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API 510 Guia
API 510 Guia
This course is written by itcSkills and Codewest. This document represents a substantial
investment of time and expense. It is provided to attendees of the course as the course
text. It is protected under the copyright laws of the United States of America and Canada
and may not be copied without written permission from Schindler & Associates and
Codewest. Do not copy or distribute this document. COPYRIGHT 2006, itcSkills, AND
CODEWEST. ALL RIGHTS RESERVED.
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TABLE OF CONTENTS
Page
Introduction and What to Expect on the Actual Examination
13
20
23
26
31
34
52
61
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Welcome to the pre-study guide for the June 2006 API 510 Training class. We are very pleased that you
have entrusted your training to us for this important examination, and we take this responsibility very
seriously. Our mission together is quite simple, and one which we will remain focused on until the day of
your examination. Simply put, this mission is:
Course Outline
Schedule and location information
API 510 Body of Knowledge
ASME/API Quiz
ASME questions and 10 practice math questions that can be studied to prepare for the
up-coming test
Answer sheets for the Quizzes/Math Problems
Actual past examination questions
Remember! This is your examination and your training course. You will only get out of it what you are
willing to put into it. Therefore, if you do not complete this material, you will only be lowering your
chances of successfully completing our mission.
You must complete this Preparatory to increase your probability of passing the test! Please set
aside time every day until class starts to study the material in this book.
Please come to class as prepared as possible. it is very important to attend every class, complete all
homework assignments, and pay very strict attention to the classroom presentation. Again, your
participation is the key ingredient to passing the test.
Once again, we appreciate the opportunity to provide this training and we are willing to go the extra mile
to ensure your success in the examination.
Review the documents upon which the examination is based and become familiar with their layout. Be
honest and identify your strong a weak areas so you can develop a study plan. Use the pre-study Guide
as a tool to prepare for the course and then come prepared with questions.
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The testing time for each part of the exam is 4 hours. Additional time has been allowed for
instructions. There is a one-hour lunch break scheduled after Part 1 of the exam, but if you complete
Part 1 before time is called, you may leave the testing room. However, you may not re-enter the
room until Part 2 of the exam is about to begin.
Candidates should bring some sharpened #2 pencils with erasers, a non-programmable calculator,
and a set of API and ASME reference materials. Highlighting, underlining, page tabs, or written notes
in the margins of the code books are acceptable. Note: API and ASME publications are
copyrighted material. Photocopies of these reference documents are not permitted in the
examination room.
No loose notes, papers, or other books of any sort may be brought into the examination room.
No test materials, documents, notes or memoranda of any sort are to be taken from the examination
room.
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No questions concerning the content of the examination may be asked during the testing period.
Candidates should listen carefully to instructions given by the proctor.
Candidates have the opportunity to comment on any question believed to be misleading or inaccurate
at the end of the examination. A form for this purpose will be provided to candidates upon request.
Be specific when commenting on a question as each comment will be individually reviewed by the
Examination Committee. Individual responses to question comments will not be provided.
Proctors are authorized to maintain secure and proper test administration procedures, including
relocation of candidates. Candidates may not communicate with each other during the examination.
Answer the questions in order, but dont waste time on questions containing unfamiliar or difficult
material. You can come back to them later, time permitting.
Make educated guesses at correct answers rather than leaving the answer spaces blank. The score
on the test will be based on only the number of correct responses, with no penalty for wrong answers.
Record your answers carefully on the separate answer sheet. The numbering of the questions in the
test booklet should match the numbering of the responses on the answer sheet.
Should you change your mind on any answer, erase previously marked responses thoroughly.
Multiple responses to a question will be scored as incorrect. Avoid making any stray marks on the
answer sheet.
A criterion referenced passing score has been established by a panel of content experts using
appropriate standard setting procedures. The passing score for each administration of the API 510 and
570 inspector certification examinations are based on a statistical equating process which adjusts for
fluctuation in difficulty levels across different examinations. Equating ensures that candidates are
evaluated according to the same competency standard from year to year.
After each examination administration, individual test questions subject to comments from candidates are
evaluated for their clarity and accuracy by the API Exam Construction Task Group prior to the grading
process. Questions determined to be ambiguous may be scored with multiple correct answers at no
penalty to the candidates.
Exams are scored using an automated system. Any grievance or requests for manual scoring must be
submitted in writing to API within 90 days after receipt of your score. Requests for manual scoring must
include a viable reason why your exam should be re-graded. There is a $50 fee for manual scoring of
exams. Requests should be submitted to:
American Petroleum Institute
Industry Services Dept.
Inspector Certification Programs
1220 L Street, NM
Washington, D.C. 20005-4070
202-962-4739 (Fax)
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Thickness Calculations: Round to the third decimal place, and dont round-up/down.
Example #1 - .0075 - is .007 - (same as on test)
Example #2 - .0993 - is .099 - (may be shown as 0.100 on test)
Example #3 - .9998 - is .999 - (may be shown as 1.00 on test)
2.
3.
Square Root - Do not round any number under a square root. Simply hit the square root button
(
) on the calculator and utilize that full number.
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Required CODES & Standards for API 510 ICP Exam June 2006
You require the following Code Books for the course and examination. Make sure you have the
correct editions and bring them with you.
ASME 2001 Edition With 2002 & 2003 Addenda
Section II, Materials, Part D, External Pressure Graphs We will give you these during the course
Section V, Nondestructive Examination
Article 1, General Requirements
Article 2, Radiographic Examination
Article 6, Liquid Penetrant Examination
Article 7, Magnetic Particle Examination
Article 23 SE-797 Only
Section VIII, Rules for Construction of Pressure Vessels, Division I
UG, General Requirements for All Methods of Construction and All Materials
UW, Requirements for Pressure Vessels Fabricated by Welding
UCS, Requirements for Pressure Vessels Constructed of Carbon and Low Alloy Steels
UHT, Requirements for Pressure Vessels Constructed of Ferritic Steels With Tensile Properties
Enhanced by Heat Treatment
Appendix 1, Supplementary Design Formulas
Appendix 2, Rules for Bolted Flange Connections with Ring Type Gaskets
Appendix 3, Definitions
Appendix 4, Rounded Indications Charts Acceptance Standard for Radiographically Determined
Rounded Indications in Welds
Appendix 6, Methods for Magnetic Particle Examination (MT)
Appendix 8, Methods for Liquid Penetrant Examination (PT)
Appendix 12, Ultrasonic Examination of Welds (UT)
Section IX, Welding and Brazing Qualifications, Part QW.
API 510 Eighth Edition June 1997 Plus Addendum 1, 2, 3 and 4
API 572 Second Edition February 2001
API 576 Second Edition December 2000
API 577 First Edition October 2004
API 577 First Edition December 2003 Only the Following Damage Mechanisms
4.2.3 Temper Embrittlement
4.2.7 Brittle Fracture
4.2.9 Thermal Fatigue
4.2.14 Erosion/Erosion-Corrosion
4.2.16 Mechanical Failure
4.3.2 Atmospheric Corrosion
4.3.3 Corrosion Under Insulation (CUI)
4.3.4 Cooling Water Corrosion
4.3.5 Boiler Water Condensate Corrosion
5
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4.4.2 Sulfidation
4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC)
4.5.2 Corrosion Fatigue
4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement)
5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
5.1.3.1 High Temperature Hydrogen Attack (HTHA)
Note: If printing from CD-Roms or company Intranets check that the graphics and tables
print completely, we have had candidates experience problems with these.
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PRACTICE QUESTIONS
TO PREPARE FOR CLASS
This section contains the following:
Answer Sheets for the above Math Problems and Code References for the Answers to the Practice
Questions.
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During the course the five API documents will be reviewed. The following practice questions cover some
of these documents . You must be able to answer all the practice questions without reference to any of
the documents to be considered to have an adequate knowledge of their content.
API 510 PRACTICE QUESTIONS
1.
boilers
pressure vessels
power piping
all the above
2.
Name three types of pressure vessels and containers that are excluded from the requirements of
API 510.
3.
How is the MAWP determined for the continued use of a pressure vessel?
4.
5.
6.
7.
8.
Above ground vessels shall be given a visual external inspection at what interval?
9.
10.
11.
12.
Name four kinds of records that the owner/user must maintain for each pressure vessel?
13.
14.
Define rerating.
15.
How many years experience must a high school graduate have to qualify as an Owner-User
Inspector under API 510?
16.
17.
When new vessels are placed into service or the service conditions are changed what are the
three methods for determining the probable rate of corrosion?
18.
What other examination methods may be used to supplement the visual examinations?
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19.
Do you always have to remove insulation at the time of each external inspection?
20.
21.
22.
23.
24.
Name and describe four items that must be considered when the minimum actual thickness and
maximum corrosion rate are adjusted?
25.
For a corroded area of considerable size in which circumferential stress governs the least
thickness along a critical element may be averaged over a length not exceeding?
26.
Can large vessels with two or more zones of differing corrosion rates have each zone treated
independently regarding inspection intervals?
27.
List 15 features that must be covered in the owner-user quality assurance manual for pressure
vessel inspection systems.
28.
What is the efficiency factor to be used when determining the MAWP for a corroded area in the
solid material area of a vessel (away from a weld by greater than 1 or twice the material
thickness)?
29.
30.
31.
When an internal inspection is to be performed name at least five safety precautions that should
be taken before entering the vessel.
32.
For buried vessels what is the basis for establishing the external inspection frequency?
33.
34.
What three things must be done when the service conditions of a vessel are changed?
35.
Repairs and alterations to pressure vessels are covered by API 510 provided what method is
employed?
36.
When both ownership and location of a vessel are changed what must be done?
37.
38.
39.
What are the minimum and maximum pressure test temperatures recommended by API 510?
40.
When a pneumatic pressure test is to be performed, what are the additional examinations
required by the ASME Code prior to the test being performed?
41.
When the pressure test pressure will exceed the settings of any safety relief valves or
appurtenances what must be done?
42.
Repair organizations that repair pressure relief valves are required to have what kind of a written
program?
9
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43.
Name at least 9 topics that are part of a pressure relief valve repair organizations quality control
manual?
44.
In addition to the 16 topics covered in the pressure relief valve repair organizations quality
program, what additional requirement must be met?
45.
What is the efficiency factor to be used when determining the MAWP for a corroded area in a
weld?
46.
What authorizations and approvals are required prior to the commencement of repairs or
alterations?
47.
What ASME Code section are welding procedures and welders qualified in accordance with?
48.
What is the welding technique that is used as an alternative to PWHT for P-1 and P-3 materials?
49.
50.
Is it permissible to substitute local PWHT for 360 degree banding on local repairs?
51.
When local PWHT is substituted what are the four conditions that must be adhered to?
52.
53.
When fillet welded patches are used for repairs what design considerations must be made?
54.
What are the requirements that must be met when a pressure vessel is rerated?
55.
Sketch the basic nameplate or stamping that is used for a rerated vessel.
56.
What alternative method may be used to determine acceptability vessel walls when corrosion has
reduced the thickness below the minimum required wall thickness?
57.
If a corroded area is found in the center portion of an ellipsoidal or torispherical head, what
formula would be used to calculate the minimum required thickness?
58.
59.
Who must review and endorse the repair procedures used on stainless steel weld overlay and
cladding?
60.
For the controlled-deposition welding technique using SMAW, the weld area shall be maintained
at what temperature and for what minimum time after completion of the repair? (assuming 7018
H4 electrodes are not used)
61.
The repair area on stainless steel weld overlay and clad vessels constructed of P-3, P-4 or P-5
base materials should have the base materials examined for what type defects and by which
NDE method?
62.
When a pressure test is not performed following a repair or alteration what is required as a
substitute?
63.
When is the controlled deposition welding method used (i.e., what additional testing is required?)
10
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64.
What is the minimum number of thickness measurements that must be taken on each vessel to
satisfy the internal or on-stream requirements?
65.
66.
67.
When there is a conflict between requirements specified in the ASME Code and API 510, which
document governs?
68.
69.
70.
71.
The RBI assessments must be reviewed and approved by whom, when used to increase or
decrease inspection intervals?
72.
73.
74.
75.
76.
77.
78.
11
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What is the most common material used in the construction of pressure vessels?
2.
Inspection of external parts while the unit is in service should be made when?
3.
4.
5.
6.
What are three materials that provide corrosion resistant surfaces in pressure vessels?
7.
List the safety precautions that must be taken prior to entering a pressure vessel?
8.
Prior to 1956 what pressure vessel construction code was used by refineries?
9.
10.
11.
List at least three problems that can occur from using faulty materials?
12.
13.
The frequency with which a pressure vessel should be inspected depends on what factors?
14.
15.
16.
What should the Inspector do before starting the inspection of a pressure vessel, particularly one
in severe service?
17.
18.
19.
What is hydriding?
20.
21.
22.
23.
24.
25.
When inspecting a pressure vessel externally what should the inspection start with?
12
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26.
Briefly describe the items to be checked when externally inspecting the following equipment:
a.
b.
c.
27.
28.
29.
What must every pressure vessel manufacturer prepare in order to obtain the ASME Code
Certificate of Authorization?
30.
In addition to checking for corrosion on an external inspection name three other items to check
for?
31.
What two methods of inspection are used when all the tubes in a bundle are to be checked
internally for through-wall defects or thinning?
32.
33.
34.
Briefly describe how you would make a detailed internal inspection of a pressure vessel?
35.
What are the three most important factors to consider when checking metallic linings?
36.
37.
On what two factors does the degree of internal surface preparation depend?
38.
39.
40.
41.
42.
43.
44.
What test method would be used for testing a vacuum vessel for leaks?
45.
What metallurgical changes would you be inspecting for and what tests would be used to
determine each change?
46.
47.
Name three conditions that will result in excess thickness of a pressure vessel shell?
48.
49.
What code would you use to determine the minimum thickness required for pressure vessel
accessories such as trays and supports?
50.
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51.
What are the three types of records that should be kept in the record file?
52.
53.
54.
When an exchanger is removed from service what test is recommended prior to dismantling?
55.
56.
57.
58.
59.
60.
61.
Some jurisdictions require the repair firm to possess what authorization to perform the repair?
62.
63.
What would be checked during the visual inspection of an extended plate exchanger?
64.
What must be done to the finned tubes of an air-cooled exchanger before starting an inspection?
65.
66.
67.
68.
69.
What two NDE methods are now primarily used to measure thickness?
70.
71.
14
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safety valve
relief valve
safety relief valve
pilot operated safety relief valve
balanced safety relief valve
rupture disk
2.
3.
4.
5.
What is a primary consideration used to establish the inspection frequency of relieving devices?
6.
There are three basis for establishing the frequency of shop inspections/overhauls. What is each
and briefly describe?
7.
What inspections and testing should be done on new relieving device installations?
8.
9.
10.
What should be done after extended shutdowns with relieving devices left on a unit?
11.
12.
13.
14.
15.
16.
What medium is normally used to test relieving devices in the shop test block?
17.
Briefly describe the shop test block used for testing with air? Make a sketch.
18.
What should be done immediately after the removal of HF relief devices that will be sent to the
shop?
19.
List the nine points that should be visually checked during the dismantle of a relieving device?
20.
Prior to the start of dismantling what test should be performed and why?
21.
During the relieving device test after reassembly what two items are to be checked?
22.
15
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23.
24.
25.
26.
What should be done with connecting piping and block valves before disconnecting relief valves?
27.
What should be done before relief lines are opened to the atmosphere?
28.
What are two types of hydrocarbon that can cause plugging or sticking?
29.
List two limitations for each of the following pressure relief devices:
a.
b.
c.
d.
e.
f.
30.
safety valve
relief valve
safety relief valve
pilot operated safety relief valve
balanced safety relief valve
rupture disk
Rupture disks should not be re-used after dismantling of the rupture disk device, even if they are
sound and have not ruptured, why?
16
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Article 6
Article 7
Magnetic Particle Examination, concentrate on the prod and yoke methods only.
In the day to day inspection activities nondestructive examinations are used and the API Inspector must
have both an understanding of the practical applications as well as the specific requirements.
It is not necessary for the API Inspector to have the in-depth knowledge of the SNT-TC-IA Level II
Examiner for the nondestructive methods but should know where in the ASME Code to find the
requirements.
ASME SECTION V AND NDE PRACTICE QUESTIONS
1.
2.
3.
4.
5.
6.
Deleted.
7.
8.
What are the IQI thickness and hole sizes for a number 30 IQI?
What are the two radiographic exposure techniques permitted by the Code?
9.
10.
Deleted
11.
Deleted
12.
13.
For single wall viewing source side markers shall be used on what components?
14.
source side
film side
15.
Where is the lead letter "F" placed when film side IQIs are used?
16.
A circumferential seam is to radiographed as a single exposure, what are the minimum number of
IQIs to be used?
17
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17.
18.
When viewing single film radiographs made with an X-ray source what is the minimum and
maximum permitted density?
19.
It is required to radiograph a steel plate with a weld. The plate thickness is 7/16 inch and the weld
reinforcement is 1/16 inch. What source side IQI is required and what is the essential hole
20.
21.
For which NDE methods are there alternative personnel qualification requirements in Section
VIII?
22.
What is the permitted density variation anywhere through the area of interest?
23.
What minimum RT detail information must be provided to the Inspector along with the
radiographic film?
24.
25.
Deleted.
26.
Deleted.
27.
Deleted
28.
Deleted
29.
Deleted
30.
Deleted
31.
32.
When using penetrant materials on nickel base alloys, austenitic stainless steels and titanium
what certifications must be obtained?
33.
Deleted
34.
Deleted?
35.
36.
slightly subsurface
open to the surface
both a and b
37.
What are the essential variables that when changed in a PT procedure may require a new
procedure to be prepared?
38.
List the two types of penetrants and the three basic penetrant processes?
39.
Deleted
18
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40.
41.
The acceptance tolerance for the MT units ammeter shall be that the reading shall not deviate by
more than _______% of full scale relative to the actual current value as shown by the test meter?
42.
43.
What is considered to be the standard temperature range for liquid penetrant examination?
44.
What is the retention time for radiographic film and reports for radiography performed on
pressure vessels?
45.
To remove excess penetrant after the penetration time has elapsed for the solvent removable
penetrant is it permissible to flush the test piece gently with solvent then wipe it dry?
46.
47.
Final interpretation shall be made not less than ___________minutes after the developer is dry?
48.
49.
What are the acceptance standards for liquid penetrant examinations of welds in pressure
vessels?
50.
The written procedure for the magnetic particle examination shall contain what minimum
information?
51.
52.
Each piece of magnetizing equipment with an ammeter shall be calibrated at what frequency?
53.
What is the acceptance criteria for the lifting power of yokes when they are checked annually?
54.
What are the acceptance standards for magnetic particle examinations of welds in pressure
vessels?
55.
Any imperfection that causes an indication in excess of ______% DAC shall be investigated?
56.
19
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When solving math problems whether for the examination or for actual work situations a few simple rules
are necessary.
1.
2.
3.
4.
5.
6.
7.
The examination math problems are normally based on the concept that the vessel or vessel part has
been in service. This means that there are no original design questions to consider.
Under these circumstances there are certain basic points that must be understood when solving the math
problems. These are:
1.
Efficiencies are determined by the extent of radiography, type of joint and the application of Table
UW-12, UW-11(a)(5)(b) and UW-12(d) as applicable.
2.
When determining allowable pressure or thickness in corroded conditions for cylindrical shells or
pipe the inside radius is taken at the bottom of the corroded area exclusive of corrosion
allowance.
3.
When solving a problem to determine tmin for use in a remaining life problem the inside radius to
use is the original radius increased by the amount of corrosion allowance specified in the
problem.
4.
Radii may have to be adjusted depending on the existence of corrosion allowances. Unless
specifically stated otherwise in the problem corrosion allowance is assumed to be "0".
5.
Static head is to be considered only when the problem gives relevant height or other data,
otherwise it is assumed to be "0".
The following are some typical math problems which cover each of the formulas that you will study.
20
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QUESTION: 1
During the inspection of a horizontal pressure vessel a corroded area was found on the inside surface,
the thickness at the point was measured to be .906 inches thick. Checking the ASME Data Report for the
vessel it was found that the shell plate was 1-1/4 inch purchased thickness, 48 inch inside diameter, of
SA-516 Gr. 70 material, the shell was rolled and welded using a type 1 longitudinal seam with full
radiographic examination. No corrosion allowance was specified. The MAWP is 600 psig at 300 F. All
openings in the vessel are fully reinforced, welded connections. S is 17500.
As the Inspector what position would you take with regard to this area of thinned shell? (Show your
calculations upon which you based your decision.)
QUESTION: 2
A vessel has fixed tube sheets with 40, 4 inch outside diameter by 0.120 inch minimum wall thickness
tubes of SA-192 material installed between tubesheets. The total unsupported length is 72 inches. The
vessel is stamped 500 psig at 400 F.
on the shell side. Do these tubes comply with Code requirements?
QUESTION: 3
A seamless 2:1 elliptical head on a horizontal pressure vessel is found by inspection to have a minimum
thickness of 7/8 inch. The nameplate shows a MAWP of 500 psi at 600 degrees. The vessel has not been
radiographed and the Data Report shows that UW-11(a)(5)(b) has not been applied. The inside length of
the major axis is 42 inches. The material is SA-516 Grade 60, S = 15,000. Must the MAWP be reduced?
QUESTION: 4
A seamless flat circular head, attached to a cylinder as shown in Fig. UG-34(b-1), has been subjected to
corrosion near the center of the head which has reduced the thickness below acceptable limits. The
reduced area is to be restored by weld buildup. The head is made of SA-105 material, S = 17500 with an
inside diameter d of 36 inches. The hydrostatic head acting on the flat head is 10 psig. From the
nameplate, the MAWP is 550 psi at 475 F and RT-3 is the extent of radiography. What is the minimum
required thickness of the head after the weld buildup has been completed?
QUESTION: 5
A vessel is to be altered to add a new nozzle to a cylindrical shell. The Engineer has provided the
following information:
P= 605 psig design pressure
t= 3.0 in. vessel thickness
E1= 1 for vessel and nozzle
tn= 1.5 in. nozzle thickness
d= 12 in. nozzle inside diameter
h= 0 in. internal nozzle projection
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QUESTION: 6
A hydrostatic test is to be performed on a pressure vessel using the same methodology as required by
Section VIII, Div. 1 Code where the MAWP is 725 psig at 700 F. The vessel is a single chamber vessel
constructed of SA-516 Gr. 70 or equal materials. Sd= 16600, St = 17500. Describe the hydrostatic test
along with the required test pressure. (Show your calculations.)
QUESTION: 7
Calculate the pneumatic test pressure and describe the pressure test for a vessel of SA-515 Gr 60, S =
15000, with a temperature of 450 F and an MAWP of 800 psig. The MDMT is 100 F.
QUESTION: 8
A welded nozzle is installed into a vessel shell using two fillet welds as shown in Figure UW-16.1(i). The
nozzle thickness tn = 0.75 in., the shell thickness t = 1.5 in., t1= 0.5 in., and t2 = 0.375 inch. Does the as
measured weld throat dimension meet Code requirements?
QUESTION: 9
A pressure vessel shell with the following characteristics is to have a plate replaced using SA-515-70
material.
Minimum thickness
Inside radius
E
MAWP
PWHT
MDMT
S
Ratio of design stress
to allowable tensile stress
1.125"
30"
1.00
641 psig @ 300 F.
Applied to original vessel but not mandatory
-20 F.
17500
1.00
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The following general knowledge areas of Section VIII, Division 1 must be studied as a basis for
answering the quiz questions. These areas are:
1.
2.
3.
4.
5.
6.
7.
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The ASME Code used for the construction of pressure vessels is:
a.
b.
c.
Section I
Section IV
Section VIII, Division 1
2.
When designing pressure vessels containing cast material what corrections are required to be
made to the allowable stress values?
3.
ASTM standards
API-ASME specifications
ASME Section II, with specified limitations
4.
Can material that is not identified with one of the permitted specifications in Section VIII be
accepted as meeting the requirements of a permitted specification?
5.
6.
7.
When calculating the required thickness or internal design pressure of a cylindrical shell the
formula most commonly used considers:
a.
b.
c.
circumferential stress
longitudinal stress
both a and b
8.
9.
A torispherical head on a vessel must be replaced, what formula would apply if the knuckle radius
is 6% of the inside crown radius?
10.
What are the two methods of calculating the MAWP for a convex head with the pressure on the
convex side?
11.
An circular unstayed flat head is to be replaced on a pressure vessel. The head is similar to that
shown in Figure UG-34(h). What formula would you use and what "C" factor would apply?
12.
What product forms are required to have a material test report or certificate of compliance?
13.
Welding materials must be provided with a Certified Test Report or a Certificate of Compliance?
True or False
14.
15.
Are openings in pressure vessels limited to only those of circular shape? If not, If no, what are the
permitted shapes?
16.
What classes of vessels are not considered to be within the scope of Section VIII Division 1?
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17.
Certain openings that are not subject to rapid fluctuation do not require reinforcement other than
that inherent in the construction. What are the size limitations for these openings?
18.
When calculating the required thickness of vessel and nozzle walls to determine the required
reinforcement what "E" factor is used?
19.
20.
What are the limits of reinforcement measured parallel to and normal to the vessel wall?
21.
Can credit be taken for reinforcement material having an allowable stress value higher than that
of the vessel wall?
22.
UG-41(b) requires that strength calculations be made for certain welded nozzle configurations.
Which configurations are exempt from these strength calculations?
23.
Nozzle necks other than those for access openings and openings for inspection require special
attention regarding their required thickness. Where are these requirements found and briefly
explain their application?
24.
A replacement torispherical head of P-No. 1, Group No. 1 material is required for a low alloy steel
vessel. The head thickness before forming is 1 inch and the knuckle radius is 3 inches. The head
is to be formed at 8000F. Does this head require heat treating after forming?
25.
When nozzles are welded into a pressure vessel what must be done to the exposed inside
edges?
26.
What are the requirements for identification of material at the completion of a newly constructed
pressure vessel?
27.
What is the maximum out of roundness permitted for any shell cross section?
28.
Under what conditions may the out of roundness tolerance exceed the 1% value?
29.
What are the shape tolerances that apply to torispherical and ellipsoidal heads?
30.
31.
The material specifications specify either a material test report or a certificate of compliance.
What is the difference between the two?
32.
When a pressure part is to be welded to a flat plate thicker than 1/2 inch to form a corner joint
some additional examinations must be made. Where are these requirements found?
33.
Define Maximum Allowable Working Pressure for a completed vessel and a part of a vessel?
34.
All pressure vessels for external pressure service must have stiffener rings installed?
True or False
35.
When determining the minimum required hydrostatic test pressure what correction factor must be
taken into account?
36.
Non pressure parts that are welded to a vessel shall meet what criteria?
37.
What is the minimum and maximum range permitted for dial indicating test gages?
38.
When openings are to pass through welded joints what additional provisions apply?
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39.
Is there any upper limit on the hydrostatic test pressure that is applied to a vessel?
40.
41.
What are the markings that can be applied to the stamping for vessels that have been
radiographed?
42.
A carbon steel vessel has a required thickness of 3/16 inch. The shell is seamless and the vessel
is stamped RT3. Must additional corrosion allowance be provided?
43.
You are reviewing the stamping on a vessel and note that the extent of radiography is RT 3. The
vessel was constructed in the year 1994. What "E" factor would you use when calculating the
shell and head thicknesses if type 1 joints were used?
44.
What special service conditions are applicable in Section VIII and where are they found?
45.
46.
What is the mandatory minimum test temperature that shall be used during a hydrostatic or a
pneumatic pressure test?
47.
Category defines:
a.
b.
location of joint
type of joint
48.
You are welding a seamless torispherical head to a seamless shell. To be able to allow the full
allowable stress value on the head what must be done to the weld joint?
49.
Do butt welds in nozzles and communicating chambers that neither exceed NPS 10 nor 1-1/8
inch wall thickness in a lethal vessel require any radiographic examination?
50.
51.
A nozzle neck is to be replaced. What are the requirements for determining the correct weld sizes
for partial penetration welds?
52.
You are reviewing the stamping on a pressure vessel and find two nameplates, one of which is
for a part. What would you expect to find when you are reviewing the Manufacturer's Data Report
for the vessel?
53.
What is the permitted alignment tolerance when joining a torispherical head to a seamless shell
with both having a section thickness of 9/16 inch?
54.
A finished Category B joint with a nominal thickness of 1-1/16 inch has a maximum reinforcement
of 9/32 inch. Does this meet Code requirements?
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55.
You are replacing the head on a vessel constructed in 1994. The Data Report shows the material
to be SA-516 Grade 60 not normalized. The nominal thickness is 1-1/2 inch. What would be the
MDMT for this material considering the required thickness times E* equals the nominal thickness
minus corrosion allowance?
56.
You are replacing the bolting on a vessel with SA-193 Grade B5 bolts. The MDMT is - 210F. Is
impact testing required?
57.
You must replace the reinforcing plate around a nozzle. What is the requirement regarding the
size of the telltale hole?
58.
59.
What alternatives to SNT-TC-1A are allowed for personnel qualifications for radiographers or UT
operators?
60.
What are the minimum sizes permitted for elliptical or obround manways or circular manways?
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Are all of the essential, supplemental essential variables when applicable and nonessential
variables as required by the process addressed on the Welding Procedure Specification and are
there any errors or incompatibilities?
Are all the essential and supplemental essential variables when applicable as required by the
process recorded on the Procedure Qualification Record and are there any other errors or
incompatibilities?
Are all the required essential variables addressed for the qualification of the welder and are
actual values and qualified ranges recorded and are they correct or do incompatibilities exist?
Part QW
a)
b)
c)
d)
You will be given several sample WPSs and PQRs to review during the course. The following
comprehensive quiz on ASME Section IX will help you prepare for that portion of the presentation.
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If a performance qualification is made on a groove weld in a pipe over 24" in the 3G test position
for what position(s) is the welder qualified?
2.
3.
4.
If a tension test specimen breaks in the base metal outside of the weld or fusion zone what are
the acceptance criteria?
5.
When corrosion resistant weld overlay cladding is not a factor would a 1/16" open defect be
acceptable for a guided bend specimen?
6.
7.
Pipe diameter is not an essential variable for a welder under the GMAW process?
8.
9.
Does procedure qualification on a 1-1/2" thick base metal qualify the procedure to be used to
repair groove welds and to make weld buildups on base metal thicknesses no exceeding 8"?
10.
11.
Groove design and retainers are essential variables for the SMAW process?
12.
Anyone can supervise the welders making procedure and performance test coupons?
13.
Performance test coupons are required to be visually examined to confirm complete joint
penetration and fusion?
14.
The base metals and filler metals used during qualification do not have to be one or more of
those listed in the WPS?
Can an existing PQR be used to support a newly written WPS?
15.
16.
Can organizations with two or more companies having different names exchange WPS's and
PQR's?
17.
The WPS specifies a single V groove design. Can the PQR use a double V groove to qualify the
WPS?
18.
For what processes and P-No.'s may welders be alternatively qualified by radiographic
examination?
19.
When and immediate retest is made following failure of the visual examination how many test
coupons are required for each position which failed?
20.
If a welder/welding operator has left the employ of an organization and has not welded for a
period of five years what are the qualification renewal requirements?
21.
If QW-404.15 is shown as a variable can a welder who has welded F-No. 4 filler metal without
backing also weld F-No's 3, 2 and 1 without backing?
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22.
Multiple reduced section specimens can be used for tension tests on thicknesses not exceeding
1 inch?
23.
If QW-406.1 is shown as a variable and the preheat temperature qualified was 3500F, would a
preheat of 4520F require requalification?
24.
25.
What is the minimum specified tensile strength of the following base metals:
a)
b)
SA-53 Type F
SA336 Type F3V
26.
If a welder uses a P-No. 1 material for a qualification test coupon what base metals is he qualified
to weld?
27.
Can a welder who has passed the required tests for groove welds make fillet in all thicknesses
and pipe diameters of any size?
28.
29.
What are the procedure qualification bend test requirements for a 3/8" test coupon?
30.
31.
32.
If a 2-7/16" OD test coupon is welded by a welder what is the minimum and maximum outside
diameters qualified?
33.
34.
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API RP 577
This document is supplemental to ASME Section IX and there is a lot of duplication. Areas to concentrate
on are those bits not covered in ASME Section IX.
API RP 571
Make sure you review the damage mechanisms listed at the beginning of this pre study guide for your
examination and only study those mechanisms. Concentrate on key data about how, where and when the
damage occurs. Critical temperatures, pH etc are common key questions.
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ANSWER KEYS
The references listed below for the written questions are where the answers to the quizzes can be found.
API 510
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
1.1
Appendix A
5.4
5.5
3.1 and 3.15
3.1
6.1
6.3
5.5
6.6
3.11
6.7
3.15
3.16
App. B
5.2
5.3
5.5
6.3
5.5
6.4
5.6
5.7
5.7
5.7
6.4
4.3
5.7
6.6
6.4
5.1
6.3
5.6
6.4
7.1
6.4
6.5
7.2.7
6.5
6.5
6.5
6.6
6.6
6.6
5.7
7.1
7.2
7.2.3.1
6.5
7.2.5
7.2.5
6.4
32
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53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
7.2.7
7.3
7.3
5.7
5.7
6.4
7.2.6
7.2.3.2
7.2.6
7.2.10
7.2.3.2
6.4
5.7
7.1
3.2
3.2
7.2
6.2
6.2
6.2
6.6
3.20
5.8
3.21
5.8
6.4
RP572
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
4.3
9.2
9.3
10.4.5
Figure A-11
4.3
10.2.1
Section 5
8.2
8.5
8.5
10.3.7
9.1
9.1
9.2
10.1
10.1
10.1
8.3.7
10.5
4.3
7.1
8.2
10.2.2
10.3.2
10.3.3, 10.3.6, 10.3.8
33
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27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
10.5
Figure 4
Section 5
10.3.13
A.9.1
10.3.13
10.8.1
10.4
10.4.5
10.4.6
10.4.2
10.4.3
10.5
10.8.1
10.4.6
12.2
10.8.2
10.8.2
10.7
10.9
10.9
Section 11
10.9
Section 11
12.1
12.2
12.2
10.8.3
12.1
12.1
Figure A-11
A.9.1
A.9.1
Section 11
Section 11
A.9.2
A.11
A.12
A.12
3.7
4.2
8.5.3
10.5
10.4.4
10.5
RP576
1.
2.
3.
4.
5.
6.
7.
8.
9.
4.2 4.9
6.3
4.9.2
6.1
6.4
6.4.1.1 6.4.1.3
6.5.2
6.4.2
6.5.1
34
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10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
6.5.4
6.2.14 6.2.21
7.1
6.2.1
7.2
4.2.1
B.2
Figure B-1
6.2.5
6.2.9
6.2.8
6.2.14 6.2.15
7.2
7.2
5.1 5.10
4.3
6.2.4
6.2.4
5.5
4.2 4.9
6.2.21
Section V
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
T-150
T-140
T-223
T-224
T-225
Deleted
Table T-233.1
T-271
T-276 or T-233
Deleted
Deleted
T-285 & Section VIII, UW-51(a)(3)
T-275.1
T-277.1
T-277.1(b)
T-277.2(b)(1)
T-277.3
T-282.1
T-276.2(a) & Table T-276
T-232
Section VIII, Appendices 6 & 8
T-282.2
T-291, T-292 & Section VIII UW-51(a)(1)
T-621.1
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
T-641
Deleted
Deleted
35
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35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
T-277.1
b,
T-600
T-621.2
T-651
Deleted
T-631
T-761(c)
T-642, T-643, T-670
T-652
Section VIII UW-51(a)(1)
T-673.3
c, T-720
T-676.1
T-272
Section VIII Appendix 8-4
T-750
T-752
T-761(a)
T-762(b) & (c)
Section VIII Appendix 6-4
T-580
T-778.1
R = 24"
ASSUMPTIONS:
No static head applies
Circumferential stress governs
Thinned area in solid plate not weld
No corrosion allowance
P does not exceed .385SE
t is less than 1/2R
FORMULA:
UG-27(c)(1)
Original thickness =
Corroded thickness =
Amount of corrosion =
P=
1.250"
0.906"
0.344"
SEt
R + .6t
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UG-28(c)(1)
A = 0.001
B = 9800
Pa =
4B
3(Do/t)
Pa = 4 x 9800
3 x 33.33
Pa = 392.039 psi
CONCLUSION:
Tubes do not comply with Code for external pressure.
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QUESTION: 3
GIVEN:
P = 500
t = .875"
S = 15,000
D = 42
E = 0.85
ASSUMPTIONS:
The minimum thickness is occurring in the knuckle region.
FORMULA:
P = 2SEt
D + 0.2t
P = 2 x 15,000 x 0.85 x 0.875
42 + 0.2 x 0.875
P = 529.046 psi
CONCLUSION:
Head can continue to operate at present MAWP.
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QUESTION: 4
GIVEN:
S = 17,500
d = 36"
P = 550
E = 0.85
Hydrostatic head = 10 psi
C = 0.17
ASSUMPTIONS:
Head is seamless.
FORMULA:
t=d
UG-34(c)(2)
CP
t = 36
SE
t = 2.88"
CONCLUSION:
The minimum required thickness at the weld buildup is 2.88".
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QUESTION: 5
GIVEN:
S & Sn = 15,000 psi
Outward weld leg = 1"
E = 1.0
t = 3.0"
fr1 & fr2 = 1.0
h=0
P = 605 psi
F = 1.0
E1 = 1.0
Rv = 36"
d = 12"
tn = 1.5"
FORMULA:
UG-37
Limits of reinforcement:
Parallel:
d = 12"
Rn + tn + t = 6 + 1.5 + 3.0 = 10.5"
Normal:
2.5t = 2.5 x 3.0 = 7.5"
2.5tn + te = 2.5 x 1.5 + 0 = 3.75"
Shell and Nozzle required thickness:
tr = PRv / SE - 0.6P
tr = 605 x 36/ 15000 x 1.0 - .6 x 605
tr = 1.488"
trn = PRn / SE - 0.6P
trn = 605 x 6/ 15000 x 1.0 - .6 x 605
trn = 0.248"
A = d x tr = 12 x 1.488 = 17.856 in2
A1 = d(t - tr) = 12(3.0 - 1.488) = 18.144 in2
A1 = 2(t + tn) (t - tr) = 2(3.0 + 1.5) (3.0 - 1.488) = 13.608 in2
A1 > A Therefore reinforcement adequate
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Figure UW-16.1(e)
use 1/4"
OK
CONCLUSION:
Nozzle reinforcement and weld sizes meet Code requirements. Nozzle adequately reinforced.
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QUESTION: 6
GIVEN:
P = 725
Design temperature = 700F
Material Sd = 16,600 psi at design temperature
Material St = 17,500 psi at test temperature
FORMULA:
UG-99
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QUESTION: 7
GIVEN:
P = 800 psi
Design Temperature = 450 F
MDMT = 100 F
Material Sd = 15,000 psi at design temperature
Material St = 15,000 psi at test temperature
FORMULA:
UG-100
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QUESTION: 8
GIVEN:
t = 1.5"
tn = 0.75"
t1 = 0.500"
t2 = 0.375"
Figure UW-16.1(i)
FORMULA:
throat dimension
throat dimension
UW-16(d)
t1 + t2 1-1/4 tmin
and
t1 or t2 not less than the smaller of 1/4 in. or 0.7tmin
tmin = the smaller of 3/4 in. or the thickness of the thinner of the parts joined.
REQUIRED:
t1 + t2 minimum is 1.25 x .75 = 0.9375 in.
0.7 x .75 = 0.525 use 1/4 in. because it is smaller of 0.525 in. and 1/4 in.
ACTUAL:
t1 + t2 = 0.500 + 0.375 = 0.875 in.
t1 and t2 both exceed 1/4 in.
CONCLUSION:
Construction does not meet Code because t1 + t2 is less than 1-1/4 tmin.
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QUESTION: 9
GIVEN:
tmin = 1.125"
R = 30 in.
P = 641 psi
S = 17,500 psi at design temperature
E = 1.00
Sd/Sa = 1.00
MDMT stamped on vessel nameplate = -20 F.
PWHT has been performed but not required by Code.
SA-515-70 material is a Curve A material per Fig. UCS-66 note (a).
ASSUMPTION:
Original plate was butt welded
FORMULA:
t = PR/SE - 0.6P
t = 641 x 30/17,500 x 1.00 - 0.6 x 641
t = 1.124"
Using Table UCS-66 or Figure UCS-66 the MDMT of the material is 75F.
MDMT =
Reduction per UCS-68(c)
+75
+30 +45 F
CONCLUSION:
Since the MDMT for the plate is 45 F. and no further exemptions are available the plate must be impact
tested at - 20 F. In accordance with UG-84, acceptance criteria is as shown in Figure UG-84.1.
45
itcSkills
API-510 PRESTUDY GUIDE
COPYRIGHT 2006 itcSkills & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE
QUESTION: 10
GIVEN:
MAWP = 125 psi
Vessel height = 175'
Pressure gage location = 25' level
FORMULA:
UG-99
46
itcSkills
API-510 PRESTUDY GUIDE
COPYRIGHT 2006 itcSkills & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE
(c),
UG-24
(c),
UG-4(a)
UG-10
UG-20(b)
UG-22 Pressure only
a,
UG-27(c)(1)
UG-16(b)
UG-32(e)
UG-33(a)(1) & (2)
UG-34 Formula (1), UG-34(c)(2), C=0.33
UG-93(a)(1)
UG-9
UG-35
UG-36(a)(1) & (2)
U-1(c)(1) thru (10)
UG-36(c)(3)(a)
UG-37(a)
Area replacement
UG-40
UG-41(a)
UW-15(b)
UG-45
UCS-79(d)
UG-76(c)
UG-77(a)
UG-80(a)(1)
UG-80(a)(2)
UG-81(a)
UG-116(e)(1) & (2)
Appendix 3
UG-93(d)(4)
UG-98(a) & (b)
UG-28
UG-99(b)
UW-5(b)
UG-102(b)
UG-36(d) & UW-14
UG-99(d)
Figure UG-118
UG-116(e)
UCS-25
UG-116(e)(3) & Table UW-12
UG-116(c) & UW-2
UW-3(a)
UW-99(h) & UG-100(c)
a,
UW-3(a)
UW-11(a)(5)(b) & UW-52
UW-11(a)(2) & (4)
Type 1 has no backing strip while Type 2 does.
UW-16
UG-120
UW-33 & Table UW-33
UW-35
Figure UCS-66 +120
Yes, Figure UCS-66 [note (e)]
47
58.
59.
60.
UW-28(d)
UW-51, Appendix 12
UG-46 (g) (1)
itcSkills
API-510 PRESTUDY GUIDE
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57.
UW-15(d)
Section IX
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
QW-461.9
QW-100.1
QW-322.1
QW-153(d)
QW-163
QW-200.1(a)
QW-355
QW-200.2(c)
QW-202.3(b)
QW-120
QW-253
QW-201 & 300.2
QW-190
QW-211
QW-200.2(f)
QW-201
QW-212
QW-304
QW-321.1
QW-322.2(a)
QW-433
QW-151.1(a)
QW-406.1
QW-161.5
QW/QB-422
QW-423
QW-303.1
QW-432
QW-451.1
QW-401
QW-452.1
QW-452.3
QW-422
QW-462.1(a)
48