 24. 3 25. 4 26. 2 27. 2 28. 1 29. 3 30. 4 31. 3 32. 3 33. 1 34. 4 35. 3
LOCATION OF ANSWER
API 510 4.1.2 UG-99 UW-12 UG-28 UW-16 UG-32 IX ART I QW-152 Fig UCS-66.1 IX ART II QW-253 IX ART II QW-253 IX ART II QW-253 VIII UW-2 (a)(1)(a)&(b) VIII UG-80 (a)(1) API 510 4.3 QW-163 Evaluate on the Convex Side only VIII UG-100 (c) SECTION V ART 6 T-652 API 510 5.7 API 510 5.7 API 510 5.7 API 510 5.7 API 510 5.7 API 510 5.7 API 510 5.7 API 510 5.7 UG-27 and API 510 Body of Knowledge UG-32 IX ART I QW-151.1(c) IX ART I QW-153 UG-99 and API 510 Body of Knowledge API 510 6.4 API 510 5.4 UG-27 UG-116-UG UG 27 UG-116 41.135 + .559 (hydro hd. in head depth)= 41.69 UG 32 (e)
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3.
UG 28
Calculate Do/t and L/Do Do/t = 2.0/.025 = 80 Factor A = .00055 L/Do = 60/2.0 = 3.0
4. t1 + t2
By the rule; t1 or t2 not less than the smaller of in. or .707x t min or .707 x .377 = 0.2665 = 0.267 Answer: 0.250 No individual throat can fall below this value per this rule. The t1 + t2
rule is still satisfied (not less than 0.47125) since 0.250 + 0.250 = 0.500
5. UG-32(d) t =
PD 2 SE 0.2 P
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6.
Specimen 1:
Specimen 2: 1 = 73,377
13.
Next inspection no more than remaining life or 10 years use the lesser.
22. 80% of the shells diameter 0.80 x 96 = 76.8 Radius = 76.8/2 = 38.4 since 31 is with in the 38.4 radius it may consider within the spherical portion. 23. Shells t min = 0.521 Pit depth = 0.333
The rule says that the pit may not exceed the parts t min 0.521/2 = 0.2605 The pit must be repaired.
24. The ID of the shell = 88 1/3 of 88 or 40 which ever is less 88/3 = 29.33 Use 29.33
25.
t =?
From UG-27
t=
PR SE 0.6 P
t=
15
t=
27. Thickness of coupon = 3.5 3.5/4= 0.875 (4 pieces for each tensile specimen) 2 tensile tests are always required therefore; 2 x 4 = 8 pieces
28.
Diameter = 0.503 Radius = 0.503/2 = 0.2515 Area of a circle = x r2 = 3.141 x (0.2515)2 = 3.141 x 0.2515 x 0.2515 = 0.19867 Finally compute the tensile strength = Load/Area = 14,876 / 0.19867 = 74,877.938 Psi
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t=? P = 150 + 3.897 = 153.897 Psi S = 15,500 psi design S= 17,500 psi test E= .85 R = 36 Hydrostatic Head = .3897 Psi Hydro Pressure 1.3 x 17,500/15,500 x 150 = 220.16 Psi at the top gauge Bottom gauge reads 220.16 + 3.897 = 224.057 Psi during test. Thickness required. From UG 27: t =
Answers: t min 0.4234 Pressure at bottom during test is 224.057 Psi 30.
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P=
SEt Ro 0.4t
Wall Loss = 0.875 - 0.745 = 0.130 Outside Diameter = 30.0 Ro = 30.0/2 = 15.0 - 0.130 = 14.87 Corroded outside radius is 14.87 Calculate pressure allowed. t = 0.745 S = 15,000 Psi P =? Ro= 14.87 E= 1.0 33. From: UG 27 P =? S = 13,000 E = .80 t = 0.875 R = 60/2 = 30 34. Depth of head = ID + Flange 56/4 + 1-1/2 = 14 + 1-1/2 = 15-1/2
100' 95'
Hydrostatic Pressure on Head 95 feet + 1.2916 feet = 96.2916 x .433 = 41.69 Psi
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