INSTRUCTIONS FOR API 510 PRE-COURSE STUDIES CONTENTS: 1. API510 Body Of Knowledge 2, API 510 Study Questions and Answers 3. ASME Section IX Welding Exercise 4, ASME Section V NDE Exercise 5, ASME Section VIII Exercise Please begin by reading all API materials including the Body of Knowledge sent with this package. Continue by reading the API Study Questions; follow this by completing the enclosed exercises over ASME VIIL, IX and, V. Please bring to the class the following items. Effective Publications for this Revision: June 4" 2004 Exam «API 510 Eighth Ed. June, 1997 with Addendums.1(Dec. 98) & 2 (Dec. 2000) & 3 (Dec.2001) API RP 572 Second Edition Feb. 2001 API RP 576 Second Edition (Dec. 2000) API Guide to Inspection of Refinery Equipment Chapter 2 ASME Section Vill Div.1 2000 Edition with 02 addenda ASME Section IX 2000 Edition with 02 addenda ASME Section V 2000 Edition with 02 addenda A simple calculator (needs to have the square root function) Highlighters and Tabs The first day of class a short test will be given over the pre-course API 510 Study Questions! THIS PRE-STUDY MATERIAL IS VERY IMPORTANT PLEASE DO NOT NEGLECT THIS WORK. STaRT Now FAST TRACK TECHINICAL TRAININGBODY OF KNOWLEDGE, APES10 PRESSURE VESSEL INSPECTOR (CERTIFICATION EXAMINATION November 2003 (Replaces Jane 2003) API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair, and alteration of pressure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed to determine if individuals have such knowledge. The following is a list of specific topies in which the APL Authorized Pressure ‘Vessel Inspector should be knowledgeable, To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from each category listed will be included on the API certification examination. Only inspection information covered in one of the references outlined in this body of knowledge will be uilized for the examination questions. ‘The examination consists of two parts. The clased book part tests the candidate on knowledge and tasks requiring everyday working knowledge of API Standard 510 and the applicable reference documents. The open book portion of the examination requires the use of more detailed information that the inspector is expected to be able to find in the documents, but would not ‘sormally be committed to memory. REFERENCE PUBLICATIONS: API publications and ASME codebooks must be brought to the examination site to be used as reference materials for the open-book part ofthe examination. A. API Publications: API 510, Pressure Vessel Inspection Code APIRP-572, Inspection of Pressure Vessels API RP 576, Inspection of Pressure-Relieving Devices API Guide For Inspection of Refinery Equipment, Chapter IT B. ASME Publications: Section V, Nondestructive Examination Section VI, Divison I, Uniod Pressure Vestls Section IX, Welding and Brazing Qualifications Note: Refer to the Publications Effectivity Sheet in the application package fora list of specific editions, addenda, and ‘supplements of the reference publications that are effective for your exam date. 11103 11. THICKNESS MEASUREMENTS, INSPECTION INTERVALS AND VESSEL INTEGRITY A. Code calculation questions will be oriented toward existing pressure vessels, not new pressure vessels. API Authorized Pressure Vessel Inspectors should be able to check and perform calculations relative to in-service deterioration, repairs, erates, or alterations. Only internal and external pressure loadings will be considered for the API S10 examination. ‘The following ten categories describe the minimum necessary knowledge and skills: CORROSION RATES AND INSPECTION INTERVALS ‘The Inspector should be able to take inspection data and determine the internal and external inspection intervals ‘The Inspector must be able to calculete: 4, Metal Loss (including corrosion averaging) (API-S10, Para 5.7,d) b. Corrosion Rates (API-510, Para 64) «, Remaining Corrosion Allowance (API-S10, Para 6.4) 4. Remaining Service Life (API-510, Para, 64) «Inspection Interval (API-510, Para, 64) ‘The formulas for performing the above calculations and rules for setting the inspection intervals may be “closed-book" during the exam. JOINT. “The inspector must be able to determine the joint efficiency "E" of a vessel weld, Inspector should be able to determine: 1, Weld Joint Categories from UW-3; ». Type of radiography (full, spot, or none) performed basis the nameplate markings (RT-1, RT-2, etc); «. Joint efficieney by reading Table UW-12; 4. Joint efficiency for seamless heads and vessels Sections per UW-12(@); and «. Joint efficiency for welded pipe and tubing per UW-12(¢). Determining joint efficieney may be part of the internal pressure problem since joint efficiency "* i used in the formulas for determining required thickness or Vessel Part MAWP. L.STATICHEAD The inspector must be able to compensate for the pressure resulting from static head. All static head will be based upon a Specific Gravity of 1.0. The inspector should be able to: 1) List the static head/pressure conversion factor (0.433 psifft); b) Know the difference between vessel MAWP and vessel part MAWP (UG-98); c) Calculate static head pressure on any vessel part; 4) Calculate total pressure (MAWP + static head) on any vessel part; ¢) Caleulate maximum vessel MAWP given vessel parts MAWP and elevations; and 8) Determine the head depth for formed heads given the vessel diameter (UG-32() & UG-32(d)). Static head calculations may also be required during the internal pressure calculations if static head data is given in the examination problem. 11103 2ALINTERNAL PRESSURE ‘The inspector should be able to determine: 4) The required thickness of «cylindrical shell based on circumferential stress given a pressure (UG-27(0X1)} ’b)_ The vessel part MAWP fora cylindrical shell based on circuraferentil stress given a metal thickness (UG-27(6)(1)} ©) Whether a cylindrical shell meets Code requirements given both pressure and meta thickness (UG 27(cX()) 6) The required thickness of a head (ellipsoidal, torispherical, and hemispherical) given a pressure. (UG32(4),(e), and (g)) e) The vessel part MAWP for a head (ellipsoidal, orisphericaland hemispherical) given 2 metal thiclmess. (UG-32 (@), (©), @and (@). 1) Whether head (ellipsoidal, torispherical or hemispherical) meets Code requirements given both pressure and metal thickness (UG 32(d),(), (9 and (g). 8) The required thickness fora flat unstayed circular head given a pressure, (UG-34(¢}(2)) Formula 1 only). ‘The inspector should also be able to compensate for the corrosion allowance: add or subtract based on requirements of the exam problem, The Appendix | formula for cylinders, which is based on outside diameter, can be used. The Appendix | formulas for non-standard heads will not be required. SLEXTERNAL PRESSURE ‘The inspector should be able to: 8) Calculate the maximum allowable extemal pressure based on material from ASME B&PV Section I, Part D (Figure G & specitic Material/Temperature Charts supplied with the examination) UG-28(6)(1); and ») Calculate whether a cylindrical shell or tube meets Code design for external pressure given 2 wall thickness and ‘a pressure (ASME B & PV, Section Il, Part D; UG 28 (e X), 6, PRESSURE TESTING ‘The inspector should be able to: 8) Calculate a test pressure compensating for temperature, (UG-99 & UG-100) 'b) Be familiar with the precautions associated with hydrostatic and pneumatic testing, such as minimum test temperatures, protection against overpressure etc. ©) Write a hydrotest Procedure (UG 99 and UG 100) d) Write pneumatic test procedure (UG 100 and UG 102) ‘LIMPACT TESTING ‘The inspector should be able to: a) Determine the minimum metal temperature of a material which is exempt from impact tes UCS-68(¢). ig (UG20 (9, UCS-66, A. WELD SIZE FOR ATTACHMENT WELDS AT OPENING ‘The inspector must be able to determine if weld sizes meet Code requirements, The inspector should be able to: 1. Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion factor (0.707); and 18) Determine the required size of welds at openings (UW-16). 11/03, 3‘9. NOZZLE REINFORCEMENT ‘The inspector should: 1b) Understond the key concepts of reinforcement, such os replacement of strength removed and limits of Credit can be taken for extra metal in shell and nozzle ©) Be able to calculate the required areas for reinforcement or check to ensure that a designed pad is large enough. “To simplify the problem: forcement. All = 1.0 AUF = 10 AILE® 10 All required thicknesses are given ” ‘There will be no nozzle projecting inside the shell Be able co compensate for corrosion allowances. Weld strength calculations are exeluded. B. The following are typleal ASME code engineering requirements that API certific expected (o know for purposes of the certification examination. a candidates will NOT be 1. Required thickness calculations for wind, earthquake, and other secondary stress loadings; 2, Supplementary design formulas and calculations for non-cylindrical shell components; 3. Most external pressure calculations; 4, Nozzle calculations for external loads; 5. Flange calculations; 6. Brazing requirements; 7. Ligament calculations; 8. Stayed flat heads and sizing of stays; 9, Tubesheet calculations (stayed or unstayed) and tube to tubesheet joints and loads; 10. Relief valve sizing; 1, Lifting lug and other structural type calculations; 12, Proof testing requirements; 13. Required inspections for new construction, except as they apply to alterations; 14, Zick analysis; 15. Integrally forged pressure components; 16. Cryogenic vessels (below -50 1); 17. Dimpled, embossed, jacketed, and non-metallic vessels and assemblies; 18. NDE requirements for acoustic emission, eddy current, and motion radiography; 19, ASME Sections UF, UB, UNF, UHA, UCI, UCL, UCD, UHT (except UHT-6), ULW, and ULT; 20. Code Cases and interpretations; 21, Welding process requicements other than shielded metal are welding (SMAW), gas tungsten are welding (GTAW), gas metal arc welding (GMAW), or submerged are welding (SAW); 2, Requirements for pressure vessels for human occupancy; and 23. Rules for natural resource vessels, API-510, Section 8 14103 4I. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASED ON ASME BOILER AND PRESSURE VESSEL CODE, SECTION IX A, WELD PROCEDURE REVIEW |. The inspector should be able to determine if procedure and qualification records are in compliance with applicable ASME boiler and pressure vessel code and any additional requirements of API-510 (API-S10 requirements will take precedence aver any ASME requirements covering the same technical ares). ‘The weld procedure review may include: 1a, Welding Procedure Specification (WPS); and ». Procedure Qualification Record (POR). ‘The weld procedure review may include: SMAW, GTAW, GMAW, OR SAW, with the following limitations: 8) No more than one process will be included on a single WPS or PR, and the WPS to be reviewed will be supported by a single PQR. )_ Filler metals limited to one-per-process for SMAW, GTAW, GMAW, or SAW. ©) The PQR will be the supporting PQR for the WPS. 1. The inspector should be able to determine: a) Whether number and type of mechanical test listed on PQR are appropriate b) Whether the results ofthe tests are acceptable ¢) Whether all required essential and non-essential variables have been properly addressed. (Supplemental essential variables will not bea part of the WPS). The following limitations or conditions will apply: Base metals limited to Pl, P3, P4, PS, and PS. Dissimilar base metal joints, and dissimilar thicknesses of base metals are excluded. Supplemental powdered filler metals and consumable inserts are excluded. Special weld processes such as carrosion-resistant weld metal overlay, hard metal ‘Welds with buttering of ferrtie member are excluded. ‘© ForP1, P3, Pé, and P5, forthe purpose of the examination the lower transition temperature will be 1333°F and the upper transformation temperature will be 1600°F. ing overlay, and dissimilar ‘BLASME Section VINl Div, 1 and API-510: GENERAL WELDING REQUIREMENTS: |. ASME Seetion VIII, Div. ‘The inspector should be familiar with and understand the general rules for welding in ASME Section VII, Div. 1, Parts UW and UCS such as: 4) typical joints end definitions b) weld sizes ©) restrictions on joints 4d) maximum allowable reinforcement e) inspection requirements 1) cheat treatment 2. APISIO ‘The inspector should be familier with and understand any rules for welding in API-S10. Any rules for welding given in API-S10 shall take precedence over those covering the same areas in ASME, Section VIII, Div. | 3. "Editorial" and non-technical requirements for the welding subject matter, the candidate is to be tested on, are excluded. This inctudes items such as the revision level of the WPS, company name, WPS number and date, and name of testing lab. However, the API 510 applicants shall know that the PQR must be certified by. signing and dating. 11103 5TILNONDESTRUCTIVE EXAMINATION ASME Section V, Nondestructive Examination NOTE: Information contained in Mandatory or Nonmandatory Appendices or referenced ASTM specifications will not be covered on the examination. The examination will cover only the main body of each referenced Article. When paragraphs are specifically noted only those paragraphs will be covered. This listing is based on ASME Section V. A. Article 1, General Requirements: ‘The inspector should be familiar with and understand; 1. The Scope af Section V, 2. Rules for use of Section V as 0 referenced Code, 3. Responsibilities of the Owner / User, and of subcontractors, 4. Calibration, 5. Definitions of “inspection” and examination”, 6. Record kesping requirements. B. Article 2, Radiographic Examination: ‘The inspector should be familiar with and understand; 1. The Scope of Article 2 and general requirements, ‘The rules for radiography as typically applied on pressure vessels such as, but not limited to: 4. required marking b. type, selection, number, and placement of T's, allowable density 4. contro! of backscatter radiation «. location markers 3. Records C. Article 6, Liquid Penetrant Examination: ‘The inspector should be faritiar with and understand: 1. The Scope of Asticle 6, 2. The general rules for applying and using the liquid penetrant method such as, but not limited to; a) procedures b) contaminants ©) techniques ) examination ©) interpretation 1) documentation and g) record keeping, D, Article 7, Magnetic Particle Examination (Yoke and Prod techniques only): ‘The inspector should be familiar with and understand the general rules for applying and using the magnetic particle method such as, but not limited t0; 1. The Seope of Article 7, 2. General requitements such as but not limited to requirements For: a, procedures b techniques (Yoke and Prod only) 11103 6. interpretation Documentation and recard keeping E. Anticle 23, Ultrasonic Standards, Section SE-797 only — Standard practice for measuring thickness by manual ultrasonic pulse-echo contact method: “The inspector should be familiar with and understand; 1). The Scope of Article 23, Section SE-797, 2) The general rules for applying and using the Ultrasonic method 3). The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7. ASME Section VIII, Div, | and API-510, General nondestructive examinati requirements: LASME Section VIII, Dv. ‘The inspector should be familiar with and understand the general rules for NDE (UG, UW, Appendices 4,6, 8, and 12) 2. APL510, The inspector should be familiar with and understand the general rales for NDE in API-510. IV. PRACTICAL KNOWLEDGE - GENERAL ‘The following topics may be covered in the examination. More information relative to each of the categories is contained in section V. PRACTICAL KNOWLEDGE - SPECIFIC 1. Organization and Certification Requirements. 2, Types and Definitions of Maintenance Inspections. 3. Types of Process Corrosion and Deterioration, 4, Modes of Mechanical, Thermal, and High Temperature Deterioration. 5, Pressure Vessel Materials and Fabrication Problems. 6, Welding on Pressure Vessels 7. Nondestructive Examination (NDE) Methods, 8, Corrosion and Minimum Thickness Evaluation, 9, Estimated Remaining Life, 10, Inspection Interval Determination and Issues Affecting Intervals. II. Relief Devices. 12, Maintenance Inspection Safety Practices. 13, Inspection Records and Reports. 14, Repaits/Alterations to Pressure Vessels 15, Rerating Pressure Vessels, 16, Pressure Testing After Repairs, Alterations, or Rerating 11/03, 7ve Each reference publication relative to study for the examination is listed below. A list of topies, which may be covered, is listed for each publication. Some topics may be listed under more than one publication. For example; ASME Section IX is ison 1 and API 510. The ASME and API documents contain additional welding requirements and exceptions to those contained in ASME Section IX. Therefore welding requirements may be listed under all three documents and all three documents may be listed under the general the PRACTICAL KNOWLEDGE - SPECIFIC e basic document for welding requirements as refsrenced by ASME Section Vill, Di heading of "Welding on Pressure Vessels" APESIO, Pressure Vessel Inspection Code NOTE: All of API 510 is applicable tothe examination unless specifically excluded, For example: Section 8 and Appendix E. are excluded, |. Organization and Certification Requirements a) Certification for API Authorized Pressure Vessel Inspectors (API-510, Section 4.2 and Appendix B). b) Authorized Inspection Agencies (API-510, Section 3.4) 2) Vessel Repair Organizations (API-S1O, Section 3.16) 4) Relief Device Testing and Repair Organizations (API-510, Section 6.6) 2. Typesand Definitions of Maintenance Inspection ¢) Internal Inspection (API 510, 6.4) £) Defect Inspection (API-510, 5.9) 12) Inspection of Parts (API-510, 5.6) hh) External Inspection & Buried Vessels (API 510, 6.3) j) Atmospheric Corrosion and Corrosion Under Insulation (API-510, 63) J) On-Stream Inspection (API-510,3.11 & 6.4) 1k) Visual Examination (API-510, 5.5) 1D) Thickness Measurements (API-510, 53, 57,63 & 64) 1m) Nondestructive Examination (API-S10, 55 & 5.7) 1h) Assessment of Inspection Findings (5.8) 3. Welding on Pressure Vessels Welding Inspection Requirements (API-510, 5.6 & 72) 4, Corrosion and Minimum Thickness Evaluation 11103 ‘The inspector should have a general knowledge of the following principles, and may be required to make caleulations using these principles. ©) Corrosion Rate Determination (API 510, 53) 1) Comosion Averaging (API 510, 5.7) 4) Widely Scattered Pitting (API 510, 5.7) #) Surfaces Remote From 2 Weld (API, 5.7) 8) Corrosion in Central Portion of Dished Heads (API $10, 5.7)3. timated Remaining Life Remaining Life = Corrosion Allowance (CA) (API510, 63) Corrosion rate ctual Thickness Minus Required Thickness cA Corrosion Rate = Metal Loss Time Metal Loss = Previous ot Initial Thickness Minus Present Thickness depending on whether corrasion rate is short ar long term ‘Time = Time Period Between Inspections 6. Inspection Interval Determination and Issues Affeeting Intervals ')._ Intemal or On-Stream Inspection Intervals (API 510, 6.4) uv) Intemal and On-stream inspection Intervals for Estimated Life (API S10, 6.4) -v) External inspection Intervals ((API-S10, 6.1-6.3) w) Deterioration Other Than Metal Loss (API $10, 5.2) %) Different Zones of a Vessel (API 510, 64) ¥) Change of Service Conditions (API $10, 6.4) 2) Change in Location and Ownership (API S10, 6.4) 7. Relief Devices aa) Repair Organizations (API-S10, Section 6.6) bbb) Minimum Requirements for Quality Control Systems (API 510, 6.6) ec) Maximum Service Intervals (API-S10, 66) 8, Maintenance Inspection Safety Practices 4, Pressure Vessel Inspection (API-S10, Section 5.1) 9. Inspection Records and Reports a, Permanent and Progressive Inspection Records (API-510, 6.7) 10. Repairs, and Alterations, to Pressure Vessels did) Authorization (API510, 7.1.1) ee) Approval (APIS10,7.1.2) + ff) Design Requirements (AP! 510, 7.2.7) 12g) Materials Requirements (API 510, 7.2.8) hh) Welding Requirements (APL 510, 721,722,723, 72.6, & 7.2.11) i) Heat Treating Requirements, including + Preheating (API510,7.23) Post weld Heat Treating (API 510, 7.23) + Local Postweld Heat treatment (API510, 7.2.5) a) Repairs to Stainless Steel Weld Overlay and Cladding (API 510, 7.2.6) 'b) Inspection (API 510, 7.2.9) ©) Rerating of Pressure Vessels (API $10, 7.3) d) Pressure Testing After Repairs, Alterations or Rerating (API-S10, 6.5 and 7.2.10) ©) Nondestructive Examination of Welds (API 510, 7.2.4) 41/03 911103 10APL RE-512, Inspection of Pressure Vessels |. Types and Definitions of Maintenance Inspections 1) Types of Pressure Vessels (API RP-572, Section 4) 'g) Construction Standards (API RP-S72, Section 5) hh) Maintenance Inspection (API RP-573, Section 6) ) Reasons for Inspection (API RP-572, Section 7) 4) Causes of Deterioration (API RP-572, 8.1 8.10) k) Frequency and Time of Inspection (API RP-572, Section 9) }) Internal Inspection (API RP-S72, 10.4) 1m) External Inspection, Typical Items Checked (API RP-572, 10:3) 1n) Visual Examination (APL-RP-572, Section 10) 9), Thickness Measurements and Limits (API RP-S72, Section 10) p) Nondestructive Examination (API RP-572, Section 10) 4}. Repair Methods (API RP-572, Section 11) Pressure Vessel Materials and Fabrication Problems Material and Fabrication Problems (API RP-572, 84 & 8.5) 3. Maintenance Inspaction Safety Practices 2 Pressure Vessel Inspection (API RP-572, 10.2) Inspection Records and Reports (API RP-512, Section 12) API RP 576, Inspection of Pressure-Relieving Devices: 1. Relief Devices a) Description of Types ~ General Knowledge of Application and Limitations (API RP-576, Section 2) 'b) Causes of Improper Performance (API RP-576, Section 4) ) Reasons for laspection and Frequency Determination (API RP 576, Sections 3 & 5) 4d) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7) ©) Maintenance Inspection Safety Practices (API RP 576, Section 6) 1) Inspection Records and Reports (API RP-575, Section 8) Chapter I, API Guide for Inspection of Refinery Equipment (RE), Conditions Causing Deterioration or Failures Note: The above reference applies to refinery equipment other than pressure vessels (e.g., piping, heaters, and tanks. Only portions applicable to pressure vessels will be covered on the examination, 1. Types of Process Corrasion and Deterioration 1103 a) Corrosive Components of Crude Oils (API IRE, Chapter Il, Section 202.02) b) Corrosion By Other Process Fluids (API IRE, Chapter Il, Section 202.03) ©) Deterioration Due To Hydrogen (API IRE, Chapter Il, 202.023) 4) Stress Corrosion Cracking (API IRE, Chapter II, 202.064) 2) Atmospheric Corrasioa and Corrosion Under Insulation (API IRE, Chapter Il, 202.04) 1) Erosion and Erosion-Corrosion (APIIRE, Chapter I,203) 8) Corrosion by Waters (API IRE, Chapter Il, 202.025)11103 bb) Other Types of Corrosion (API IRE, Chapter Il, Section 202.06)2. Modes of Mechanical, Thermal, and High Temperature Deterioration 18) Mechanical and Thermal Problems (API IRE, Chapter Il, 205.208) b) High Temperature Problems (API IRE, Chapter Tl, Section 204) 3. Pressure Vessel Materials and Fabrication Problems a) Faulty Material and Equipment (API IRE, Chapter I Section 210) b) Known Prablems Associated With Design and Fabrication (API IRE, Chapter Il, 210.02) 11103 BAPI 510 STUDY QUESTIONS HOW TO USE THESE QUESTIONS The following questions and answers on the API material are for memorization. The API questions will be open book on the first part of the exam and closed book during the second half. Practice remembering the key words as opposed to learning the entire answer.API510 EIGHTH ED., JUNE, 1997 ADDENDA # 1 DEC. 1998, #2 DEC. 2000, # 3 Dec. 2001 REVIEW QUESTIONS Section 1 - General Application 1, The primary code for the inspection of pressure vessels after they enter service is? at) = The API510 Code 2, Relative to pressure vessels, when does API 510 apply? a) ‘+ Only applicable to vessels after they have been placed in service. 3, What does the API inspection code cover? (a) © Maintenance inspection, repair, alteration, and re-rating procedures for pressure vessels used by petroleum and chemical process industries 4. What type of pressure vessel is exempt from periodic inspection requirements? + Pressure vessels on movable structures covered by other jurisdictional requirements. * All classes listed for exemption from the inspection scope of the ASME Code Section VIII, Division I. + Pressure vessels that do not exceed specified volumes & pressures, Section 3 - Definitions ‘5. What is an alteration? en ‘+A physical change in any component or a re-rating which has design implications which affect pressure-containing capability beyond the scope of existing data reports. 6. What three situations should not be considered alterations? G1) © Comparable or duplicate replacement * Addition of reinforced nozzle less than or equal to existing reinforced nozzles, * Addition of nozzles not requiring reinforcement 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WHW.APTEXAMS.ORGG2) 3) G4) 10. 5) 13, In what situation would the term "applicable requirements of ASME Code" be used? When the ASME Code cannot be followed because ofits new construction orientation (new or revised material specifications, inspection requirements, certain heat treatments and pressure test, and stamping and inspection requirements), the engineer or inspector shall conform to this inspection code rather than to the ASME Code. If an item is covered by requirements in the ASME Code and this inspection code or if there is a conflict between the two codes, for vessels that have been placed in service, the requirements of this inspection code shall take precedence over the ASME Code. As an example of the intent ofthis inspection code, the phrase "applicable requirements of the ASME Code" has been used in this inspection code instead of the phrase "in accordance with the ASME Code." What is an Authorized Inspector or Inspector? An employee of an Authorized Inspection Agency who is qualified and certified to perform inspection under this inspection code, List 4 examples of an Authorized Inspection Agency. Inspection organization of the jurisdiction in which the pressure vessel is used or; Inspection organization of insurance company which is licensed or registered to write and actually writes pressure vessel insurance. ‘An owner or user of pressure vessels who maintains an inspection organization for activities relating only to his equipment and not for vessels intended for sale or resale. ‘An independent organization or individual licensed or recognized by the jurisdiction in which the pressure vessel is used and employed by or acting under the direction of the owner or user. Define "construction code". ‘The code or standard to which a vessel was originally built, such as AP/ASME, API, or State Special/non-ASME. ‘What does the term "inspection code" refer to in API 510? Shortened title for API 510 used in this publication, Define Jurisdictions. A legally constituted government administration, which may adopt rules relating to pressure vessels, Define Maximum Allowable Working Pressure (MAWP) as it relates to API S10. (3.9) and (Sect VIII UG-98) 08/02 ‘The maximum gage pressure permitted at the top of a pressure vessel in its operating position for a designated temperature that is based on calculations using the minimum (or average pitted) thickness for all critical vessel elements, not including corrosion allowance or loading other than pressure Rev 8 FAST TRACK TECHNICAL 281.482.2253 | WHW.APIEXAMS.ORG14, G10) 17, When determining Minimum Allowable Shell Thickness, what must be considered winen making calculations? ‘Temperature, pressure, and all loading. . What type of inspection uses nondestructive examination procedures to establish the suitability of pressure vessels for continued operation? On-stream Inspection ‘What is the key element of an On-stream inspection? Because the vessel may be in operation while an on-stream inspections being carried out, the vessel is not entered for internal inspection, What is a Pressure Vessel?” (3.12) and (Sect VIII U-1 (a)) 18, (3.13) 19, G14) 20. G13) A container designed to withstand intemal or external pressure, which can be imposed by an external source, by the application of heat from a direct or indirect source, or by any combination thereof. This definition includes unfired steam generators and other vapor generating vessels, ‘which use heat from the operation of a processing system or other indirect heat source. (Specific, limits and exemptions of equipment covered by this inspection code are given in Section Land ‘Appendix A.) Who shall be a pressure vessel engineer? Shall be one or more persons ot organizations acceptable to the owner-user who are knowledgeable and experienced in the enginecring disciplines associated with evaluating ‘mechanical and material characteristics which affect the integrity and reliability of pressure vessels, The pressure vessel engineer, by consulting with appropriate specialists, should be regarded as a composite of all entities needed to properly assess the technical requirements, What is the definition of quality assurance as given in API 510? All planned, systematic, and preventative actions required to determine if materials, equipment, or services will meet specified requirements so that equipment will perform satisfactorily in service. ‘The contents of quality assurance inspection manual are outlined in 4.3. What is a Repair? ‘The work necessary to restore a vessel to a condition suitable for safe operations at the design conditions. "IF* design temperature or pressure changes due to restoration, then re-rating requirements shall also be satisfied. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS. ORa G16) 2, G7 23, @u7 24, @.18) 25, (3.19) 08/02 List the four examples of a Repair Organization. ‘The holder of a valid ASME Certificate of Authorization for the use of an appropriate ASME Code symibol stamp ‘An owner or user of pressure vessels who repairs his own equipment in accordance with the API 510 code. A contractor whose qualifications are acceptable to the owner or user of pressure vessels and makes repairs in accordance with this inspection code. A repair concern that is authorized by the legal jurisdiction What is re-rating? A change in either the temperature ratings or the maximum allowable working pressure rating of a vessel, or a change in bot. The maximum allowable working temperature and pressure of a vessel may be increased or decreased because of a re-rating, and sometimes a re-rating requires a combination of changes. De-rating below original design conditions is a permissible way to provide for corrosion. When a re-tating is conducted in which the maximum allowable working pressure or temperature is increased or the minimum temperature is decreased so that additional mechanical tests are required, it shall be considered an alteration. What is a permissible way to provide for corrosion? De-rating below original design conditions. ‘What distinguishes an examiner from and inspector? A person who assists the API authorized pressure vessel inspector by performing specific NDE on pressure vessels but does not evaluate the results of thoso examinations in accordance with API 510, unless specifically trained and authorized to do so by the owner or user. "The examiner need not be certified in accordance with API 510 or be an employee of the owner or user but shall be trained and competent in the applicable procedures in which the examiner is involved. Define Controlled-Deposition Welding Any welding technique used to obtain controlled grain refinement and termpering of the underlying heat affected zone (HAZ)in the base metal. Various controlled-deposition fechniques, such as temper-bead (tempering of the layer below the current bead being deposited) and half-bead (fequiring removal of one-half of the first layer), are included. Controlled-deposition welding requires control of the entire welding procedure including the joint detail, preheating and post heating, welding technique, and welding parameters. Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS.ORGSection 4 - Owner-User Inspection Organization, 26. What are the education and experience requirements for becoming an inspector? (4.2 go to Appendix B) ‘+ Degree in engineering & 1 year experience in the design, construction, repair, operation, or inspection of boilers or pressure vessels © 2-year certificate in engineering or technology fiom a technical college & 2 years of experience in the design, construction, repair, operation, or inspection of boilers or pressure vessels, ‘+ Equivalent of a high school education plus 3 years of experience. (and). ‘+ Five years experience in the inspection of boilers or pressure vessel. 27, Who will be responsible to the owner-user when alterations, inspections, or repairs are performed? a) ‘© The API authorized pressure vessel inspector. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APTEXAMS. ORGSeetion 5- Inspection Practices 28. Why are safety precautions important in pressure-vessel inspections? (5.1) * Because of the limited access to and the confined spaces of pressure vessels. 209. What guidelines must an inspector follow to enter a vessel that has been in service? ‘+ OSHA Regulations regarding Confined Space Entry. 30, Explain the safety precautions and procedures that should be taken when performing an intemal inspection, (1) Isolate vessel from all sources of liquids, gas or vapors Drain, purge, clean and ventilate. Gas test. Wear protective equipment as required Wam all persons working around the vesse! that inspection personnel are inside. ‘War all inside the vessel of work that is done outside the vessel Check all tools and safety equipment needed before inspection, 31. When developing an inspection plan for vessels that operate at elevated temperatures (750 to 1000 ° F) what things should be considered when assessing the remaining life of the vessel? + Creep deformation and stress rupture, ‘+ Creep crack growth, ‘+ Effect of hydrogen on creep. + Interaction of creep and fatigue. + Possible metallurgical effects, including a reduction in ductility. 32. Locations where metals of different thermal coefficients of expansion are welded together are susceptible to what? (5.2) © Thermal Fatigue. 33, The actual or estimated levels of what four items must be considered in any evaluation of Creep? (52) + Time Temperature + Stress Material Creep Strength 34, Atambient temperatures, carbon, low alloy, and other ferrtic steels may be susceptible to what? 62) © Brittle Failure 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS.ORG35 (52) 36. (52) 37. (3) 38. 64) aL (5.5) 42, (35) 08/02 Define Temper Embrittlement. A loss of ductility and notch toughness due to PWHTT or high temperature service above 700 degrees F. (370 degrees G) ‘What kind of steel is prone to Temper Embrittlement? Low alloy steels, especially 2 1/4-Cr-I Mo What three methods may be used to determine the probable rate of corrosion? Caleulate rate from data collected from same or similar service Estimate rate from owner-user experience or from published data on comparable service. (On-stream determination after 1000 hours of service using a suitable corrosion monitoring device or NDE thickness measurements (UT), subsequent inspections shall be made until the corrosion rate has been established. How should the MAWP for the continued use of a pressure vessel be established? By using the Code to which the vessel was fabricated or by using the appropriate formulas and requirements of the latest edition of the ASME Code to establish the design temperature and pressure, In corrosive service, the wall thickness used in the MAWP calculations shall be the actual thickness obtained by inspection minus : Twice the estimated corrosion loss before the date of the next inspection, except as modified in section 6.4 Whaat is the most important and the most universally accepted method of inspection? Careful visual examination ‘What determines the parts of a vessel that should be inspected? ‘The type of vessel and its operating conditions For proper visual examination, what surface preparation is required? The type of surface preparation depends on individual circumstances, but surface preparation such as wire brushing, blasting, chipping, grinding, or a combination of these may be required. Rev B FAS? TRACK TECHNICAL 281.482.2253 WHW.APTEXAMS. ORG4B. (5) 44. (6.5) 45. (5.6) 46, 6.6) 41. (6 48. 6.7) 49, GA If distortion is suspected during the inspection of a pressure vessel what is the proper course of action? Ifany distortion of a vesscl is suspected or observed, the overall dimensions of the vessel shall be checked to confirm whether or not the vessel is distorted and, if itis distorted, to determine the extent and seriousness of the distortion. The parts of the vessel that should be inspected most carefully depend on the type of vessel and its operating conditions What type of examiners shall the when the owner/user requires inspection for detection of interior surface breaking planar flaws? Industry-qualified UT Shear Wave examiners. List the inspections, which include the features that are common to most vessels and that are most important. Examine the surfaces of shells and heads carefully for possible cracks, blisters, bulges, and other signs of deterioration, Examine welded joints and the adjacent heat-affected zones for service-induced cracks or other defects Examine the surfaces of all man ways, nozzles, and other openings for distortion, cracks, and other defects. ‘Name two reasons why itis necessary for the API 510 inspector to examine flange faces, To look for distortion To determine the condition of gasket-seating surfaces Corrosion may cause what two forms of loss? Uniform loss - a general, relatively even wastage of a surface area Pitted appearance - an obvious, irregular surface wastage ‘Name three ways the minimum thickness of a pressure vessel can be determined, Any suitable nondestructive examination ‘Measurements taken through drilled test holes Gauging from un-corroded surféces in the vicinity of the corroded area, Fora corroded area of considerable size in which the circumferential stresses govern, the least thickness along the most critical element of the area may be averaged over # length not exceeding wihat? For vessels with inside diameters less than or equal to 60 inches (150 centimeters), one half the vessel diameter or 20 inches (50 centimeters), whichever is less. For vessels with inside diameters greater than 60 inches, one third the vessel diameter or 40 inches (100 centimeters), whichever is less. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW.APIEXAMS. ORG10 7 ty When san wey seater pis be gored? & ‘No pit depth is more than 1/2 the vessel wall thickness exclusive of corrosion allowance. Total area of pits does not exceed 7 sq. inches in any 8 inch diameter circle. Sum of pit dimensions along any straight Line within the circle does not exceed 2 inches. 51, When should the design by analysis methods of Section VIII, Division 2, Appendix 4, of the ASME Code be used? (5.7) + To determine if components with thinning walls, which are below the minimum required wall thicknesses, are adequate for continued service. © To evaluate blend ground areas where defects have been removed. 52, What do you use to determine if the thickness at the weld or remote from the weld governs the allowable working pressure when the surface at the weld has a joint factor other than 1.07 ‘© For this calculation, the surface at a weld includes 1 inch (2.5 centimeters) on either side of the weld, or twice the minimum thickness on either side of the weld, whichever is greater. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS. ORG33. (5.7.4) sa. (5.72) 55. (5.72) 56. (5.7.h) 31, (5.8) 1 Describe the governing thickness when measuring the corroded thickness of ellipsoidal and torispherical heads ‘The thickness of the knuckle region with the head rating calculated by the appropriate head formula. ‘The thickness of the central portion of the dished region, in which case the dished region may be considered a spherical segment whose allowable pressure is calculated by the code formula for spherical shells. ‘What is the spherical segment of both ellipsoidal and torispherical heads? ‘That area located entirely within a circle whose center coincides with the center of the head and ‘whose diameter is equal to 80% of the shell diameter. On torispherical heads, what is used as the radius of the spherical segment? Radius of the dish. ‘The radius of the spherical segment of ellipsoidal heads shall be considered to be what? ‘The equivalent spherical radius K;D, where D is the shell diameter (equal to the major axis) and K is given in Table 1 ‘When evaluating metal loss in excess of a vessel’s corrosion allowance what API document should be consulted? APIRP 579 Sections 4.5 and 6 Section 6 - Inspection and Testing of Pressure Vessels and Pressure-Relieving Devices 38. (6.1) 39. (6.1) 60. (6.2) 08/02 When is an internal field inspection of new vessels not required? ‘When the manufactures’ data report (U1) assuring that the vessels are satisfactory for their intended service is available. ‘Name two factors to be considered when inspection intervals are being determined, ‘The risk associated with operational shutdown and start-up and the possibility of increased corrosion due to exposure of vessel surfaces to air and moisture, ‘What are the essential elements of a risk based assessment inspection? ‘The combination of likelihood of failure and the consequences of failure, Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS. ORG64 (6.3) (63) 66. (63) 67. (6.4) 8/02 12 . What other factors should be considered in a RBI program? Appropriateness of the materials, vessel design conditions relative to operating conditions, appropriateness of the design codes and standards utilized, effectiveness of corrosion monitoring programs; and the quality of inspection / quality assurance and maintenance programs What action should be taken afier an effective RBI assessment has been finished? Choose the most appropriate inspection tools and methods based on the degradation expected. Set the appropriate frequency for internal and extemal and on-stream inspections. Determine if pressure testing will be required based on damage or after repairs. Decide on prevention and mitigation steps to reduce the likelihood of a vessel failure. . How often should each above ground vessel be given a visual external inspection? ach vessel aboveground shall be given a visual external inspection, preferably while in operation, at least every 5 years or at the same interval as the required internal or on-stream inspection, whichever is less ‘When making an external inspection, what shall the inspection include? Condition of the exterior insulation Concition of the supports Allowance for expansion General alignment of the vessel on its supports Buried vessels shall be periodically monitored to determine their external environmental condition, What shall the inspection intervals be based on? Corrosion rate information obtained during maintenance on adjacent connecting piping of similar material. Information from the interval examination of similarly buried corrosion test coupons of similar ‘material Information from representative portions of the actual vessel Information from a vessel in similar circumstances, ‘What is the minimum interval for checking the insulating system or outer jacketing of vessels that are known to have a remaining life of over 10 years or that are protected against external corrosion? Every 5 years and repaired as needed, ‘What is the maxirum period between internal ot on-stream inspection? ‘The maximum period shall not exceed one half the estimated remaining corrosion-rate life or 10, years, whichever is less. Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS. ORC68 (64) 9. (6.4) 70. (A) n (64) 2. (6.5) 13 [IF the remaining safe operating life of a vessel is less than 4 years, what is inspection interval? Interval may be the fall remaining safe operating life up to a maximum of 2 years. Under whet conditions would a vessel with a corrosion rate less than 0,005 inch (0.125 millimeter) per year and an estimated remaining life greater than 10 years be exempt from an intemal inspection and inspected externally instead? When size, configuration, or lack of access makes vessel entry for intemal inspection physically impossible. ‘When the general corrosion rate of a vessel is known to be less than 0.005 inch (0. 125 millimeter) pper year and the estimated remaining life is greater than 10 years, and all ofthe following, conditions are met: ‘The corrosive character of the contents, including, the effect of trace components, has been ‘established by at least $ years of the same or comparable service experience with the type of contents being handled. ‘No questionable condition is disclosed by the external inspection specified in 6.2. ‘The operating temperature of the steel vessel shell does not exceed the lower temperature Limits for the creep-rupture range of the vessel materia The vessel is not considered to be subject to environmental cracking or hydrogen damage from the fluid being handled. The vessel is not strip-Lined or plate-tined. ‘Write the corrosion rate formula to be used when determining the safe remaining life of a vessel ‘actual —tmin, Rem. Life Yrs. = et corrosion rate Where: tactual = the thickness, in inches millimeters), measured at the time of inspection for the limiting section used to determine the minimum allowable thickness. tminimum = the minimum allowable thickness, in inches (millimeters), for the limiting section or zone. ‘There are two kinds of corrosion rates to be considered when calculating the remaining life of a vessel. What are these types? Short Term and Long Term rates. ‘When conducting a pressure test as part of a periodic inspection, what shall the shell temperature ‘be during the test? To minimize the risk of brittle facture during the test, the metal temperature should be maintained at least 30° F (1 °C) above the minimum design metal temperature for vessels that are more than 2 inches thick, or 10°F (-12 °C) above for vessels that have a thickness of 2 inches or less. The ‘est temperature need not exceed 120 °F (50 °C) unless there is information on the britle characteristics of the vessel material indicating that a lower test temperature is acceptable or a higher test temperature is needed. 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WwW. APIEXAMS. ORGB. (6.5) 16. (6.6) 71. 67) 14 ‘When should pneumatic testing be done and what are some of the considerations to be taken into account? Pneumatic testing may be used when hydrostatic testing is impracticable because of temperature, foundation or process reasons, however, the potential personnel and property risks should be considered. Should safety relief valves ever be removed from a vessel during pressure testing? ‘Yes, ifa pressure testis being conducted in which the test pressure will exceed the set pressure of the safety relief valve with the lowest setting. ‘When a pressure relief valve requires repair, who shall make this repair? ‘Testing and repairs shal! be made by a repair organization experienced in valve maintenance. The repair organization shall have a written quality control system with the minimum requirements as listed in 4.5 of the API 510 code and maintain a training program to insure the qualifications of the repair personnel, How often shall a safety relief valve be tested? The intervals between pressure relieving device testing or inspection should be determined by the performance of the devices in the particular service concerned. Test or inspection intervals on pressure-relieving devices in typical process services should not exceed 5 years, unless service experience indicates that a longer interval is acceptable. For clean (non-fouling), non-corrosive services, maximum intervals may be increased to 10 years. Pressure vessel owners and users are required to maintain permanent and progressive records of their pressure vessels. What things are included in these records? Construction and design information. Operating and inspection history. Repair, alteration, and re-rating information. Fitness-for-service assessment documentation, Section 7- Repairs, Alterations, and Re-rating of Pressure Vessels 78. 1) 08/02 Who must approve any repairs or alterations? All repair and alteration work must be authorized by the authorized pressure vessel inspector ‘before the work is started by a repair organization (see 3.13). Authorization for alterations to pressure vessels that comply with Section VII, Divisions I and 2, of the ASME Code and for repairs to pressure vessels that comply with Section VIII, Division 2, of the ASME Code may not be given until a pressure vessel engineer experienced in pressure vessel design has been consulted about the alterations and repairs and has approved them. ‘The authorized pressure vessel inspector will designate the fabrication approvals that are required. The authorized pressure vessel inspector ‘may give prior general authorization for limited or routine repairs as long as the inspector is sure that the repairs are the kind that will not require pressure test. Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW. APTEXAMS. ORG.15 79. Who shall approve all specified repair and alteration work? 7.12) + The API authorized pressure vessel inspector, after the work has been proven to be satisfactory and any required pressure test has been witnessed. |. What must be removed from base material prior to welding? * Surface irregularities and contamination. 81. All repair and alteration welding shall be in accordance with what code? + ASME Code, except as permitted in 7.2.11 . What must be done before Preheat or Controlled Deposition Welding is used in lieu of PWH" ‘Prior to using any alternative method a metallurgical review must be conducted to determine if the proposed alternative is suitable for the application. 83. Name the materials allowed when using the alternative preheating method when notch toughness testing is not required. 723.1) ‘The materials shall be limited to P-Nos. P-No. 1 Group 1,2 and 3 and P-No. 3, Group 1 and 2 (excluding Mn-Mo steels in Group 2), 84, Name the materials allowed for use with the Controlled-Deposition Welding Method. ©The materials shall be limited to P-No. 1, P-No. 3 and P-No. 4. 85. Can local post weld heat treatment (PWHT) be substituted for 360 degree banding? «YES provided the following conditions are met: «Application is reviewed and procedure developed by engineer experienced in pressure vessel design & PWHT requirements + Inevaluating the suitability of a procedure, all applicable factors (base metal thickness, material properties, ec.) are considered. + Preheat of 300 degree or higher per WPS is maintained, + PWHT temperature is maintained for distance not less than 2 times base metal thickness measured from weld. A minimum of 2 thermocouples is used. Heat is applied to any nozzle or other attachment in PWHT area, 08/02 Rey @ FAST TRACK TECHNICAL 281.482.2253 WWW, APTEXAMS. ORG16 86. What considerations must he given to the repair of stainless steel overlay and claddings? (72.6) © Consideration shall be given to factors which may augment the repair sequence such as stress level, P number of base material, service environment, possible previously dissolved hydrogen, type of lining, deterioration of base metal properties (by temper embrittlement of chromium- molybdenum alloys), minimum pressurization temperatures, and a need for future periodic examination. 87. Per API 510, state the design requirements for: ‘Butt Joints, Replacement Parts, New Connections, Fitlet Weld Patches, Overlay Patches, Flush patches (72.2) BUTT JOINTS - shall have complote penetration and fusion. REPLACEMENT PARTS - shall be fabricated in accordance with the applicable requirements of the appropriate code. + NEW CONNECTIONS - design, location, and method of attachment shall be in accordance with the applicable requirements of the appropriate code. + FILLET WELDED PATCHES - require special design considerations, they are temporary repairs. Also it must be true that; {a) The fillet-welded patches provide design safety equivalent to reinforced openings designed according to the zpplicable section of the ASME Code. (b) The fillet-welded patches are designed to absorb the membrane strain ofthe parts so that in accordance with the rules of the applicable section of the ASME Code, the following result: + The allowable membrane stress is not exceeded in the vessel parts or the patches, «The strain in the patches does not result in fillet-weld stresses that exceed allowable stresses for such welds. © OVERLAY PATCHES - shall have rounded corners. + FLUSH (insert) PATCHES shall have rounded comers and be installed with full penetration butt Joints. 08/02 Rev @ FAST TRACK TECHNICAL 281.482.2253 WWW.APTEXAMS.ORG17 88, Summarize the rules for the use of a full encirclement lap band on a pressure vessel. Br 2.1) ‘+ A full encirclement lap band repair may be considered a long term repair ifthe design is approved, and documented by the pressure vessel engineer and the authorized API pressure vessel inspector and the following requirements are met: ‘The repair is not being made to a crack in the vessel shell. ‘The band alone is designed to contain the full design pressure. All ongitudinal seams in the repair band are full penetration butt welds with the design joint efficiency and inspection consistent with the appropriate code. ‘+ The circumferential fillet welds attaching the band to the vessel shell are designed to transfer the full longitudinal load in the vessel shell, using a joint efficiency of 0.45, without counting on the integrity ofthe original shell material covered by the band, ‘+ Fatigue of the attachment welds, such as fatigue resulting from differential expansion of the band relative to the vessel shell, should be considered if applicable, + ‘The band material and weld metal are suitable for contact with the contained fluid atthe design conditions and an appropriate corrosion allowance is provided in the band. ‘+The degradation mechanism leading to the need for repair shall be considered in determining the need for any additional monitoring and future inspection of the repair. Non-penetrating nozzles, (including pipe caps attached as nozzles) may be used as long term repairs for other than cracks when the design and method of attachment comply with the applicable requirements of the appropriate code. The design and reinforcement of such nozzles shall consider the loss of the original shell material enclosed by the nozzle, The nozzle material shall be suitable for contact with the contained fluid at the design conditions and an appropriate corrosion allowance shall be provided. 89, Describe the material suitable for making repair or alterations. (7.2.8) + Shall conform to the applicable section of the ASME Code, be of known weldable quality and be ‘compatible with the original material. Carbon or allow steel with a carbon content over 0.35 percent shall not be welded, 90. When making a repair or alteration, what should the acceptance criteria include? (129) + NDE techniques that are in accordance with the applicable sections of the ASME Code or another applicable vessel rating code. 91, After repairs or alterations, is a pressure test required? (72.10) ‘© Repairs - pressure test only applied if inspector believes one is necessary. ‘+ Alterations - pressure test are normally required. Subject to the approval of the Jurisdiction (where the jurisdiction's approval is required), appropriate nondestructive examinations shall be required where a pressure test is not performed. Substituting nondestructive examination procedures for a pressure test after an alteration may be done only after a pressure vessel engineer experienced in pressure vessel design and the authorized pressure vessel inspector have been consulted. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXANS. ORG18 92, List the minirmum tensile stength requirements for filler metals used on vessels weld repairs and the details of this method of repair. (2.11) + The filler metal used for weld repairs should have minimum specified tensile strength equal to or greater than the minimum specified tensile strength of the base metal. If filler metal is used that has a minimum specified tensile strength lower than the minimum specified tensile strength of the base metal, the compatibility of the filler metal chemistry with the base metal chemistry shall be considered regarding weld ability and service degradation. In addition, the following shall be met: + The repair thickness shall not be more than 50 percent of the required base metal thickness, excluding corrosion allowance. + The thickness ofthe repair weld shall be increased by a ratio of minimum specified tensile strength of the base metal and minimum specified tensile of the filler metal used for the repair. © The increased thickness of the repair shall have rounded comers and shall be blended into the base metal using a 3 to | taper. * The repair shall be made with a minimum of two passes. 93, List the requirements associated with re-rating 2 pressure vessel. (73) + Calculations from either the manufacturer or an owner-user pressure vessel engineer (or his designated representative) experienced in pressure vessel design, fabrication, or inspection shall justify re-rating, ‘© A re-tating shall be established in accordance with the requirements of the construction code to ‘which the pressure vessel was built or by computations that are determined using the appropriate formulas in the latest edition of the ASME Code if ail ofthe essential details comply with the applicable requirements ofthe code being used. If the vessel was designed to an edition or addendum of the ASME Code earlier than the 1999 Addenda and was not designed to Code Case 2290 or 2278, it may be re-rated to the latest edition/addendum of the ASME Code if permitted by Figure 7- ‘+ Current inspection records verify that the pressure vessel is satisfactory for the proposed service conditions and that the corrosion allowance provided is appropriate. An increase in allowable working pressure or temperature shall be based on thickness data obtained from a recent internal or on-stream inspection, + The pressure vessel has at some time been pressure tested in accordance with the new service conditions, or the vessel integrity is maintained by special nondestructive evaluation inspection techniques in lieu of testing. ‘+ The pressure vessel inspection and rerating is acceptable to the authorized pressure vessel inspector. 94, When is the re-ating ofa pressure vessel considered complete? 73) ‘© When the API authorized pressure vessel inspector oversees the attachment of an additional, nameplate or additional stamping that carries the following information: Rerated by: Maximum Allowable Working Pressure psi at degrees F. Date 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WHW.APTEXAMS, ORG.19 API RECOMMENDED PRACTICE 576 SECOND EDITION, DECEMBER 2000 REVIEW QUESTIONS Section 1 - General 1. What is the general scope of API RPS76? @ ‘+ To deseribe inspection and repair practices for automatic pressure-telicving devices commonly used in the oil and petrochemical industries. Section 2 — References 2. What document should be referenced to determine the appropriate size for a pressure relief device? @ + RP 520 Sizing, Sclection, and Installation of Pressure-Relieving Devices in Refineries Section 3 — Definitions 3, Describe a pin-actuated device. GB.13) © Anon-reclosing pressure relief device actuated by static pressure and designed to function by buckling or breaking a pin, which holds a piston or plug in place. 4. What is a huddlisig chamber? 3.2.2) + Anannular pressure chamber located downstream of the seat of a pressure relief valve for the purpose of assisting the valve in lifting. 5. Describe “rated relieving capacity”. 836) «The relieving capacity used as the basis for the application of a pressure vessel relief device determined using the applicable code or regulation, Section 4 ~ Pressure-Relieving Devices 6. What is the function of pressure-relieving devices? Ga) ‘+ Toprotect refinery equipment and personnel by automatically opening at predetermined pressures. 7. Name common examples of pressure relieving devices. (4) Direct spring loaded Pilot PRV Rupture disks Weight loaded devices Pressure/Vacoum vent valves 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 © WWW. APTEXAMS. ORG20 8. Name the five types of pressure relief valves. (42,43, 4.4, 46, 4.7) Safety valve Relief valve Safety relief valve Balanced Safety Relief Valve Pilot-operated safety relief valve 9. Describe a safety valve. (4.2\Section VII UG-126 foot notes) Actuated by static pressure upstream ofa valve. Spring fully exposed outside casing to protect from escaping steam, ‘+ Normally not pressure tight on their downstream side, 10, Safety valves should not be used in what situations? (4.22) Corrosive refinery services, Any back pressure service. ‘Where discharge is piped to remote locations. Where escape of lading fluid around blowing valves is not desirable In liquid service As pressure control or bypass valves. 11, Describe a relief valve, (4.3}(Section VII UG-126 foot notes) * Actuated by static pressure upstream of a valve. Lifts in proportion to the increase in pressure. ‘Usually reaches full lift at either 10% or 25% overpressure, 12. Why do relief valves have closed bonnets? (43) * To prevent the release of corrosive, toxic, flammable or expensive fluids, 13, Relief valves should not be used in what situations? (43.2) + Insteam, air, gas, or vapor service. ‘* _Inservices piped to an enclosed header unless the effects of any constant or variable backpressure hhave been accounted for. ‘© As pressure control or bypass valves. 14, There are two types of safety relief valves. What are these two types? (4.5, 4.6) + Conventional & Balanced 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW.APIEXAMS.ORG21 15, Describe a conventional safety relief valve. (4.5) ‘+ Opening pressure, closing pressure and relieving capacity are affected by back pressure. + Hasa closed bonnet ©The bonnet cavity is vented to the downstream side, 16, Where are conventional safety relief valves used? (451) © Refinery process industries that handle flammable, hot, or toxic materials. 17, May a conventional safety relief valve be used on boiler steam drums or super heaters? (4.5.2) + No 18, Describe a balanced safety relief valve. (4.6) ‘+ Balanced safety relief valves are direct spring loaded and incorporate a bellows or other means to minimize the effects of backpressure, 19, What are the proper applications for these pressure balanced safety relief devices: (4.6.1) © Balance safety relief valves are normally used in applications with flammable, hot or toxic materials, where high pressures are present at the discharge of the valve. 20. What is a pilot-operated safety relief valve? (4.7)(Section VIII UG-126 foot notes) * A pressure-relief valve in which the major relieving device is combined with and is controlled by a selF-actuated pressure relief valve (called a pilot valve. 21, What are some applications of pilot-operated safety relief valves? (47.1) Where a large relief area and/or a high pressure is required, Where a low differential exists between normal vessel pressure and set pressure of valves. On large low-pressure storage tanks (See API Std 620). Where very short blow down required. ‘Where back pressure is very high and a balanced design is required. Where the process requires the sensing of pressure at one location and the relief of fluid at another. Where inlet and outlet frictional losses are high. Where in-situ, in-service, set pressure verification is desired. Name some limitations on the use of pilot-operated safety relief valves. = Where fluids are dirty. + Thick or viscous fluid service. * With vapors which polymerize in the valve. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW.APIEXAMS.ORG22 23. What are the three basic categories of pressure and/or vacuum vent valves? (48) ‘* Weight-loaded pallet vent valve ‘+ Pilot-operated vent valve ‘© Spring and weight-loaded vent valve 24, What are the applications and limitations of pressure and/or vacuum vent valves? (48.Land 2. + They are designed to protect atmospheric and low pressure storage tanks and are not generally used in applications requiring set pressures above 15 Ibf7in® 25. Describe the parts of a Rupture Disk Device. 4.9) ‘+The combination of a rupture disk and rupture disk holder is known as a rupture disk device. 26, Name the types of rupture disks. 49) + Conventional Rupture Disk, + Scored Tension-Loaded Rupture Disk, © Composite Rupture dist. © Reverse-Acting Rupture Disk, © Graphite Rupture Disk. 27. What is one advantage of the graphite disk over metal disks? (4.9.15) * High corrosion resistance 28, What is usually the service life of pre-bulged metal rupture disks installed so that pressure acts ess against the concave side? * One year- If not replaced periodically they can rupture under normal pressures without warning 29, Normally the operating pressure of a system protected by a pre-bulged rupture disk is from 65% to aan 85% of the disk's predetermined bursting pressure, What determines this pressure range? * The exact percentage depends on the disk’s type. 30. What precaution should be taken when a rupture disk is used in combination with another relief device and removed for any reason and will be reused? (4.9.3) ‘They should be handled with care to avoid damage which might cause premature rupture. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 | WWW. APTEXAMS. ORG.23 Section 5 — Causes of improper Performance 31. What is the basic cause of many the difficulties encountered with pressure relief devices? 6.1) © Corrosion 32. What effect can the severo over sizing of a relief valve have? (62) 6) = Damaged valve seats. 33. List the major causes of improper performance in pressure-relieving devices. Corrosion Damaged seating surfaces Failed springs Improper seating & adjustments Plugging and sticking Misapplication of materials Improper location, history, or identification Rough handling Improper differential between operating and set pressures Improper piping test procedures 34, To prevent leakage of the lading fluid, what must be maintained in the flainess of seating surfaces on pressure relief valves? (5.2) = An optical precision on the order of 3 light beads/bands, 35, What are some reasons for damaged valve seats? (5.2) Corrosion Forcign particles getting into valve Improper or lengthy piping to the valve inlet or obstructions in the line. Careless handling during maintenance. Leakage past the seating surfaces of a valve after it has been installed. Improper blow down ring settings. Severe over sizing. 36, What almost always causes broken springs in pressure relief valves? 63) Corrosion (Note: two types - surface & stress) 37. What chemical frequently causes stress-corrosion spring fiilure in petrochemical plants? 3) «Hydrogen sulfide (H2S) 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WW. APIEXAMS. ORG38. (33) 39. G4) (55) 41 6.6) (58.1) 43 (3.8.2) 44 (583) 45. (5.10) 08/02 24 ‘What may be done to prevent spring failure due to corrosion? Spring material which can resist the action of the corrosive agent. Spring isolated by a bellows. Spring coated by a coating that can withstand the operating temperature and environment, ‘What medium should be used to set the following pressure relief devices? Safety relief valve - air or other gas, ‘Vapor service valve — air or inert gas. Steam service valves ~ steam but ait may be used if suitable corrections are applied. Liquid service valves ~ water. ‘What is recommended for lubricating sliding parts and threads on valves to prevent fouling? ‘Valve parts should be lubricated with a material that is compatible with the service and temperature. In general, what should be considered in determining the material to be used for pressure-relieving devices? Temperature Pressure Corrosion resistance requirements Atmospheric conditions . Why should relief valves be shipped in an upright position? When relief valves are laid on their sides, the springs may not exert the same force all around the seating surface. What is one important aspect of the work done to PRDs in the maintenance shop? Rough handling should be avoided such as the application of excessive backpressure to bellows type valves, IFRV inlets and outlets are not covered during shipment what provisions should be made? Provision should be made for such covering during all future shipments. What risks are incurred when a hydrostatic test of discharge piping for a PRD is performed? The disk, spring and body area on the discharge side of valve can be fouled. The bellows of a balanced relief valve can be damaged by excessive back pressure. The dome area and/or the pilot assembly of a pilot-operated pressure RV are fouled and damaged by the back flow of the fluid. Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APTEXAMS.ORG25 Section 6 — Inspection and Testing, 46. Name two types of inspections. (6.1) * Shop inspections/ overhauls and visual on-stream inspections. 47, When a relief valve is removed for inspection or overhauls what additional inspection should be made? (6.2) ‘+ Inletand outlet piping should be inspected for internal deposits and records made of their conditions. 48, After a PRV has been reinstalled what should be checked? (6.2.1) ‘+ After reinstalling the related piping should be checked to ensure that itis not imposing loads that ‘would cause problems with the pressure relief valve’s body such as distortion leading to in-service leakage. 49, A complete operating history of each pressure relief valve should be maintained and should inckide what? (623) ‘+ Information on upsets and their effects on the valve, * The extent of any leakage that has occurred in operation, + Any other evidence of malfunctioning, 50. When a relief device is removed from a system that is in operation, name a necessary step to prevent an unexpected pressure release, (6.24) ‘©The space between the relief valve and the adjacent block valve should be vented to release all pressure, 51. What must be done to valves in hydrofluoric acid service as soon as they are removed? ‘+ They must be correctly neutralized immediately after removal. Since inspection of RV piping cannot be done when removing the valve while the system is in service what alternative inspection can be done to check for line any major blockage or fouling? + Radiographic Inspection 53. What can visual inspection of the piping after the removal of a PRD indicate? (62.6) © The condition of the process piping whose interior is not visible, 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS.ORG26 54, Why should caution be used with the rigging to remove a large PRD for maintenance? (6.2.7) + Prevent auxiliary piping and pilot assemblies from being damaged. 55. Prior to pesforming the as received pop test on a PRD what should be inspected and checked? (623) © Check that the seals are intact on the pressure set screw and the blow dowa ring serew cover. 56. When may the as received pop pressure test be waived by the owner/user? (6.28) * When the valve is extremely fouled and the test may damage the valve. 57. When unusual corrosion, deposits, or conditions are noted upon receipt of a PRD at the shop what should be done? (629) + The inspector should participate in the shop inspection of the PRD. 58, When is it nt necessary to disassemble at PRD at the shop? (6.2.10) «Ifthe valve has been tested at the appropriate API 510 interval and the as received pop test shows the valve to be operating properly disassembly is not mandatory. 59, List atleast four of the steps in the inspection of a relief valve upon disassembly. (62.11) Measure cach part’s dimensions, Check components for wear or corrosion. ‘Seating surfaces should be checked for roughness or damage. Springs should be checked for cracking 60. During re-assembly of a pressure relief valve what should never be done? (6.2.12) + The nozzle and seating surfaces should never be oiled. 61. After re-assembly ofa relief device how should any blow down rings be set? (62.13) + Inaccordance with the manufacturer's recommendations 62. Why do some manufucrures recommend at least three pop tests before releasing a relief device for installation? (62.14) ‘© [tis believed thatthe first pop test helps to align all of the components and that the successive tests verify the actual set pressure. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS. ORG.27 63. Once the valve is set to pop at its CDTP (cold differential test pressure) it should be checked for 2 (6.2.15) Leakage and seat tightness by increasing the pressure on the test block to 90% of the CDTP. 64. When applying the hydraulic test method to ASME Section VIII pressure relief valves while on equipment, what precautions should be taken? (62.17) + The potential for failure of the rupture disk in disk/telief valve combinations. * Possible introduction of foreign material into the valve seat are from popping, Possible release of process material to the atmosphere. 65. May a pilot operated pressure relief valve be tested in place ifno block valve exists beneath it? (6.2.19) ‘+ No, it may be inspected and repaired only while the vessel is out of service, 66, Where is a weight loaded pressure and/or a vacuum vent used? (6.220) On pressure storage tanks. 67, What type of failure are pressure and/or vacuum vent valves prone f0? (6.220) = Sticking. 68. Is it permissible to reinstall a rupture disk once it has been unbolted and removed from its holder? (6.2.21) * No, it may not be possible to get a tight seal and unreliable performance is probable. 69. What are the objectives of a visual on-stream inspection of relief devices? (63) + Make sute the correct device is installed, that the correct pressure can be determined, that there are not any blinds or gags installed, that the seals are intact and that the valve is not leaking. Also bellows if so equipped are connected and clear and vent piping is routed to a safe location. Any upstream or downstream block valves are sealed or chained in the proper position. That discharge piping is supported, valve body drains and vent stacks are open, any required lifting lever is present and properly positioned, Any heat tracing or insulation required is in good condition and operational and if a rupture disk is installed itis properly oriented. 70. API 510 establishes the maximum interval between device inspections or tests of 10 years, what else should be considered when setting the frequency of inspection and testing? © The performance of the device in a particular service. 08/02 Rev 8 FAST TRACK TECHNICAL 281.492.2253 WHW.APIEXAMS.ORG28 71. How (64.1.1) the frequency of shop inspoction or overhaul normally determined? ‘+ By the operating experience in the valve’s present service, corrosion service would be more frequent for example, Section 7- Records and Reporis 72. What is the principal objective in keeping records on pressure-relieving devices? an + To make available the information needed to ensure the performance of the devices meets the requirements of their various installations. 73. What should the record for a pressure-reliving device include? (12) ‘Its specification data and a continuously accumulating record of its tests and inspections results. 74. Which of the following per API 576 might be expected to initiate a work request on a PRD? The API inspector or the Process Unit Operator? (73) © Process Unit Operator 08/02 Rev 8 FAST TRACK TRCHNICAL 281.482.2253 WHW.APIEXAMS. ORG29 API RECOMMENDED PRACTICE 572 SECOND EDITION, FEBRUARY 2001 REVIEW QUESTIONS Section 1 - General 1. What are the main points covered in API RP 572? at) Descriptions of the various types of pressure vessels. Standards for construction, Reasons for inspection. Causes of deterioration. Frequency & methods of inspection, ‘Methods of repair. Preparation of records and reports Sections 3, 4, 5 and 6 contain duplicate information to that found in the API 510. You should still read these sections however, at least once. Section 7 - Reasons for Inspection 2. What are the basic reasons for inspection? ly # To-determine the physical condition of the vessel. * Determine the type, rate and causes of deterioration. 3, _Listat least four additional reasons for inspections. (7.4,7.2) © Safety maintained '* Periods of operation without shutdown extended - well planned maintenance program. ‘* Rate of deterioration often reduced ‘+ Future repair and replacement requirements estimated Seetion 8 - Causes of Deterioration 4, List the 4 general forms of deterioration. @D Electrochemical Chemical Mechanical Combination of all three 08/02 Rey 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS. ORC(81) 2 (1) 10. (8.22) 08/02 30 List the 4 general classifications of things that cause deterioration upon coming into contact with a vessel surface. Organic & inorganic compounds ‘Contaminated or fresh water Steam Atmosphere ‘Name 6 factors, which accelerate the rate of deterioration. ‘Temperature Stress Fatigue Impingement High velocity Imregularity of flow ‘What is the prime cause of deterioration in a pressure vessel? Corrasion What are the most common internal corrodents in refineries? Sulfur Sall(Chloride compounds Define erosion. ‘The removal of surface material caused by numerous individual impacts of solid or liquid particles or cavitation, Erosion is typically found where in a vessel? Downstream of control valves Downstream of orifices Downstream of pump discharges At any point of flow direction change, such as impingement baffles. Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW.APTEXAMS.ORG(8.2.3) (8.2.4) 1B. (8.25) (8.2.6) 15. (8.2.7) 18, 31 Problems with environmental cracking have been experienced of high hardness, arcas of high sttess of both, Examples of this include Chloride stress corrosion cracking of austenitic stainless steels due to moisture under insulation, Polythionic acid stress corrosion cracking (PSCC) Caustic stress corrosion also know as caustic embrittlement Amine stress corrosion cracking in non-stress relieved vessels. Carbonate stress corrosion cracking in alkaline systems Wet hydrogen sulfide stress cracking, hydrogen induced cracking, and hydrogen blistering. Corrosion beneath refractory linings can cause what? Bulging of the refractory ‘What does fatigue cracking in a vessel result from? Excessive cyclic stresses the are often below the yield strength of the material such as; Pressure stresses Mechanical stresses ‘Thermal stresses Creep damage may be difficult to detect until Significant damage has occured ‘What facior increases susceptibility to high temperature hydrogen attack in a vessel's material? Increasing carbon content of the materials Inthe absence of, , Sulfide corrosion rates of are relatively low at metal termperatures below Water 450°F ‘When buried vessels are equipped with adequate cathodic protection when will excavation be required for inspection? When evidence of coating or wrapping damage is revealed What are the most important microorganisms that directly influences the rate of metallic corrosion? (8.2.10) 08/02 Sulfate reducing bacteria found in may soils Rev 8 FAST TRACK TECHNICAL 281.482.2253 | WWH.APIEXAMS. ORG19. (83.7) 20. (8.5) 21. (8.5.1) 22, (8.5.2) (8.53) 24. (854) 28. (8.5.5) 32 ‘What causes titanium alloys to lose duetility? Absorption of hydrogen Many of the problems that may develop in pressure vessels are traceable to what? Faulty material or fabrication Poor welding, improper heat treatment, fabrication with dimensions outside tolerances allowed by ASME Coe, improper installation of internal equipment, and assembly of flanged or threaded Joints are examples of what problem? Faulty fabrication List several consequences of improper welding techniques, Incomplete penetration Lack of fusion Cracking Undercutting Slag inclusion Porous welds . High residual stresses near welds affecting the physical properties and corrosion resistance of the metal is caused by what? Improper heat treatment Dimensional intolerance can lead to what? Stress concentrations and subsequent feilures ‘What are the consequences of improper installation of intemal equipment? Inefficient operation Blockage of passages Displacement of internal equipment with pressure surges 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS. ORG33 26, Improper fitting or tightening of flanges or threaded joints may lead to what? (8.5.6) * Leaks and possible failure Section 9 — Frequency and Time of Inspection 27. What are the important factors when determining the frequency with which a pressure vessel should be inspected? * The rate of deterioration © The remaining corrosion allowance 28. What event can provide and opportunity for an inspection? (9.2) * An unscheduled shutdown 29, What occasional check may locate the cause of functional deterioration? Oa ctockota vessels operating cont 30. What are the most important issues when scheduling a unit for inspections? 8) stay and cetbitty Section 10 Inspection Methods and Limi 31, Before starting inspection of a pressure vessel, what are some basic things the inspector should do? (10.1) ‘+ Determine pressure and temperature conditions under which the vessel has operated since last inspection ‘© Ascertain the character ofthe vessel contents end the Function the vessel serves in the process 32, Name at least 8 types of tools required by an inspector to inspect a pressure vessel. (10.2.2) Portable lights ‘Thin bladed knife Broad chisel or scraper Mirrors Calipers Steel tape measure(S0 feet) Hammer Notebooks and pencils 33. Where should the external inspection start? (105.2) ‘+ External inspection should start with ladders, stairways, platforms, or walkways connected to or bearing on the vessel. ‘The condition of most parts can be determined by hammering, 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 © WHW.APIEXAMS. ORG34 34, What are most foundations constructed of? (10.3.3) + Foundations for vessels are almost always constructed of steel-reinforced concrete structural steel fireproofed with concrete. 35. Cracks in concrete or fireproofing may be caused by what? (10.3.3) Excessive heat ‘Mechanical shock Corrosion of reinforcing steel Freezing of entrapped moisture 36. What types of vessels are most likely to experience uneven settling of their foundations? 03.3) * Vessels supported on long concrete slabs or on two or more separate foundations. 37. What is the proper way to check an anchor bolt ona piece of equipment for deterioration below the base plate? 03.4) + Asideways blow with a hammer 38, Often corrosion of structural elements can be virtually eliminated by a simple procedure, which is? (10.3.6) © Proper painting 39. A bulge in fireproofing is noted on steel structural member, what does that indicate? (203.6) + Corrosion beneath the fireproofing is present. 40. ‘The inside surface of a skirt is may be subject to corrosion, below what temperature is this likely? (103.6) + 100°F 41, What should you inspect guy wires for? 10.3.7) ‘+ Tightness and correct tension - a visual inspection should be sufficient. 42. What type of corrosion are turnbuckles subject to? (003.7) © Crevice corrosion 08/02 Rev @ FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS. ORG35 43, Ifsettling ofa vessel has occurred, what should be checked for distortion and cracks? (103.8 = Nozzles 44, What is the recommended resis (10.3.9) ce for grounding connections? © Sohms or less, not to exceed 25 ohms 45, Unchecked vibrations on auxiliary equipment such as gauge connectors can cause what type of failure? (103.10) © Fatigue failure 46. What type of inspection is usually sufficient for protective coatings and insulation? (103.11) © Visual 47, At what operating temperature does CUI become a concern on externally insulated vessels subject to moisture ingress? (203.11) * Between 25 to 250°F 48. What are the normally required measurements on extemal metal surfaces of a vesscl? (10.3.12) * Under normal conditions, at least one measurement in each shell ring and one on each head. Ifno history exists for a vessel, then geta reading in each quadrant of each shell ring. 49. What types of corrosion are found on external surfaces of vessel? (103.13) © Atmospheric + Caustic Embrittlement + Hydrogen blistering * Soil corrosion 50, Vessels containing acidic corrodents are subject to hydrogen blistering, Where is this normally found in the vessel? (103.13) ‘© Those areas below the liquid level in vessels containing acidic corrodents are more likely than other areas to be subject to hydrogen blistering. Blisters are normally on the inside, but can occur on the outside surface as well. 51. What should a vessel be checked for ifa caustic is stored in it? (10.3.13) + Ifa caustic material is stored or used in a vessel, the vessel should be checked for caustic ‘embrittlement, 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WW. APIEXAMS. ORG36 52. Evidence of white salts seeping through cracks will indicate what type of material?” (103.13) © Caustic material 53. Unless readily visible, leaks are best found by what means? (103.13) © Pressure or Vacuum testing 54, Describe how you would determine the extent of bulging or buckling on a vessel in service. (10.3.13) ‘+ By measuring the changes in circumferences or by making profiles of the vessel wall. Profiles are ‘made by taking measurements from a line parallel to the vessel wall. A surveyor’s transit ora 180 degree optical plummet may also be used. 58, ‘The degree of surface preparation needed for internal inspection will vary with several fuctors. Foremost among these are: (10.4.2), ‘= Type of deterioration expected © Location of any deterioration 56. Cracks in vessels are most likely to occur where? (10.4.3) + Inplaces winere there are sharp changes in shape or size or near welded seams, especially if@ high stress is applied. 57. What may preliminary inspections reveal? (10.4.3) * Unsafe conditions, such as those due to loose internals that may fall or due to badly corroded or broken internal ladders or platforms. 58. A detailed inspection should start at one end of the vessel and work toward the other end and include what? (10.4.4) ‘+ A systematic procedure to avoid overlooking obscure but important items. 59. What should all parts of a vessel be inspected for? (10.4.4) + Corrosion + Erosion + Hydrogen blistering + Cracking + Laminations 60. Some times the depth of a pit can be estimated by using what simple method? (10.4.4) + Extending the lead of a mechanical pencil 08/02 Rev @ FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS. ORG.37 61. What types of methods are used for determining the extent of cracks? (0.4.4) Dye penetrant Magnetic-particle (wet or dry) Ultrasonic shear-wave 62, Explain the difference in appearance between erosion and corrosion. (10.4.4) + Erosion is characterized by a smooth, bright appearance: marked by the absence of the erosion product; and metal loss, is usually confined to a clearly marked local area. + Corroded areas are not often smooth or bright. 63. Shells and heads of vessels should be inspected for deformation. Which is more likely to suffer deformation? (8.44) The shell ofa vessel 64, How do you check for (a) small distortions, (b) bulging or buckling (c) out-of-roundness or bulging? (10.4.4) ‘Small distortions - by placing a straight edge against a vessel Bulging/buckling - measuring the changes in circumference or by profile (measuring from a line strung parallel to the vessel) © Out-of round/bulge - by measuring the minimum and maximum internal deviation at the cross sectional area and comparing the two. 65. What is the best method of locating suspected deformations? (10.4.4) * Direct flashlight beam parallel to the surface to check for shadows in depressions and on the nnon-light sides of internal bulges. 66, What is the most sensitive method of locating surface cracking? (10.4.4) ‘+ Fluorescent Magnetic Particle Method. G7. What is the difference between cracks and laminations? (10.4.4) ‘+ Laminations run at a slant to the plate surface. + Cracks run at right angles to the surface. 68, Name three important factors in the inspection of metallic linings. (10.4.5) That there is no corrosion + That the linings are property installed ‘+ That no holes or cracks exist. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW, APTEXAMS. ORG38 69. Explain how the Corrosive Tab Method is used to determine the metal loss on vessel linings. (104.5) ‘© Small | by 2 inch tabs of lining that forma right angle are welded onto the lining with one leg extended into the vessel. During inspections the thickness of the protruding log is measured, and, since both sides of the leg are exposed to corrosive action, the loss in thickness would be twice that of the lining 70, What is the principle method used to inspect nonmetallic linings like glass, plastic, rubber, concrete, and carbon block of brick. (10.4.6) ‘© Forthe most part all of the above will be visuelly inspected for discontinuities or physical damage, Specific: For paint, glass, plastic, & rubber lining the spark tester method is used to locate holidays. For concrete, brick, tile, or refractory lining the hammer testing method is used to locate lack of bond. 71. Name the factors to consider when selecting tools for thickness measurements. ‘© Accessibility from both sides. ‘+ Desire for NDE methods, = Accuracy desired, ‘+ Time available. + Bconomy 72. What is the primary means of obtaining thickness measurements? © Ultrasonic instruments, 73. To analyze defects in welded seams that are not visible on the surface of the metal, what two methods are used?” Radiography. Shear-wave Ultrasonic. 74, How does the Hammer Test function in supplementing visual examination of a vessel for the inspector? (10.8.1) "Thin" - Locate thin sections in vessel walls, heads, and attachments, "Tightness"- Check for tightness of rivets, bolts, brackets. "Cracks and Lack of Bond” ~ Check for cracks in metallic linings and lack of bond in concrete lining: = Remove scale accumulations for spot inspections. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APTEXAMS. ORG39 75. When is use of the Hammer Test not recommended? (10.8.1) © When vessels are under pressure, ‘© On piping upstream froma catalyst bed. 76, What is pressure testing? (1082) ‘+ Filling a vessel with liquid or gas end building up an intemal pressure to 2 desired level. 77. Which is the preferred method, pressure or vacuum testing, and why? (0.8.2) ‘© Pressure testing. Leaks from an internal pressure source are more easily located, With vacuum testing you will know if there are leaks, but the location is not evident. 78. What should an inspector examine before applying test pressure to the shell side of an exchanger? (10.8.3) ‘© He should inspect the tube walls to be sure there is sufficient wall thickness to withstand external pressure, 79, In an exchanger where the cooling water is the lower pressure stream and a hydrocerbon is the higher pressure stream, what is a possible way to detect a leak? (10.8.3) + Itmay be possible to assess the hydrocarbon content upstream and downstream of the suspect exchanger. 80. Name the two most limits of corrosion or other deterioration that must be known by inspection. + The retiring thickness of the part considered. «The rate of deterioration. 81. Often vessels have excess thickness above that required for pressure. When taking credit for this excess thickness what must always be considered? (0.9) + In some eases the excess thickness of the shell or head plates was used by the designer 10 compensate for nozzle openings. 82, Before determining the limiting or retiring thicknesses of parts of any pressure vesscl, what must be known? (19.9) Which Code and edition of that Code it is to be rated under. Are there specific regulations regarding limits and allowable repairs. 08/02 Rev 8 FAST TRACK TECHNICAL 281.492.2253 WHW.APTEXAMS.ORG40 Scetion 11 - Methods of Repair 83. When is it required that a repair concem making welded repairs to a vessel have a National Board R stamp? ql) ‘© When the jurisdiction dictates that the these repairs are to made by only R stamp holders 84, When is a pressure test of a vessel normally a requirement? an © After an alteration Section 12 - Records and Reports 85. A complete record file should contain what thtee types of information? 2.) ‘+ Basie data —manufecturer's drawings, data reports and specifications, design information, results of any material tests. ‘+ Field notes - notes and measurements recorded on site including record of condition of all parts inspected and repairs required. ‘+ Continuous file - all information on the vessel's operating history, previous inspections, corm rate tables, records of repairs and replacements, 86. When making reports recommending repairs, who should receive these reports? (2.2) * All management groups. This would normally include engineering, operation, and maintenance departments. Reports should include the location, extent, and reasons for recommended repair. Appendix A - Exchangers 87. Why should bundles be checked when they are first pulled from the shells? (A9.1) * The color, type, amount, and location of scales and deposits often help to pinpoint corrosion problems, 88. A distinctive Prussian blue on bundle tubes indicates the presence of what? (A9.2) * Ferriferrocyanide 89, Coils in open condenser boxes and double-pipe exchanger shells should be inspected according to what API Recommended Practice? (A10) © RPS74 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS. ORG.aL CHAPTER CONDITIONS CAUSING DETERIORATION OR FAILURES SECOND EDITION, 1973 201 General 1. What are the modes of failure that can be found in refinery equipment? (201.2) + Fatigue Failures - caused by stress reversals. (In machinery these cracks start at the surface and progress with each stress reversal.) + Distortion Failure - occurs when equipment is subjected to temperatures above design temperature. (At high temperatures the metal becomes weaker and distortion occurs which may result in failure.) * Brittle Fracture - carbon steels are susceptible to brittle fracture at ambient temperatures and below. (A number of tank failures have been attributed to the brittle condition of steel at low ‘temperatures, combined with high loads thet have been imposed by thermal stress set up rapid temperature changes.) ‘+ Excessive Metal Loss - may result in failure if remaining wall thickness gets below safety valve settings. This is a rare occurrence. ‘+ Wrong Material or Wrong Gaskets - may lead to failure. 202 - Corrosion 2. Corrosion problems in refining operations can be divided into three major groups. What are these groups? : (202.1) © Corrosion from components present in crude oil. © Comosion from chemical used in refinery processes. ‘* Environmental corrosion, 3, Name the corrosion compounds found in crude oil. (202.01) Hydrogen Chloride end organiclinorganic chloride, Hiydrogen sulfide, mereaptans, & organic sulfur compounds, Carbon dioxide Dissolved oxygen and water. Ongenic acids. Nitrogen compounds 4. What is hydrogen chloride? When does it become a corrosion problem in process streams? (202.022) © A dry hydrochloric acid (normally not corrosive in process streams), It becomes corrosive when water is available to form hydrochloric acid. 5. What do all crude oils contain? (202.022) © Salt 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEMAMS. ORG42 6. What is the most active of the sulfur compounds in causing corrosion in refinery equipment? (202.023) + Hydrogen Sulfide 7. At what temperature range does accelerated hydrogen sulfide corrosion occur in refinery equipment? (202.023) © Between 450 and 900 °F 8, What makes earbon dioxide corrosive? (202,024) © When itis combined with water, it becomes carbonie acid. 9. Where is corrosion by carbon dioxide found to be most severe? (202,024) + Inhydrogen plants, 10, Dissolved oxygen and water is a corrosion problem in what equipment? (202.025) * Storage tanks. LL, When are organic acids very corrosive? (202.026) + Attheir boiling temperatures. ‘The most severe form of corrosion occurs upon condensation. 12, What two forms of corrodens ae formed when nitrogen is cracked ina cracking or catalytic cracking 202027) ‘+ Ammonia & Cyanide 13, What is phenol and what is it used for? (202.033) + Carbolic acid - Used in refinery operations in the manufacture of lubricating oils and aromatics. 14, What is caustic and what is it used for in refinery operations? (202.035) * Sodium Hydroxide - Used for the neutralization of acid components and for grease manufacture, 15, When ammonia is permitted to contact copper base alloys in pH ranges of 8.0 and above, severe corrosion in three form of general metal loss and stress corrosion cracking will occur. How may this attack bbe identified? (202.037) + By the appearance ofa blue salt deposit on the metal’s surface. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS. ORG43 16. What are the primary uses of ammonia in the refining industry? (202.037) + Asa refrigerant + For neutralization of acidic components in overhead streams, from pipe stills, and catalytic cracking units. 17. What materials is ammonia harmful to? (202.037) + Copper base alloys. 18. What is chlorine used for in refinery operations and when does it become very corrosive? (202.038) ‘© Used for treating cooling water and for the manufacture of sodium hypochlorite for treating oils. It becomes very cortosive in contact with small amounts of moisture 19, Aluminum Chloride - What is it used for? What does it form in the presence of water? How does it affect carbon stee! and stainless steels? (202.039) © Used as a catalyst in isomerization units .t forms hydrochloric acid in the presence of water. Hydrochloric acid causes severe pitting corrosion in carbon steel and intergranular and stress corrosion cracking in stainless. 20. What is the term applied to atmospheric corrosion? (202.041) © Galvanic. 21, What is needed to prevent atmospheric corrosion? (202.041) «Eliminate water from the surface of the metal by means of a protective barrier or coating, 22, At what temperature does hidden corrosion take place under insulation and fireproofing if moisture penetrates through cracks in the insulation? (202.042) + Invessels and piping operating below approximately 250 "F. 23, When does oxygen become destructive? (202.052) + Athigh temperatures oxygen reacts with steel to cause scaling (iron oxide). 24, Why may steam at high temperatures cause scaling? (202.053) Because the steam may be decomposed to hydrogen and oxygen, and the free oxygen may cause severe scaling 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WHW.APTEXAMS. ORG44 25. Vanadium oxide corrosion does not take place below what temperature? (202.054) + 1,100°F 26, The extent corrosive attack by hot sulfur compounds (sulfur dioxide, hydrogen sulfide) depends on ‘what three things? (202.055) + Concentration, temperature, and oxidizing power of the environment. 27. At what temperature does all gray cast iron begin to deteriorate, resulting in extreme brittleness, loss of strength, scaling, and growth? (202.056) + 800° 28. Growth of cast iron results from what two things? (202.056) ‘+ Graphitization & infiltration of corrosive gases into the structure. 29, What is graphitic corrosion? (202.063) © Low temperature corrosion of gray cast irons in which metallic iron is converted into corrosion products, eaving the graphite intact. 30. In what material do you find graphitic corrosion and at what temperature does it occur? (202.063) ‘+ Incast iron at temperatures below the dew point of water. 31. How can you recognize graphitic corrosion? (202.063) ‘© By the soft porous structure that remains inthe areas where it occurs. 32, What materials is mercury harmful to? (202.064) ‘© Monel and copper based alloys (stress corrosion cracking) © Aluminum alloys. 33. Define Stress Corrosion Cracking, (202.064) © The spontaneous failure of metals by cracking under the combined action of corrosion and tensile stress, 08/02 Rev @ FAST TRACK TECHNICAL 281.482.2253 WW. APIEXAMS. ORG45 34, What is dezincification? (202.066) A type of corrosion that can occur in copper - zinc alloys (brasses) containing less than 85% copper and used in water service. 33. What are three types of dezincification? (202.066) + Plug - occurs in localized areas. = Layer - covers large areas. ‘© Intererystalline - occurs along grain boundaries. 36. What are inhibited brasses? (202.066) ‘© Brasses which have been alloyed with arsenic, antimony, or phosphorus to inhibit dezincification. 37. What is galvanic corrosion? (202.087) * Anelectrochemical type corrosion that occurs witen two different metals are electrically connected, either by direct contact or by an electrical conductor, and are in contact with an electrical solution called an "electrolyte". 38. What is contaet corrosion (crevice corrosion)? (202.068) © Atype of corrosion that occurs at the point of contact or in a crevice between a metal and nonmetal or between two pieces of metal in the presence of a corrodent. 39. Whats biological corresion? (202.069) © Corrosion influenced by primitive organisms. 40. What are the most important microorganisms that directly influence the rate of metallic corrosion’ (202.069) ‘+ Sulfate reducing bacteria found in many soils, 203 - Rrosion 41, Erosion is frequently a problem in equipment utilizing the fluidized - solids principle. What is this principle? (203.02) + Ifa gas stream of sufficient velocity is passed through a mass of finely divided solids, such as a powder, the mass of particles will bebave very much like 2 trae liquid. 42, What method of deterioration does cavitation induce? (203.022) + Erosion. Cavitations erosion is associated with the formation and collapse of cavities in a liquid at the metal to liquid interface. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS.ORG46 204 - Effects of High Temperatures 43, Define creep. (204.012) ‘© The flow or plastic deformation of metals held for long periods of time at stress lower than the normal yield strength. 44. A stress - rupture is what type of failure? (204.013) + A brittle type failure - stress rupture relates the time to failure with temperature and stress. 45, When austenitic stainless steels are heated or cooled in the temperature range of 750 to 1,650°F, what does this make the material susceptible to? (204.022) © Intergranular corrosion, 46, When ferritic steels are heated above a certain temperature (above 1,100 °F for mild steel), how does this affect the material? (204.022) Leads to general lowering of the tensile strength, 47. What is incipient melting (burning)? (204.022) ‘+ When ferric steels ate heated above approximately 2,600 °F, melting and oxidation will begin at the grain boundaries. The stee! is called "burned!" and will be very weak and brittle upon cooling, 48. What is Graphitization? (204,022) ‘+ A structural change in certain ferritic steels that have operated for a long period of time between 825 and 1,400 °F. Carbide is unstable in that temperature range and may decompose into iron (ferrite) and graphite (carbon), 49, What are the two general types of Graphitization? (204.022) + Random Graphitization - graphite distributed uniformly throughout the steel. ‘© Localized Graphitization - graphite highly concentrated in local regions. 50, What is Sensitization? What happens to sensitized steel when exposed to corrodents? (204.022) © When Austenitic stainless steels arc exposed to temperatures of 750 to 1650 °F, precipitation of complex chromium carbides at the grain boundaries takes place. When the sensitized steel is exposed to comrodents, intergranular corrasion takes place. 08/02 Rev 8 FAST TRACK TECHNICAL, 281.482.2253 WHW.APIEXAMS, ORGa7 51, What is decarburization? (204.034) ‘* The loss of carbon from the surface of a ferrous alloy as a result of heating in a medium that reacts with carbon, This results in lower tensile strength, hardness , and fatigue strength. It can only be found by metallurgical examination. 52. At what temperature does hydrogen have a very destructive effect on steels? (204.035) © Above 450°F 53. What curve shows the different steel/temperature limits for hydrogen service? (204.035) © Nelson Chart 205 - Subnormal and Ambient Temperature Effects 54. Define notch toughness (a property of metals). (205.01) ‘+ The amount energy necessary to cause fracture in the presence of a sharp notch or stress concentrator. 55. Brittle fracture can be recognized by several characteristics. What are these characteristics? (205.01) Cracks propagate at high speed. There may be a loud report or sharp tending sound, There is almost a complete lack of ductility ‘The fractured surface has a brittle or faceted surfice. 206 - Excessive Pressure 56. What is excessive pressure? (206.01) Those in excess of the MAWP of the equipment under consideration, 57, Name four causes of excessive pressure. (206.021; 206.022; 206.023; 206.024; 206.025) a, Added heat in excess of normal operations b. Blocking off against a pressure source ¢. Thermal expansion of a trapped liquid. 4. Hydraulic hammer or resonant vibration. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS.ORG48 207 - Overloading 58. What are some indications of overloading of equipment? (207.02) + Visible distortion, © Change of shape. ‘© Change of position. Appendix 1 ‘59, Steel (ferrous alloy) is an alloy of iron and carbon, What is the carbon content range? (App L.A) © 0.01% to 1.7% (Max. carbon content of weld able steels for Code purposes is 0.35%) 660. Usually for refinery construction steels have less than what percent carbon? (App 1.A) © Less than 1%, 61. Steels for w (App 1.4) ing have a maximum of what percent carbon content? = 035% 62. There are two general types of steels. What are these? (App LA) ‘+ Ferritic Steel - ordinary carbon steel, low and intermediate alloy steels, and high alloy steels (straight chromium), © Austenitic - chromium - nickel stainless steels. 63, Nonferrous metals and alloys contain what percent iron? (App 1B) = Less than 50% 64, What is the only common copper - nickel alloy and what is it used for? (App 1B) ‘* Monel It is used for relatively low temperature corrosion resistance. 65. What are the major uses of commercially pure copper in refineries? (App 1B) + Electrical conductors, gaskets, and corrosion resistance, (66, What are the major uses of aluminum and its alloys in refineries? (App 1B) © Corrosion resistance and for structures which lightweight is a necessity. 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS. ORG.49 CORROSIVE MATERIALS AND THEIR USES IN THE PETROCHEM INDUSTRY © Sulfurie Acid and Hydrogen Fluoride - used in alkylation’s units as a catalyst, Concentrations of 85% to 95% for sulfuric acid and above 65% for hydrogen fluoride. * Phenol (Carbolic Actd) - used for the manufacture of lubricating oils and aromatic hydrocarbons. * Phosphoric Acid - used for a catalyst in polymerization units. ‘© Caustic (Sodium Hydroxide) - used for neutralization of acidic components * Mercury - used in instruments + Ammonia - used 2s 2 reftigerant and for the neutralization of acidic components, ‘© Chlorine - used to treat cooling tower water and for the manufacture of sodium hypochlorite used to treating oils. ‘© Aluminum Chloride - used as 2 catalyst for isomerization units. 08/02 Rev 8 FAST TRACK TECHNICAL 261.482.2253 WHW.APTEXAMS. ORG50 THIS PAGE LEFT INTENTIONALLY BLANK 08/02 Rev 8 FAST TRACK TECHNICAL 281.482.2253 WHW.APIEXAMS. ORG.ASME SECTION IX EXERCISES, THE FOLLOWING EXERCISES ARE COMMON TO BOTH THE API 510 AND API 570 EXAMINATIONS. THESE EXERCISES SHOULD BE WORKED AS THE CANDIDATE PROGRESSES THROUGH THE READING OF THE SECTION IX PARAGRAPHS APPLICABLE TO THESE EXAMINATIONS. 04/02 Rev 6 Fast Track Technical 1ASME SECTION IX EXERCISES TASK #1 Read the following paragraphs then answer the questions. General Requirements QW-100 thru QW-195 1.The cut surfaces of guided-bend test specimens is designated as the: (a) sides. (b) face. (c) root. 2. What is the angular deviation for groove weld tests from the specified inclined plane? (a) None ° (b) £5°) is what (a) WPS-PQR-WPQ (b) WPS-WPQ-WPS (c) WPS-PQR-WPS 4. What Figure Number is used for procedure qualification, reduced-section tension tests specimens, for pipe having an O.D. greater than (a) OW-462.1 (a) (b) QW462.1 (b) (c) QW462.1 (c) 5. Where are notch-toughness requirements for the specimen, orientation and acceptance criteria found? (a) ASTM E208 (b) SA-370 (c) Construction Code 6. The radiographic acceptance criteria for welders qualified in accordance with QW- 142 is found in: (a) The Construction Code (b) QW-191.2.2 (c) QW-192,2 04/02 Rev 6 Fast Track Technical 2ASME SECTION IX EXERCISES TASK #1 7. The qualification of a new WPS or the re-qualification of an existing WPS shall be in accordance with the: (a) component contract date. (b) current Edition and Addenda of Section IX. (c) 1962 or later Edition of Section IX. 8. In relation to the surface of the plate or pipe, what is the required test position orientation of a stud during welding? {a) Perpendicular to the surface. (b) £15 “from the specified horizontal plane (c) +15 ° from the specified vertical plane. 9. How is the minimum specimen curvature of guided-bend jig specimens verified’? (a) A 1/8" diameter wire cannot be inserted between the specimen and the die (b) A 1/8" diameter wire cannot be inserted between the specimen and the plunger. (c) The specimen is bottomed ejected. 10. How is the tensile strength of a tension test specimen computed? (a) Dividing the maximum load by the least cross-sectional area of the specimen as measured before the load is applied. (b) Dividing the maximum load by the least cross-sectional area of the specimen as measured after the load is applied. (c) Measuring the percent of outer fiber elongation as required by the construction Code. 11. What pipe fillet weld test positions are not to be rotated during welding? (a) 2F-3F-4F-5F (b) 1F-3F-5F (c) 2F-4F-5F 12. What pipe fillet weld test positions are allowed to be rotated during welding? (a) 1F-2F-2FR (b) 1F-2FR-3F (c) 1F-2FR 04/02 Rev 6 Fast Track Technical 3ASME SECTION IX EXERCISES TASK #14 13, Procedure and performance macro-examination specimens are etched to give clear definition of. {a) weld metal and heat affected zone. (b) inclusions and porosity. (c) root of the weld. 14. Under what conditions are tension tests considered acceptable if the specimen breaks in the base metal outside the weld or fusion line? (a) If there are no open defects exceeding 1/16" measured in any direction. (b) If the strength is not more than 5% below the specified minimum tensile strength of the base metal. (c) If there are no open defects exceeding 4/8" in the bond line. 04/02 Rev 6 Fast Track Technical 4ASME SECTION IX EXERCISES TASK #2 Reading: General Requirements QW-100 thru OW-195 41. Under what conditions may a WPS PQR or WPQ qualified in accordance with the 1957 Edition be used? (a) When they meet the requirements of the 1962 or any later Edition. (b) After they have been revised to reflect the latest Edition of Section IX. (a) Not permitted 2. The methodology for the qualification of welders and welding operators by radiography are given in: (a) QW-191.2 (b) Article 2, Section V (c) The construction Code 3. When may longitudinal-bend tests be used in lieu of transverse guided-bend tests to qualify a WPS? (a) When the axis of the weld is transverse to the longitudinal axis of the specimen. (b) When the weld metal or base metal combinations differ markedly in bending properties between the two base metals or the weld metal and base metal. (c) When the axis of the weld is parallel to the longitudinal axis of the specimen. 4, The dimensioning requirements for reduced-section tension specimens for pipe having an O.D. less than 3 in. are found in; (a) QW-462.1 (a) (b) QW-462.1 (b) (c) QW-462.1 (c) 04/02 Rev 6 Fast Track Technical 5ASME SECTION IX EXERCISES TASK #2 5. Welding procedures qualified in accordance with the 1974 Edition needs to be amended or revised to the Edition mandated for construction. (a) True (b) False | 6. What is the angular deviation in groove weld test positions from the specified horizontal and vertical planes during welding? (a) #5° (b) +10° (c) #15" 7. Tension tests and Guided-Bend tests are two mechanical weld tests which employ type weld joint configurations. (a) stud (b) groove (c) filet 8. What are the test orientations of pipe groove welds? (a) 1 G-2G-56-6G (b) 1 G-3G-56~66 (c)1 G-26-36-46 9. What is the purpose of the welding operator's performance qualification? (a) To determine the operator's ability to deposit sound weld metal. (b) To determine the operator's mechanical ability to operate the welding equipment. (c) To determine the WPS is capable of producing the required mechanical properties. 04/02 Rev 6 Fast Track Technical 6ASME SECTION IX EXERCISES TASK #2 10. What dimensional requirement is there for the guided-bend test jig mandrel being used on specimens wider than 1-1/2"? (a) At least %4" wider than the specimen width: (b) At least 1/8” wider than the specimen width. (c) At least % ‘wider than the specimen width. 14. The substitution of radiography for mechanical testing is permitted for welder and welding operator performance qualifications except as restricted by QW-304 & 305. (a) True (b) False 12. At what base metal thickness shall the multiple turned tension specimens be used? The specimens are cut through the full thickness of the weld with their centers parallel to the metal surface and not over 1" apart. (a) 5/8" (b) > 1" ()5/8" 8. A butt welded coupon consisted of 1-1/2" carbon steel and %" stainless steel base metals, what base metal thickness range does this coupon qualify? (Notch toughness is not a requirement). (a) 1/16" to 8" for both metals, (b) 1/16" to 1/2" for stainless steel 3/16" to 8" for carbon steel. (c) 1/16" to 1/2" for stainless steel 3/16" to unlimited thickness for carbon steel. 9. An organization's operational control of welding procedure qualification for two or more companies of different names shall be defined in their (a) Manufacturing Procedures (b) Quality Control System (c) Qualified Supplier's List 04102 Rev 6 Fast Track Technical BASME SECTION IX EXERCISES TASK #5 10. What is the purpose of assigning Group Numbers to base metals? (a) To classify the different base metal Grades. (b) To classify the metals within P-No's. for the purpose of procedure qualification where notch-toughness requirements are specified, (c) To simplify the identification of ASTM materials. 11. In procedure qualification; groove weld qualifications on 1/2” plate qualify fillet welds for in base metal thicknesses and in diameters on pipe and tube. (a) 118"to 1", 2 7/8" O.D. and over (b) All, All (c) All, 2 7/8" O.D. and over (d) 1/16" to 1”, all 12. The is a true record of the variables that were used during the welding of the test coupon and that the resulting tensile, bend or macro-etch (as required) test results are in compliance with Section IX (a) WPS (b) PQR. (c) WPQ (d) All of the above 04/02 Rev 6 Fast Track Technical “4ASME SECTION IX EXERCISES TASK #6 Reading: Performance Qualifications QW-300 thru QW-383 1.What are the retest requirements for a welder who has failed his renewal qualification test after he has received additional training or practice? {a) Complete requalification in accordance with QW-301. (b) A new test shall be made for each position he failed. (c) Weld a single test coupon of either plate or pipe. 2. What is the length of a welder's first production weld that needs to be radiographed for qualification? (a) 3° ()3" (c) 6" 3. What is the extent of radiography for a welder who is qualified by radiography? (a) 3' and shall include the weld circumference for pipe. (b) 3" and shall include 1/2" either side of the weld on plate. (c) 6" and shall include the weld circumference for pipe. 4, By what method does a Manufacturer identify the work of a welder or welding operator? (a) By assigning an identification number, letter, or symbol. (b) By having the welder or welding operator initial the traveler or process sheet (c) This is no longer required 5. How are the thickness limits determined for a welder when qualified using multi- process procedure? (a) By the thickness of the weld he deposits with each welding process; in which this thickness shall be considered the test coupon thickness as given in QW - 451. (b) By the thickness of the weld he deposits with each welding process, in which this thickness shall be considered the test coupon thickness as given in QW - 452. 04102 Rev 6 Fast Track Technical 5ASME SECTION IX EXERCISES, TASK #6 6. Using a combination procedure a welder may be qualified with each individual welding process in separate test coupons, or with a combination of welding processes in a single test coupon. (a) True (b) False 7. Welders and welding operators who pass the tests for groove welds are qualified for what groove and fillet weld positions? (a) The positions of groove and fillet welds shown in QW-461.9. (b) In all thicknesses of material, sizes of fillet welds, and diameters of pipe and tube 2- 7/8" and less. (c) In all thicknesses of material sizes of fillet welds, and diameters of pipe and tube 2- 7/8" and over. 8. The three methods by which a welder or welding operator may be qualified are of initial production weld, radiography of or taken from a test coupon. (a) radiography-test coupon-bend tests (b) bend tests - test coupon-tension tests (c) tension tests-test coupon-bend tests 9. What welding positions on pipe test coupons omit the specimens in the upper right and lower left quadrants, and replaces the root bend specimen in the upper left quadrant with a face-bend? (a) 2G or 5G (b) 1G or 26 (c) 5G or 6G 10. What are the immediate retests required if a welder fails the mechanical tests of QW-302.1 or radiography examination of QW-302.2? (a) Mechanical tests. (b) Mechanical tests and radiographic examination respectively. (c) Radiographic examination. 04/02 Rev 6 Fast Track Technical 16ASME SECTION IX EXERCISES. TASK #6 11. With the exception of GTAW, what P-Nos. are prohibited in the qualification of welders by radiography? (a) P-2X, P-4X, and P-5X (b) P-2X, P-3X, and P-5X (c) P-2X, P-5X, and P-6X 12. Machine welding is classified as a category. (a) manual (b) welding operator (c) semi-automatic 13 A welder who welds in only one position for more than six months loses his qualification in other positions for which he is qualified in a given process. (a) True (b) False 04/02 Rev 6 Fast Track Technical 17ASME SECTION IX EXERCISES, TASK #7 Reading: Performance Qualifications ‘QW-300 thru QW-384 1. Performance qualifications conducted in special orientations are valid for the special position actually tested and the , except that an angular deviation of is permitted in the inclination of the and the rotation of the (a) vertical position + 5 ° weld axis production piece (b) fiat position +5 ° production piece weld fixture (c) flat position 15 ° weld axis - weld face. 2. What option does a Manufacturer have if a welder fails the production weld alternative of QW-304.1? (a) Radiograph an additional 6” of the same production weld. (b) Radiograph an additional 12" of the same production weld. (c) Radiograph an adcitional 12" of the same production weld. 3. If the radiograph of the alternative production weld used for qualification does rot meet the radiographic standards: (a) Radiograph an additional 6” of the same production weld. (b) The welder shall be retested by mechanical tests. (0) The welder has failed the test, requiring RT of all his production welds and repaired by a qualified welder. 4. What is the intent of performance qualification tests? (a) To determine the ability of welders and welding operators to make sound welds. (b) Provide direction to the welder or welding operator. (c) To prove the mechanical properties of the weldment. 5. Why is the Manufacturer responsible for conducting tests to qualify welders and welding operators in accordance with a qualified WPS which his organization employs in construction? (a) The welder's performance is not transferable from employer to employer, (b) To assure that they are capable of developing the minimum requirements specified, (c) The responsibility of the qualifying welders can not be delegated to another organization. (d) All of the above. 04/02 Rev 6 Fast Track Technical 18ASME SECTION IX EXERCISES TASK #7 8. A welder shall be re-qualified whenever a change is made in one or more of the variables listed for each welding process (a) essential (b) supplemental essential (c) essential and nonessential 7. Awelder may be qualified by radiographic examination in the GMAW process with short-circuiting mode. (a) True (b) False 8. What information shall as a minimum be recorded on the WPQ? (a) Essential and nonessential variables for each welding process. (b) Essential variables, type of tests and test results, and the ranges qualified. (c) Essential and nonessential variables, type of tests and Fig. No.’s, and the ranges qualified. 9. When performance qualification is done in accordance with a WPS that requires preheat or post weld heat treatment, these may be omitted. (a) True (b) False 10. What are the requalification requirements for a welder who has had his qualifications revoked because there was a specific reason to question his ability to make sound welds? (a) Weld a single test coupon of either pipe or plate, of any material, thickness or diameter, in any position. (b) Weld a test coupon appropriate to qualify him for the production work he will do and tested in accordance with QW-301 and QW-302. (c) May be extended when welding with another process. 04/02 Rev 6 Fast Track Technical 19ASME SECTION IX EXERCISES TASK #7 44. What position limitations are placed on the welder if he prepares the WPS qualification test coupons? (a) Qualification of the WPS in any position qualifies for all positions. (b) Qualified only within the limits for positions specified in QW-303. (c) Qualified only for the position(s) used during the welding of the test coupon. 12. For performance qualification, how are the deposited weld metal thickness limitations determined if a single test coupon is used for a combination welding process? (a) They are considered individually for each welder and each process used. (b) In accordance with QW-451. {c) In accordance with QW-452. 13. Failure of any portion of a combination test in a single test coupon constitutes failure of the entire combination. (a) True (b) False 04/02 Rev 6 Fast Track Technical 20ASME SECTION IX EXERCISES, TASK #8 Welding Data QW-400 thru QW-450 1. A manufacturer is qualifying a WPS in GMAW process in short circuit arc transfer mode. The test coupon is ‘%” thick the maximum thickness qualified for the WPS would be, (a) 0.5" (b) 0.275" (c) 0.25" 2. Under what conditions may a WPS that has been qualified without notch toughness be used for applications where they are applicable? (2) Qualification without notch toughness qualifies the procedure with notch toughness requirements. (b) After the procedure has been requalified to include the notch toughness requirements. (c) After preparing an additional test coupon using the same essential variables, but additionally with all the required supplementary essential variables, in a coupon long enough to provide the necessary specimens. 3. What effect did the 1974 Edition have on material in the 1974 Edition when new P- No.'s, or the assignment to different subgroups within a P-No. were given? (a) Procedure and performance qualifications continued to be valid based on the new P-No. designations. (b) Required re-qualification of those welding procedures. (c) Required re-qualification of welders and welding operators. 4. As a convenience, variables for procedure and performance qualifications are summarized in and respectively. (a) QW-250 - QW-350 (b) QW-451 - QW-452 (c) QW-252 - QW-265 5. A SMAW WPS was written with notch-toughness test. The test coupon on the supporting POR is 3/8” in thickness. What would be the base metal thickness qualified range for the WPS? (a) 1/16" thru 3/4" (b) 3/8" thru 3/4" (0) 3/16" thru 3/4" 04/02 Rev 6 Fast Track Technical 2ASME SECTION IX EXERCISES TASK #8 6. A change in a welding condition which will affect the mechanical properties of a weldment or the ability of a welder to deposit sound weld metal is dependent upon which type of variable? (a) Nonessential (b) Essential (c) Supplemental Essential 7. The test coupon for a PQR consisted P5A to P4 materials when notch toughness is not a factor, the base metals qualified would be; (a) P-No.5A to P-No.4 only (b) P-No.5A to P-No.4, P-No.3, and P-No.1 (c) P-No.5A to P-No.5A and P-No.4 to P-No.4 (d) None of the above 8, The grouping of and by are essentially based on usability characteristics, which fundamentally determine the ability of welders to make satisfactory welds. (a) base metals - filler metals - Group No.'s (b) electrodes - welding rods - F-No.'s (c) P-No.'s - F-No.'s - A-No,'s 9. What production base metals is a welder qualified to weld if a P No.8 base metal was used in his qualification? (a) P-No.1 through P-No.11 P-No.34 and P-No.4x to same. (b) P-No.1 through P-No.8 and P-No.4x to same (c) P-No.1 through P-No.8 to same (d) P-No. 8 to P-No. 8 10. What welding process addresses the essential performance variables for the flux cored arc welding process? (a) SAW (b) PAW (c) GMAW 04/02 Rev 6 Fast Track Technical 2ASME SECTION IX EXERCISES TASK #9 Welding Data QW-451 thru QW-492 1. When qualifying a welder at 6G position using a 6" schedule, 40 (0.280) pipe test coupon, the required type and number of tests are: (a) One face bend test and one root bend test (b) Two side bend tests (c) Either two face and two root bend tests or four side bent tests (d) Two face and two root bend tests 2. A welder has been qualified by a 2" nominal schedule. 40 pipe in the 5G position. Is he qualified to weld a groove weld of a 3/4" nominal, 3000 Ib. coupling in the overhead position in the field? (a) yes {b)no 3. In reviewing the form QW-483 (PQR form) in a Code shop, the Authorized Inspector noticed the thickness of test coupon was documented as 3/4" SA-2B5C plate. However on the back of the form thickness of the specimen was recorded as 0.725". The difference in thickness is most likely because. (a) A mistake in the testing laboratory, they documented a different set of coupon on this POR. {b) The thickness of the specimen is approximate. (c) The test coupon has been machined down to 0.725" to offset the heat distortion due to welding. 4, A welder was qualified by a plate at 4G (overhead) position in the lab. He will be qualified to weld pipe 2 7/8" O.D. and over, but under 24" O.D. in the field in the overhead position. (a) True (b) False 04/02 Rev 6 Fast Track Technical 23ASME SECTION IX EXERCISES TASK #9 5. The SAW process is commonly classified as a process in and GMAW as a process for welding. (a) Automatic, semi-automatic (b) Semi-automatic, manual (c) Machine; semi-automatic welding 6. A welder is qualified in 6G position on a 2" schedule 160 pipe (2-3/8" 0..). What is the diameter range and position the welder is qualified to weld? {a) 2.375" O.D. and over, 6G position (b) 2" NPS and over, all positions (c) 1.00", 0.D. and over, all positions 04/02 Rev 6 Fast Track Technical 24ASME SECTION IX EXERCISES Section IX Exercises ‘Vask#1 Ref Para, Task#3 — RefPara, Task #5 Ref Para. LA Qw-484 1B QW-201 LA Qw-l6l 2 QW-153.1 (6) 2.C — QW-200.4, 451.1 2B Qw-120 3.B QW-163 3A QW-200. (@) 3.c QW-100.1 4A QW-100.1 4.C — QW-2003 4B QW-151.2 5B QW-151.1(€) S.C QW-203 5.c QW-171.2,171.3 6c QWw-100.2 6. QW-200.1 (0) 6B Qw-191.2.2 1B QW-100.1 TA QW-213 7B Qw-1003 BA Qw-i61 8B QW-451.1 BA QWw-123.1 9.8 Qw-i61 9B QW-201 9A QW-162.1 10.B QW-2003 1A QW-152 Task#4 — Ref Para, 11.B — QW-202.2(0) TLC QW-132,2, 132.3,1324 12.B QW-200.2 (a) 12. QW-132.1, 132.2 LA Qw-211 13.A QW-183 2.c Qw-201 Task#6 Ref Para 4B QW-153.1(8) 3c Qw-203, 4a Qw-200.3, LB Qwazi4 Task#2 Ref Para. 5A Qw201 2.C — QW-304.1 GA QW-200.2(c) 3.C — QW-3022 LA QW-100.3 TA QW-200.2 (a) 4A QW3013 2B QWeI9L.t BA QW-200.4 (b) 5B QW-306 3.B QW-16L5 6A QW-306 4c QW-I5L2 TA QW-4619 5B QW-1003 B.A QW.302, 304 6c QW-120 9B QW-3023 7B QW-141.1, 141.2 10.8 QW321 BA Qw-122 11. QW-304 9B Qw-100.2 12.B QW-361.1 10.C — QW-162.1 13.B QW.322.1 A QW-142, 143 12.B QW-151.3 (0) 04/02 Rev 6 Fast Track Technical 25ASME SECTION IX EXERCISES. Section IX Exercises Task#7 — Ref Para, Task#9 Ref Para. Lc QW-303.3 LD QW-452.1 notes 486 2c QW.321.3 (b) 2B QWw.452.1 3c Qw-3042 3c QW-462.1 (a) 4A QW-30L.1 4A Qw-4619 5.D Qw-300.2 5.c QW-492 Definitions of Machine and Semi-automatic 6A QW-351 6c Qw-4523 461.9 7B Qw-304 8B QW-301.4 9A Qw-301.2 10.B — QW-322.2 (b) 1B QW3012 12.0 QW-306 13.A — QW-306 Task#8 Ref Para, LB QW-403.10 2€ Qw-4013 3A QW-420.1 4A QW-401 5A QWASLL 6B QW-4OL.1 7.B QW-424.1 3.3 Qw-43i 9A QW-423.1 10.C QW-355, 04/02 Rev 6 Fast Track Technical 26ASME SECTION V EXERCISES TASK # 1 API 510 READ: ARTICLE 4 T-110 THROUGH T-190 1. The requirements for NDE given in Section V are Code requirements: a. Which must always be met. b. Which must be met when specifically referenced in a construction Code. . Which must be met when specifically referenced and made a requirement by a construction Code. ° 2. Subsection A of Section V describes: |. The mandatory standards that must be met. . The methods to be used if referenced in another Code. c. The qualifications of personnel. op 3. The responsibility of the is to ensure that the examination equipment being used conforms to the requirement of d . Authorized Inspector / Code of construction. Manufacturer / this Code Section (V). oo 4. The recognized document(s) for the certifying NDE personnel is/are: . ANSI/ASNT CP-189 or SNT-TC-2A or ACCP |. ANSI/ASNT CP-189 or SNT-TC-1A or ACCP c. ANSI/ASNT SNT-TC-1A 2 5. If a Code does not reference Article 1 of Section V for personnel qualifications, qualifications may involve: a. Demonstration of abilities in a production setting. b. In house written examinations for required skills, c. Qualifications from a previous employer if per Section V requirements. 6. When are written procedures required for NDE performed under Section V? . When the owner/user requires such written procedures. a b. When required by the referencing Code. c. Atall times, no exceptions are allowed. 03/04 Rev 6 Fast Track TechnicalASME SECTION V EXERCISES TASK #1 7. ooo oy oop Who shall have the responsibility for ensuring that vessels or pressure parts have been inspected in accordance with Section V and the Code of Construction? |. The manufacturer's quality control personnel. . The inspector concerned with the fabrication of such components. . The owner's or user's representative. . When ASTM documents refer to “Inspector” this may describe what the ASME Code calls “ . Authorized Inspector. Examination or Examiner, Ownerluser’s examination personnel. . Who is responsible for any or all of the records of inspection required by Section V? |. The examiner The Authorized Inspector. . The Manufacturer. 03/04 Rev 6 Fast Track TechnicalASME SECTION V EXERCISES TASK #2 API 510 READ: ARTICLE 2 T-210 THROUGH T-292 1. When contouring welds by grinding in preparation for radiographic examination what are the acceptable surface conditions? a, Smooth with no noticeable weld ripple. b. Flush to the surface or reasonably uniform crowns. c. Flush with the surface. 2. How shall densitometers be calibrated? a. By comparison with a calibrated densitometer. b. By using a calibrated ladder film cassette. c. By comparison with a national standard step tablet or a step wedge calibration film. 3. When choosing radiation energy which of the following shall be followed? a. Iridium 192 for steel b. Tritium 90 for titanium c. An energy source that will achieve the density and IQ image required by Article 2 d. Uranium 90 is the default source 4. When location markers are to appear as radiographic images on film . they shall be marked with the lead letter F . they shall be placed on the film holder . they shall be placed on the film cassette they shall be placed on the part eoon a |. What must always be attached to back of a film holder/cassette? a. The lead symbol B with the minimum dimensions of %4" in height and 1/16" thick. b. The lead symbol B with the minimum dimensions of %4" in height and 4/8” thick. . Alocation marker for each individual film cassette. |. The name of the NDE Company doing the radiography. ap 03/04 Rev 6 Fast Track TechnicalASME SECTION V EXERCISES TASK #2 6. When viewing radiographic film, the film viewer must have a . current calibration sticker . vision which meets 20/20 with correction c. sufficient variable light source op 7. The diameter of the 2T hole in a #25 penetrameter is: |. 0.025" . 0.050" . 0.100" oop 8. Aradiation source size is normally verified . by actual measurement . by using a Lockland advanced source meter or its equivalent . by manufacturer’s publications such as technical manuals esp 9. When choosing a Hole Type penetrameter, what shall the size of the holes be based on? .. The thickness of the part to be radiographed. . Whether the radiography will be a single-wall or double-wall shot. The side the radiation source is on relative to the film cassette. |. All of the above. aocp 10.1f one or more film holders are used for a radiographic exposure what shall normally be the required number IQIs? a. Two per holder, one on the top and one on bottom of the holder. b. One in the lightest area of interest. c. Atleast one per holder. 41.When placing the radiation source on the axis of a cylindrical component for a single exposure, what will be the least number of IQs? a. Atleast 6, one each 60 degrees around the circumference. b. Three, placed at each 120 degrees around the circumference. c. Atleast three placed at 120 degrees apart. 03/04 Rev 6 Fast Track Technicat 4ASME SECTION V EXERCISES TASK #2 12.When performing radiography, Geometric Unsharpness shall not exceed the values of Section V paragraph T-285. a. False b. True 13. If a light image of the B appears on a darker background of a radiograph protection from backscatter is considered unacceptable. a. True b. False 14. The requirements for a hole type penetrameter shim's dimensions are: a. Shims must be smaller than the penetrameter. b. Shims must be larger than the penetrameter on at least two sides. c. Shims must be larger than the penetrameter on at least three sides. d. Shims must be larger than the penetrameter on no more than three sides. 15.Upon inspection, a radiograph has a density that varies through the area of interest by minus 20% from the density through the body of the Hole Penetrameters used, What is the appropriate action? a. Re-radiograph using an additional penetrameter at each exceptional area or areas. b. Develop by technique shots acceptable variations in density. c. Evaluate the need for shims for the penetrameters. 16,The manufacturer must always fill out a which must list which of the following item(s). a. RT Evaluation / a list of radiographic locations b. Technique Documentation / an evaluation and disposition statement. c. Radiographic Review Form / information required by T-291. 17. The single-wall exposure technique is mandatory whenever practical. a. True c. False 03/04 Rev 6 Fast Track Technical 5ASME SECTION V EXERCISES TASK #3 API 510 READ: Article 23 - SE-797 Scope 1. This practice provides guidelines for measuring the thickness of materials using the method at temperatures not to exceed, |. pulse-echo / 200°F wall to wall / 250°F . back wall / 250°F contact pulse-echo / 200°F aocm 2. The pulse-echo ultrasonic instrument of the ultrasonic pulse through the part being measured. . calculates the decay . measures the transit time . measures the decay of sound through the part, . calculates the reflection time divided by sound velocity aocp 3. Thickness readout instruments are modified versions of the instrument. The elapsed time between the | pulse and the first echo or between multiple echoes is converted into a meter or digital readout. a. pitch and catch b. echo locator c. pulse-echo 4. If a thickness readout instrument has the capability to read thin sections, a highly damped, high-frequency search unit is generally used. High-frequency (10 MHz or higher) delay line search units are generally required for thicknesses less than about 0.6 mm (0.025 in.). a, True b. False 03/04 Rev 6 Fast Track Technical 6ASME SECTION V EXERCISES TASK # 3 API 510 SE-797 Cont'd 5. Which of the following applies the Direct Contract Single Element Search unit? a. The display start is synchronized to the initial pulse. All display elements are linear. Full thickness is displayed on CRT. b. When using this search unit, it is necessary that the equipment be capable of correcting for the time during which the sound passes through the delay line so that the end of the delay can be made to coincide with zero thickness. 6. Four step thickness calibration blocks have the following thickness steps a. .100”, .200”,.300", and .400" b. .250",.500", .750”, and 1.00" c. .100", .300", .5600" and .750" d. None of the above 7. Highest accuracy for thickness measurement can be obtained from materials with a. dual transducers b. parallel or concentric surfaces c. parallel surfaces d. concentric surfaces 8. For direct contact single element search units you place the search unit on a test block of a known thickness with a suitable Couplant and adjust the instrument controls (material calibrate, range, sweep, or velocity) until the display presents the appropriate thickness reading, you should then ; |. check and adjust on test blocks with a thickness of a lesser value . check and adjust on test blocks with a thickness of a greater value . check and adjust on test blocks with a thickness of a greater and lesser value |. check and adjust on test blocks with a thickness of a greater or lesser value aoe 03/04 Rev 6 Fast Track Technical 7ASME SECTION V EXERCISES TASK #4 API510 READ: ARTICLE 6 T-610 THROUGH T-690 1. The time interval between penetrant emval and developer application is determined by a. the surface condition of the weld being inspected b. the written procedure's specification c. directions given by the penetrant manufacturer 2. Evaluation of indications for penetrant exams shall be a, in terms of the acceptance standards of the referencing Code b. discarded after review and completion of any needed repairs c. kept for one year 3, Standard SE-165 applies to the process. a. visible water washable b. fluorescent water washable ©. specific procedures used for a 4, Where are precautions about surface conditioning surfaces prior to penetrant examination found in Section V? SE-165, Annex 1. . Non-Mandatory ASTM SE-747. . Article 6. eon 5. When examining a long run of weld metal (ie. 30 feet) what steps may be needed to insure proper control over interpretation? a. Article 6 requires that no more than 10 feet of continuous weld metal be examined in a single process application. b. Itmay be necessary to perform the inspection in increments to stay within the 7 to 60 minutes allowed by Article 6 before interpretation. c. The length of the weld does not have any bearing on interpretation. 03/04 Rev 6 Fast Track Technical 8ASME SECTION V EXERCISES TASK #4 6. You are performing a penetrant inspection at 75 ° F on a weld in a material designated by Code to be of P-No. 21 (aluminum). This material is prone to cracking in weld metal. What would be the required dwell time for the penetrant prior to cleaning and application of the developer? 7 minutes. 5 to 7 minutes. . 5 minutes. |. None of the above. aocm ~ . When applying the Fluorescent Penetrant Method, inspection personnel should observe the following precaution. a. Ensure that adequate lighting is present in the inspection area (50 Foot Candles Minimum). b. Test the luminance of the black light and wear eye protection if itis above 350 angstroms per cm?. c. Enter the darkened area for at least one minute prior to starting the inspection. 2 . How soon after application of a dry developer does development time begin? . Not until the developer is dusted off. . Immediately after application. . After drying by heating lamps or gentle heated air. . 1 to 10 minutes depending on the humidity. aoc © What must be obtained for liquid penetrant to be used on austenitic stainless steel inspections? . Certification of contaminant content. . Penetrants that have a hydrocarbon content of less than 10 ppm. c. Penetrants and developers that have fluorine content by weight of 1 milligram orless. oo 10.When performing penetrant examination at other than standard temperature, what must be the course of action? a. Qualify the procedure using liquid penetrant comparator blocks made of quenched and cracked Type 6010 aluminum. b. Qualify the procedure using liquid penetrant comparator blocks made of quenched and cracked Type 2024 aluminum. 03/04 Rev 6 Fast Track Technical 9ASME SECTION V EXERCISES TASK #5 API510 READ: ARTICLE 7 T-710 THROUGH T-773, T-776, T-780, and T-790 1. Each piace of magnetizing equipment with alan shall be calibrated at least once a |. alarm / shift . ammeter / year . black light! shift eon 2. Article 7 of Section V is in conformance with: a. SE-709 b. ASTM-1079 c. Section Vill Div. 3. Article 7 must always be used in conjunction with a. the referencing Code b. the SE given in the appendix of V c. Article 1 of Section V 4. When performing fluorescent particle Inspections a black light must be allowed to warm up for at least . 10 minutes: . 15 minutes . 1 minute |. 5 minutes eocp a .. Which of the following is prohibited when performing any magnetic particle examination? . Non approved fluorescent particle propellants. . Broad areas of particle accumulations. c. Prods, which have not had their lifting power, verified. op (03/04 Rey 6 Fast Track Technical 10ASME SECTION V EXERCISES TASK #5 6. When performing dry particle tests, how many examinations are required at each location of inspection? At least 2, which must be approximately perpendicular to each other. . One when performing dry particle testing. c. None, dry particle is considered a volume examination. oo 7. If demagnetization of an inspected part is required due to a process reason, when shall this demagnetization be performed? a. Immediately b. Just before the part moves to the next process. c. Any time after completion of the examination. d. Only as given in the referencing Code. 8. The following is a statement. The magnetic field indicator is only permitted for determining field adequacy of the AC Yoke Method of inspection. a. True b. False 9. The maximum spacing for prods is a. 8" b. 3" c. 6" d. not defined in Section V Article 7. 10.{f the open circuit voltage of the prod procedure is greater than 25 Volts what should be modified about the technique? a. Prod spacing should be closer. . Prod tips should changed to another metal than the standard copper. c. Prods should be dressed so as to have a blunt tip. 11.Except for materials %" or less in thickness AC Yokes are superior to direct current yokes of equal lifting power for the detection of surface discontinuities. a. Tue b. False 03/04 Rev 6 Fast Track Technical uwASME SECTION V EXERCISES Solutions Task#1 Task#4 1 Cc T-110 41. B T-675 2. B T-120 2. A T-680 3. B T-130 3. c T-610 4, B T-140, 4. A T-642 footnote 5. A 1-140, 5. B T-676.1 6. B T-150 6. Cc Table T-672 7. B T-170 7. Cc T-676.4 8. B 7-170 8. B T-675.3 9, Cc T-190 9. A T-641 10. B T-653.2 Task#2 Task#5 1. B T-222.2 1. B T-761 2 Cc T-262 2. A T-710 3. c T-272.2 3. c T-710 4. D T-275 4. D T-778.2 5. A T-223 5. c T-780 6. c T-234 6. A T-771 ley B T-233.1 7. c T-755 8. c T-261.1 8. B T-753 9. D Table T-276 9. A T-773.3 10. C T-277.2 10. B T-773.3 11. °C T-277.2 11. A T-776.2 footnote 12. B T-285 13. A T-284 14. C T-277.3 15. A T-282.2 16. C T-292 17. A T-271 Task#3 SE-797 Only 14 42 613 6.2 744 Appendix X-1 84 PNOARONS PUDS>oODG TAA 03/04 Rev 6 Fast Track Technical 2Practice Questions for Section VIII Div.1 ‘These questions cover both the open and closed book portion of the exam; in general any table lookup questions would be in the open book part of the examination. Only the correct choice and the paragraph where the answer is found are given, s0 you will be required to read the paragraphs ta confirm the answers. 1, Which of the following describes the service restrictions on welded joint types in lethal substance service? 1. All joints of Category A shall be Type No. (1) of Table UW-12. 2. All joints of Category A and B shall be Type No. (1) of Table UW-12. 3. All joints of Category B and C shall be of Type No. (2) of Table UW-12. 4, All joints may be of any type permitted in Section VIII Div.1 2, When a vessel is to be used with a lethal substance it shall be; |, completely ultrasonically tested if made of any high alloy. 2. pre-heated if constructed of carbon or low alloy steel 3, receive Postweld heat treatment 4, made only from an approved list of base materials in Section VIII Div.1 . 3. The term Category used in Section VIII Div. refers to? 1. The type of substance that is to be contained by a vessel. 2. The location of a welded joint in a vessel. 3. The type of weld used to make the welded joint, 4, The welding process used to make the welded joint. 4, Which of the following describe? “A welded joint used to make flange connections” 1, Category A 2. Type C 3. Type B 4, Category 5. A Category “A” butt-welded joint can be which of the following? 1. Circumferential weld connecting one shell course to another shell course. 2. A Circumferential weld connecting a hemispherical head to a shell 3. A flange connection to a head 4, A nozzle connection to a shell or head. 6. Materials used in the construction of welded pressure vessels shall be of weldable quality. This requires that a material be proven by; 1, Successful qualification of a Welding Procedure in accordance with Section IX of the ASME Code. 2, Acceptance by Section I Part D of the ASME Code. 3. Chemical tests and mechanical testing, 4, Listing in the stress tables in Section VIII Div. 17, Welding materials used for production shall comply with the requirements of Section VIII Div. 1, those of Section IX, and the applicable qualified welding procedure specification. When the welding materials comply with one of the specifications in Section I, Part C; the marking or tagging of the material, containers, or packages as required by the applicable Section II specification may be accepted for identification in place of, 1, The actual testing of the weld filler metal 2. The welding procedure requirements, 3. The certificate of compliance or certified test report. 4. Markings may not be substituted for a manufacturer's documentation 8. The minimum thickness for shells and heads of vessels built to Section VIII Div. 1 is 3/32" 5/32” va" wie” 9. The mill under tolerance for 2 plate of 1/2” thickness in Section VIII Div. is; 1, 6% of the thickness. 2. 010" 3. 001" 4. 3% of the thickness. 10. The loadings to be considered in designing a vessel shall include those from: Internal pressure only. Intemal and extemal pressure only. Internal and external pressure, weight of the vessel and contents, Iniemal and external pressure, weight of the vessel and contents and superimposed loads from attachments. 11. Section VITI Div.1 states that when specifying a corrosion allowance ; 1. A corrosion allowance may be given to all vessels. 2. A corrosion allowance can be considered in MAWP calculations. 3.,The owner/user shall designate any corrosion allowance for a vessel subject to corrosion or thinning and it should be adequate for the expected life ofthe vessel. 4, No requirement for a corrosion allowance exists in Section VIII Div. 1; itis solely up to the owner/aser to require one. 12. According to Section VIII Div.1 telltale holes may be used; 1. To determine if welding penetration is adequate 2. To determine if a repad is leaking. 3. To determine ifa fillet weld has adequate throat dimensions. 4, To determine if thickness of a vessel part has been reduced to a dangerous degree. 13, Corrosion resistant or abrasion resistant linings, whether or not attached to the wall ofa vessel shall; 1. Not be considered as contributing to the strength of the wall, 2. Be considered as contributing to the strength of the wall. 3. Always contribute to the strength of the vessel wall. 4, Not be considered as contributing to the strength except as listed in Part UCL.14, The thickness of shells under internal pressure shall be not less than that computed by the following. formulas, In addition, provision shall be made for; 1, Any of the other loadings listed in UG-22, when such loadings are expected. 2. Corrosion. 3. Atmospheric pressure, 4, Extemal loadings, 15, When calculating the extemal pressure allowed on 2 vessel you shall enter the Factor A. chart when the value of L/De is greater than 50 at ; 1. The value divided by two. 2. The value of 50 3. The value of Doit. 4. You cannot use the chart you must use the formulas of Appendix 5. 16. When cutting plate or other stock for fabrication of « Section VIII Div.1 vessel the; 1. The cutting shall only be performed by mechanical means, sawing etc. . 2. The edges shall be rounded if exposed to corrosion. 3, Exposed inside edges shall be chamfered or rounded. 4. The cutting shall be performed by thermal processes only, 17. For traceability of parts used in a Section VIII Div.1 vessel the vessel Manufacturer shall maintain traceability of the material to the original identification markings by which of the following methods: 1. Identification by a coded marking traceable to the original required marking, 2. Marking the part numbers on the fabrication drawings. 3. Welding maps to be turned over the owner/user of the vessel. 4. No markings are required 18, If the material used in the fabrication of a vessel has defects they: 1. May not be repaired and the entire part shall be rejected, 2. May be repaired only by the stecl mill who manufactured the part material, 3. Defects in material may be repaired provided acceptance by the Inspector is first obtained for the method and extent of repairs 4, Defects in material may be repaired. Defective material that cannot be satisfactorily repaired may be rejected at the inspector's discretion. 19, All plates for shell sections and for heads shall be formed to the required shape by any process that will ‘not unduly impair the physical properties of the material. If plates are to be rolled to form a cylinder; 1. They must be heated to the materials transition temperature prior to rolling 2. They must be volumetrically examined by a suitable NDE process prior to rolling, 3. The adjoining edges of circumferential joints of cylindrical vessels shall fist be shaped to the proper curvature by preliminary rolling or forming in order to avoid having objectionable flat spots along the completed. 4, The adjoining edges of longitudinal joints of cylindrical vessels shall first be shaped to the proper curvature by preliminary rolling or forming in order to avoid having objectionable flat spots along the completed20. For a cylindrical shell that was designed for internal pressure the tolerance for out-of-roundness must be maintained and is based on the difference of the maximum and minimum inside diameters. This tolerance is; 1. It shall not exceed 1% 2. It shall not exceed 0.10% 3. It shall not exceed 10% 4, It shall not exceed 1.5% 21. The inner surface ofa torispherical, toriconical, hemispherical, or ellipsoidal head shall not deviate outside of the specified shape by more than; 11-12 % of D 2.1:3/4 % of D 3.2% of D 4, 1-1/4 % of D 22. When plate specification heat treatments are not performed by the material manufacturer, they shall be performed by, or be under the control of, the fabricator who shall then place the lettex(s); 1.“T" following the letter G" in the Mill plate markings 2. “HT” following the letter G” in the Mill plate markings “T" following the letter GP” in the Mill plate markings 4, “HT” following the letter MG” in the Mill plate markings 23, For plates, the vessel Manufacturer shall obtain; 1, Detailed list ofall heat numbers, 2. A complete set of all mill test coupons. 3, The material test report or certificate of compliance. 4, The steel mills nun logs that apply to the heat number stamped on the plate at the mall 24, All materials to be used in constructing a pressure vessel shall be examined before fabrication for the purpose of detecting, as far as possible, imperfections which would affect the safety of the vessel. This would include; 1. Particular attention to rounded edges and other paris of pipe which would disclose the existence of serious laminations, shearing cracks, and other imperfections 2. Particular attention to comers of lap plates. 3, Particular attention to the inside corners of reinforcement plates. 4, Particular attention to cut edges and other parts of rolled plate which would disclose the existence of serious laminations, shearing cracks, and other imperfections. 25. The shall examine the pressure retaining parts to make certain they conform to the prescribed shape and mect the thickness requirements after forming. The shall verify the dimensions, 1. Manufacturer, Inspector. 2. Inspector, Manufacturer. 3. Vendor surveyor, Manufacturer. 4, Manufacturer, Vendor surveyor.26. The maximum allowable working pressure for a vessel is the maximum pressure permissible at the top of the vessel in its normal operating position atthe designated coincident temperature specified for that pressure, Itis the least ofthe values found for maximum allowable working pressure for any of the essential parts ofthe vessel by the principles given in (b) below, and adjusted for any difference in 2 1. the height of the vessel 2, the weight of the vessel 3. any static head that may exist 4, any static head exerted on the part with the highest MAWP 27. Which of the following describes a Standard Hydrostatic Test? 1. Test to be conducted at the calculated MAWP of the vessel. 2. Test to be conducted at the calculated MAWP of the vessel multiplied by 1.5. 3. Test to be conducted at the calculated MAWP of the vessel multiplied by 1.1 4, Test to be conducted at the calculated MAWP of the vessel multiplied by 1.3. 28. The visual inspection of joints and connections for leaks at the Standard Hydrostatic ‘Test Pressure caleuloted by dividing the ratio of stresses may be waived provided: 1. No gas leak test will be applied. 2. Substitution of the gas leak testis by agreement reached between Manufacturer and Owner. 3. The vessel will not contain a “lethal” substance 4, The vessel will not contain a “flammable” substance, 29. A small liquid relief valve set to ___times the test pressure is recommended for the hydrostatic pressure test system, in case a vessel, while under test, is likely to be warmed up materially with personnel absent. 118 112 LA 13/4 30, Prior to performing a Pneumatic Test per Section VII Div. the manufacturer mast perform non destructive tests. The requirements for these tests are given in 1.UG-40 2.UW-50 3.UG-50 4, UW-35 31. The pressure in the vessel shall be gradually increased to not more than one-half ofthe test pressure. ‘Thereafter, the test pressure shall be increased in steps of approximately _ of the test pressure until the required test pressure has been reached. 1. Approximately one-tenth 2. One-quarter 3. One-fifteenth 4, Exactly onectenth,32. Subject to the provisions of UG-99(a)(1) and (a)(2), a pneumatic test prescribed in this paragraph may be used! in liew of the standard hydrostatic test prescribed in UG-99 for vessels: 1. Are readily dried and are to be used in services where traces of the testing medium can be tolerated. 2, That are so designed and/or supported that they cannot safely be filled with water. 3. That are so designed and/or supported that they can be safely filled with water, 4, Only for vessels with an enamel lining, 33. An indicating gage shall be connected directly to the vessel. Ifthe indicating gage is not readily visible to the operator controlling the pressure applied 1. second operator must be used to shout out pressure steps. 2a pressure chart recorder must be used. 3. an additional indicating gage shall be provided where it will be visible to the operator throughout the duration of the test. 4. the hydrostatic test equipment must be moved to provide the operator with a clear line of sight to the gage. 34, Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test pressure, but in no casc shall the range be less than 11/2 nor more than 4 times that pressure. having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages. 1. Scientific laboratory gages 2, Chart recording gages 3, Mason-Hanson dial feeder gage 4, Digital reading pressure gages 35. The name plate on an ASME Section VIII Div.1 vessel has the single letter P stamped on it, this means? 1. Itwas constructed using pressure welding. 2. Itwas proof tested in lieu of hydrostatic testing. 3. Itwill be a permanent vessel and will not be on a trailer or otherwise transported. 4, There is no such example given in the ASME Code Section VIII Div.1 36, The letters PHT shall be applied under the Cade Symbol when; 1. the vossel has received Postweld Heat Treatment as provided in UW-10. 2. only part of the complete vessel has been Postweld Heat Treated as provided in UW-10. 3, the vessel has received only partial heat treatment, to its longitudinal seams. 4, the vessel has received only partial heat treatment, to its circumferential seams. 37. An additional nameplate in accordance with (a) through (4) may be installed on the skirt, supports, jacket, or other permanent attachment to a vessel. All data on the additional plate, including the Code ‘Symbol, shall be as required for the mandatory nameplate. The marking need not be witnessed by the Inspector. The additional nameplate shall be marked: 1, REPRODUCTION" 2. “COPY” 3, “DUPLICATE.” 4, Only one nameplate is permitted,38, A Data Report shall be filled out on. by the Manufactarer and shall be signed by the Manufacturer and the Inspector for each pressure vessel marked with the Code U Symbol. 1, Form U-I or Form U-1A 2. Form U-2 or From U-2 3. Form R-1 or Form R-1A 4, Form UG-1 or UG-1A. 39, Data Reports for those-parts of a pressure vessel which are furnished by a parts Manufacturer to the user of an existing Code vessel as replacement or repair parts shall be executed on Form U-2 or U-2A by the parts Manufacturer and his Inspector in accordance with the requirements of this Division. A copy of the shall be forwarded to the owner ofthe vessel. 1. U-l Form 2. Material Test Report and the Form U-2 or U-2A. 3. Certificate of Conformance and the Form U-2 or U-2A 4, Form U-2 or U-2A 40, Safety, safety relief, and relief valves shall be of the 1. bellows expansion type 2. direct spring loaded type 3. indirect spring loaded type. 4. dead weight type. 41, The set pressure tolerances, plus or minus, of pressure relief valves shall not exceed __psi for pressures up to and including 70 psi and __ for pressures above 70 psi. 1.2,3% 2.5,5% 3.1,3% 4.3,2% aA isa pressure relief valve actuated by inlet static pressure and characterized by rapid openitig or pop action. A is a pressure relief valve actuated by inlet static pressure which opens in proportion to the increase in pressure over the opening pressure, A isa pressure relief valve characterized by rapid opening or pop action or by opening in proportion to the increase in pressure over the opening pressure, depending on application. A 1 pressure relief valve in which the major relieving device is combined with and is controlled by a self-actuated auxiliary pressure relief valve. 1. safety relief valve - safety valve - relief valve - pilot operated pressure relief valve. 2. safety valve - relief valve - safety relief valve - pilot operated pressure relief valve 3. pilot operated pressure relief valve — safety relief valve ~ safety valve ~ relief valve 4, relief valve — safety valve — pilot operated pressure relief valve ~ safety relief valve 43.4 isa pressure relief device which is designed to reclose and prevent the further flow of fluid after normal conditions have been restored. 1. balanced bellow control valve, 2. vacuum vent valve, 3. pressure relief valve. 4, Anderson ~Greenwood reducing pressure regulator.44, A rupture disk device bbe used as the sole pressure relieving device on a vessel. 1, may not 2. may under certain circumstances 3. may 4. can if approved by the owner 45. In accordance with Section VIII Div. a liquid relief valve can be no smaller that___in pipe size (NPS) 1,34 inch, 2.1 inch 3. 5/8 inch 4.1/2 inch, 46. Carbon or low alloy steel having a carbon content of more than __ by heat analysis shall not be used in welded construction or be shaped by oxygen cutting (except as provided elsewhere in this Division), 1.0.035% 2.0.35% 3.35% 4, 0.035% 47. When radiographic examination is required for butt welded joints by UCS-57, joints of Categories _ and ___(see UW-3) shall be of Type No. 1 or No. 2 of Table UW-12, 1.BandC 2.AandD 3.AandB 4, Cand D. 48, Shells of pressure vessels may be made from scamless pipe or tubing listed in Table 1A of Section II, Part D provided the materiel of the pipe is manufactured by the process, 1. Open-hearth, basic oxygen or electric furnace 2. Open hearth, reducing oxygen 3. Closed-hearth, basic oxygen or electric furnace process 4, Basic oxygen or electric furnace process. 49. Ellipsoidal, torispherical, hemispherical, and conical heads having pressure on the convex side are also referred to as 1. Plus heads 2. Minus heads 3. Reverse concave heads. 4, Inverse convex heads. 50, Before applying the detailed requirements and exemptions in these paragraphs, shall be performed. 1. satisfactory weld procedure qualifications of the procedures to be used 2. satisfactory heat treatment tests of the procedures to be used 3. chemical and mechanical tests of a production coupon 4. a survey of current ASTM requirements$1, The operation of post weld hess treatment sal be cared ou ry one af the procedures given in UW40 in accordance with the following requirements 1. The temperature ofthe furnace shall not exceed 800°F at the time the partis placed in it 2. The temperature of the furnace shall not exceed 400°F at the time the part is placed init 3. The temperature of the furnace shall not exceed 600°F at the time the part is placed in it 4, The temperature of the furnace shall not exceed 300°F at the time the partis placed in it. 52. During the heat treatment holding period there shall not be a greater difference than ___ between the highest and lowest temperature throughout the portion of the vessel being heat treated. 1, 100°F 2. 250°F 3. 150°F 4. 50°F 53, As concems Impact Testing exemptions for a material that is 2 inches thick and assigned to Curve C in the tables of Section VILI Div.1 the coldest Minimum Design Metal Temperature allowed is, without impact testing, disregarding any other exemption? 1, 26°F 2. 99°F 3. -4°F 4.6°F 54. Section VIII Div.1 paragraph UCS-67(a) states that welds made with filler metal shall be impact tested in accordance with UG-84 when any of the following apply: L. When both base metals require impact testing. 2. Whea either of the base metals requires impact testing, 3. Whea the vessel will be in lethal service. 4, When the vessel will be a non-stationary vessel. 55. Welded joints shall comply with UW-2(6) when the minimum design metal temperature is colder than + unless the coincident ratio defined in Fig. UCS-66.1 is less than 0.35. 1,-20°F 2. 55°F 3, 55°F 4. 20°F 56. Carbon and low alloy stecl plates shall_formed cold by blows. 1. not be 2.be 3. may be 4.not be unless post weld heat treated after forming, 57. The rules in Part UHTT are applicable to pressure vessels and vessel parts that are constructed of ferritic steels suitable for welding, whose tensile properties have been enlienced by 2 1. forming while heated to the lower transformation temperature. 2. heat treatment, 3. mechanical blows followed by heat treatment, 4, forming at the upper transformation temperature and heat treating.58. Part UHT states that impact test procedures, and size, location and orientation of the specimens shall be the same as required by ___except that for plates the specimens shall be oriented transverse to the final direction of rolling and for cizcular forgings the specimens shall be oriented tangential to the circumference. 1. UCS-66 2. UCS-68 3.UG-42 4.UG-84 ‘59. A cylindrical shell ifto be rolled and welded and is made of SA-517 Grede A plate. The nominal thickness of the shell course is 1.0”. Which of the following is the heat treatment temperature range? 1, 1025-1085 °F 2. 1000-1100 °F 3,950 -1100 °F 4.1025 — 1125 °F 60. Which of the following UHT materials can be exempted from production impact tests of the weld metal in accordance with UG-84? 1.SA-393 2.SA-517 3.8A-724 4, SA-933 61. The requirements of UW-35(a) and UW-51(b) shall be met except that for___ material the ‘maximum weld reinforcement shall not exceed 10% of the plate thickness or s/s in, (3.2 mm), whichever is less. 1.$A-724 2, SA-953 3.SA-S17 4, SA-645 62, Radiographic indications with a maximum length of three times the width or less on the radiograph are defined as indications. These indications may be circulsr, elliptical, conical, or irregular in shape and may have tails. When evaluating the size of an indication, the tail shall be included. The indication may be from any imperfection in the weld, such as porosity, slag, or tungsten, 1 elongated 2. transverse 3. rounded 4. ellipsoidal 63, The maximum size of a random rounded indication om a radiograph in US customary units for 2 thickness of 1/2" is 1.0,125" 2..0.0125" 3.0.158" 4,0.100"64, A linear indication when using magnetic particle testing is described as one 1. having a width greater than two times the length. 2. having a length greater than four times the width, 3. having a length greater than three times the width. 4 having a width greater than three times the length. 65. After repairs to a defect found by the use of magnetic particle testing have been made, the repaired area shall be blended into the surrounding surface so as to avoid sharp notches, crevices, or comers and reexamined by the magnetic particle method and by all other methods examination that were originally required for the affected area, except that, _ feradiography may be omitted, |. when the depth of repair is morc than the radiographic sensitivity required 2. when the depth of repair is less than the magnetic sensitivity required 3, when the depth of repair is less than the radiographic sensitivity required. 4, when the depth of repair is more than the magnetic sensitivity required 66. An indication of an imperfection found using the dye penetrant technique may be larger than the imperfection that causes it; however, the size of the indication is the basis for acceptance evaluation. Only indications with major dimensions greater than__in, shall be considered relevant, 1.16 2. U8 3. 1/32 4h 67. These penetrant acceptance standards shall apply unless other more restrictive standards are specified for specific materials or applications within this Division, All surfaces to be examined shall be free; 1. relevant rounded indications greater than 1/16 in. 2. relevant rounded indications greater than 1/8 in 3, relevant rounded indications greater than 1/4 in 4, relevant rounded indications greater than 3/16 in 68. Section VIII Div. 1 states that when performing ultrasonic examination of weld that imperfections which produce a response greater than __of the reference level shall be investigated to the extent that the operator can determine the shape, identity, and location of all such imperfections. 1. 1B oft 2.10% 3.20% 4 Ud oft 69. Openings in vessels not subject to rapid fluctuations in pressure do not require reinforcement other than {hat inherent in the construction under the following conditions: 1. The vessel will not contain a lethal substance. 2. The vessel will not have a rated MAWP greater than 15 psig. 3. Section VIII Div. 1 listed size thickness combinations are not exceeded. 4, The vessel will not be constructed to Part UHT so Section VIII Div. 170, Section VIII Div. 1 states that no two isolated __ cach other than the sum of their diameters; ‘openings, shall have their centers closer to 1. unreinforced 2. reinforced 3. beveled. 4. fillet welded 71. All pressure vessels for use with and those subject to internal corrosion or having parts subject to crosion or mechanical abrasion, except as permitted otherwise in this paragraph, shall be provided with suitable manhole, handhole, or other inspection openings for examinetion and cleaning, 1. sulfuric acid 2. water 3. hydrogen chloride 4. compressed air 72. As regards the Section VIII Div.1 formula for the calculation of unstayed flat heads when determining, the variable C, a value of m must first be found, this done by finding the ratio of thickness of the ‘o L. shell to the head 2. thickness required of a scamless shell to the actual thickness of the shell. 3. thickness required of a seamless shell to the nominal thickness ofthe shell. 4, any long seam joint efficiency in the shell and that of a seamless shell. 73, Section VIII Div. 1 states that for formed head that E = lowest efficiency of any joint inthe head; for hemispherical heads this ineludes head-to-shell joint; for welded vessels, use the cfficiency specified in UW-12, what category of weld joints do all hemispherical heads contain? 1. AandC 2.Bonly 3. Aand B aa 74, The required wall thickness for tubes and pipe under external pressure shall be determined in accordance with the rules in : 1,UG-28 2. UW-28 3. UCS-28 4.UG-32 75. Section VIII Div. allows that in some cases itis desirable to pressure test vessels when partly filled with liquids. For such vessels a combined hydrostatic and pneumatic test may be used as an alternative to the pneumatic test ofthis paragraph, provided the liquid level is set so that the maximum stress including the stress produced by pneumatic pressure at any point in the vessel (usually near the bottom) or in the support attachments, does not exceed 1.3 times the allowable stress value of the material multiplied by the |. ratio of materials stress at test and design temperatures. 2. applicable joint efficiency 3. material stress allowed at design temperature, 4, material stress allowed at test temperatureSolutions Practice Questions far Section VII Div.1 These questions caver both the open ard clased book portion ofthe exam; in general any tle lookup ‘questions would be in dhe open book part of the examination. Only the corect choice and the paragraph ‘where the answer is found are given, so you will ke required to read the paragraphs to confirm the 1. Which ofthe following describes the service restrictions on welded joint types in lethal substance service? 1 Alljolas of Category A shall be Type No (1) of Table UW-12.[._. All joins of Category A and B stall be Type No, (1) of Tate UWI Alljins of Category Band C shal eof Type No. (2) of Tale UW-12 All joints may be of any type permined in Section VIII Div. 1. 2, When a vessel isto be used with fethal substance it shall be: 1. completely ultrasonically tested if made of any high alloy, 2. presheated if constructed of carbon or low alloy steel 4. receive Poscweld heat ereatment. 4, made only from an approved lst of tase maieals Gomes og wwe 3. The term Category used in Section VIM Div.1 refers to? 1. The type of substance tht is vo be contained by a vessel 2. The location of a welded joint in a vessel. | 3. The type of weld used to make the welded joi 4. The welding process used to make dhe weed Joint Goan aS 4. Which of de following describe? “A welded join used to make flange connections” 1. Catepory A 2. Type C 3. Type B 4, Category Cl 5. A Category “A” bute join can be whic of following? 1. Circumferential weld connecting one shell course another sh! eure. 2A Circumferential wet comesting a hemphrical heed ta shel. | ae TE 5. A flange connection toa hea. 4 & nozzle conrecson toa shel or head. da 6, Materials used in the construction of welded pressure vessels shall be of weldable quality. This requires that material be proven by, 1, Successful qualification of» Welding Procedure in accordance with Section IX of the ASME. Code : 2, Acedpiace by Sexton 3. Chemical tests and mechanical testing. 4. Listing in the stress tables in Section VIII Div. 117, Welding materials used for production shall comply withthe requirements of Section VII Div. 1, those bf Section EX, and the applicable qualified welding pracedure specification. When the welding materials comply with one of the speifieations in Section Il, Part; the marking or ageing ofthe material, containers, or packages as required by the applicable Section II specification may be accepled for idenifcaton in place of, 1. The acta esting of the wold ler meta 2. The welding prosedare requirements 3, The cereal of complies or certified test report 4 Markings my not be baited fora manufrs dosienain, 8. The minimum thickness for shes and heads of vessels bull to Section VIN Div. 1 is; srs2" 5132" ve wis" _ ~~ (CamReRE STE 9. The mill undertolerance fora plate of 1/2” thickness in Section VII Div. i; 6% of the thickness. 1 2 OO a aan oececceeeeee cen f ComMNaNE OG Te (6H das aco 3. ‘oom Fa ley le lee pees 7157) 4, 396 ofthe thickness 10. The loadings to be considered in designing a vessel shall include those fom: eral pressure only. Inceral End extemal pressure only. Intera and extemal pressure, Weight ofthe vessel and contents. Internal and extemal presuce, Weight ofthe vessel ard costens and superimposed loads fom attachments _~ (Caen 11, Section Vill Div1 states that when specifying a corosion allowance ; 1. A corrosion allowance may be given taal vessels. 2. A corrsion allowance ean be considered in MAWP calculations, 3. The owneriuser shal designate any corrosion allowance for vessel subject to corrosion oF ‘thinning ad it should be adequate forthe expected Fife the vassal 4. Na requirement fora corrosion allowance exists in Section VIM Div. iit solely up i the owners to require one. Gamer veas 12, According to Scetion VII Div. telltale holes may be used |. To determine if welling penetration is adequate. 2, Todetemmine ifa repad is lesking. 3. Todetemnine fa filet weld hes adequate troat dimension. 4, To determine if thickness ofa vessel pact hus been reduced tow dangerous degree. | 13, Comsion resistant or abrasion resistant linings, whether or not attached to te wall of vessel sali; (Goninon 005 1. Notbe considered as contributing to the strength ofthe wal. 2, Be considered as contributing fo the siength ofthe wall. 3 Always contribute to the strngth ofthe vessel wall 4 Not be considered as contributing tothe strength excep a listed in Part UCL14, The thickness of shells under internal pressure shall be not less than that computed by the flowing formules. In addition, provision shall be made for; ‘Comment uGa7 1. Any ofthe ether loadings sted in UG-22, when such loadings are expected. | 2. Corrosion 3. Atmosphere pressure. 4 External losdings. 15. When calculating the external pressure allowed on a vessel you shall enter the Factor A. chart when the value of L/Deis greater ban 50 at; 1. The value divided by two. 2, The value of 30) 3. The value of Dov 4. You cannot use the chert you must use the formulas of Appendix 5. 16. When eutng plate or other sick for fbricaton ofa Section VII Div. vessel the; |The cutng shal any be performed by mechanical mess, se 2 The edge al be munded ifexposl a corosion. 3. Expond inside ego sal be ehumfred or rounded 4, Th eating shall be performed by thermal processes oy. 17, For traceability of pats used in a Section VIII Div. vessel the vessel Manufacturer shall maintain ‘eaceabiity ofthe material to the original identification matkiags by which ofthe following methods: 1 Menicaon by a coded marking oceale othe orginal required marking | 21 Marking the pat numbers onthe fabrication drawings. 5. Welding maps to be tured ver te pwnedaseraf the vss 4. No markings are required 18, Ifthe material sed inthe fabrication of vessel has defects they: ee tend nt exe of in eed ; asi ia CSE SRN 19, All plates for shell sections and for heals shall be forme! 1 the required shape by any process that will ‘no unduly impair the pnysical properties of the material. If plates are to be rolled to form a cylinder; | They must e ese othe materials tanson epee prior rong 2. They must be volumeticaly exmaed by sulble NDE proces poring 5. The odjring edges of chun jl ofeyiare vessel abe apd tthe proper erate oy peli lig Toming i ner avid having oeconae fat {pas ag te comple heen edges oflnghuin! joins of eins vest sal fest be shaped othe proper curva by peli lingo ming inorder wold aving cbjeconae at pow slog th comple ean convene CBmRTERE LE20, Fora cylindrical shell that was designed for internal pressure te tolerance for out-of-roundness must be maintained and is based on the diference of the maximum and minimum inside diameters. This tolerance is; 1. Kesha ot exceed 16 ce (CRETE 2 esha no exesed 0.10% 3. shall no exceed 10% 4 shal no exceed 1.5% 21. The inser surfie ofa torispherical, orieonical, hemispherical, or ellipsoidal head shall not deviate ‘outside of the specified shape by more than; 114A % of 2134 $ oD 32% of ALM %orD. : recreate ce" (CTT 22, When lt spt ical aks nl pol bythe wc way al be pevtorned yor beunder te cont oe iar who sal ea pace ie tert) 1.1 folowing the fete nthe Mil plate markings | 2H" flowing the eter Gin the Mil plate markings 3. lowing the eter GP" inthe Mil plate markings 4S TFT allowing the eter MG" inthe A plate markings 23. For plates, the vessel Manufacturer shall obtain; 1, Dated fist of at beat numbers 2. Acorplte set of ll mil test coupons 3.The maar et report oreerifcate of compliance aae0 4h ste mils run fos that apply tthe het mame’ imped ata i 24, All materials o be used in constructing a pressure vessel shall be examined before fabrication forthe purpose of detecting, a faras posible, imperfections which would affect tbe safety ofthe vessel. This ‘would include; 1. Panicular attenon to rounded edges and other parts of pipe which would disclose the existence of serious laminations, shearing eracks, and other imperfections 2, Particular attention to comers of lp plates. 3 Particular attention tothe inside comers of reinforcement plates. 4. Particular attetion to et edges and othe parts of rolled plate which would disclose the existence of serious laminations, shearing racks, and other imperfections} Gane eas 25. The, shall exemine the pressure retaining pars to make certain they conform to the prescrbal shape ud met the thickness requirements after forming. The shall verify the ‘dimensions. WEA aT 1 Manatees, nopector 2 Inspector Matic 3. Vendor surveyor, Maitre 4. Marathons, Veo surveyor.26, The maximum allowable working pressure fora vessel is the maximum pressure permissible atthe top ‘of the vesel in its normal operating position at the designated coincident temperature specified for that pressure Its the least ofthe values found for maximum allowable working pressure for any ofthe essential parts of the vessel by the principles given in (b) below, and adjusted forany differenes in 1 the eight ofthe vessel 2 the weight ofthe vessel 3.any stati ea that may exist ae ‘any state head exerted om the pa Wi the Highest MAW: 27. Which ofthe following éescribes x Standard Hydrostatic Test? 1. Test t9 be conducted atthe calculated MAW ofthe vessel. 2, Test to be conducted atthe calculated MAWP of the vessel multiplied by 1.5, 5, Test fo be conducted atthe calculated MAWP of te vessel mulplied by 1.1 4. Test lo be conducted atthe calculated MAWP of te vessel multiplied by 1.31 {Gamniens 0099 28. The visual inspection of joints and comestons for leaks atthe Standard Hydrostatic Test Pressure calculated by dividing the rato of stresses may be waived provided: 1. No gas leak test will be applied 2. Substitution of the gns lek tet is by agresmont reached between Manufacturer and Owner, 5.the veel will oteontain “thal abnnee Pee 4. The vessel will vot contin a “flammable” substi 29. A small liquid relief valve sett __simes the rest pressure is recommended for the hydrostatic pressure test system, in cusea vessel, While under test likely tobe warmed up materially with personnel absent. Lug, eto {Comament Ues eaoe 212 ee 3a 413 30. Prior to performing a Pneumatic Test per Section VII Diy the manufacturer must perform non “dstrtive tests, The requirements for these tests ae given in, powsd TEL Suwe3s 31. "The pressure in the vessol shall be gradually increased to not more han one-half ofthe test pressure. ‘Thereater, the test pressure shall be increased in steps of approximately of the est pressure until the required test pressure has been reached. 1. Approximately one-teatt - 2. Oncequarier 3.One-fineenth 4. Exactly one-tenth,32. Subject to the provisions of UG-99(a}(1) and (2(2) pneumatic test preseribed inthis paragraph may be used in lew ofthe standard hydrostatic test preseribed in UG-99 for vessels |. Ate readily dried and ate to be used in services where traces ofthe testing medium ean be tolerate 2, That are so designed and/or supported that they cannot safely be filled with water. | 3, That are so designed andlor supported that they ean be safely filled with water. 4. Only for vessels with an enamel Fining. ~(Cormments 106 ff 33. An indicating gage shall be connected direcly tothe veal. to the operstor controling the pressure applic, | indicating gage is not readily visible 1. second operator must used to shout ov presse steps. 2a pressure chart recorder mst be used 3.an ational indicating gage stl be provide where it wil be isle othe operator thoughout the duration of hee ee ETE) 4 the hyrostc test equipment mise vedi avid he opera wh ele in fst tothe gage 34, Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test pressure, bu in no case shal the range be less than Tv nor more than 4 times that pressure having wider range of pressure may be used provided the readings give the same or greater degree oFaccuracy as obtained with dal pressure pages. 1. Scientie laboraory gages 2. Chart recording gages 3. Masoa-Hanson dial feeder goge 4. Digital reading pressure gages 35."The mame plate on an ASME Section Vill Div.1 vessel has the single lester P stamped on it | Ws const using prestre welding! 2 itwas proof ested in eu of hydrostatic ei 3. Itwil bea permanent veel and wil rtbe ona irile orothervie transported. 4: Theres nosoch example given in the ASME Code Secon Vill Div.) 136. The leters PHT shall be applied under the Code Symbol when; 1. the vessel hus received Postweld Heat Treatment as provided ia UW-LO, 2oaly pat o he complete vese has been Postweld Heat Teeted as provided in UW-10 - 3. the vessel has received only partial heat treatment, tits longitudinal seams. 4 the vessel has received only partial heat treatment, tits circumferential seams, 37. An addtional nameplate in accordance wit (a trough (2) may be installed on the skirt, supports, Jacket, or other permanent aachment toa vessel, Al data on the additional plate, including the Code ‘Symbo}, shall be as reguiced forthe mandatory nameplate. Te marking need not be witnessed by the Inspector. The ad onal nameplate shall be marked: “REPRODUCTION” 2."cORY" 3. “DUPLICATE. 4. Only one nameplite ie per.‘38. A Data Repor shall be filled out on, by the Manufacturer and shall be signed by the ‘Manufucturer and the Inspector for eaci pressure vessel marked with the Code U Symbol |. Form U-t or Form U=1A) 2, Form U2 or From U-2A 3. Form Rl or Form RA 4 Form UG-1 or UG-IA, 30, Data Reports for those parts oF a pressure vesel which are furnished by a parts Manufacturer tothe ‘ser ofan existing Code vessel as replacement or repair parts sll be executed on Form U-2 or U-2A by the paris Manufacturer and his Inspector in accordance with tie requremens ofthis Division. A copy of the shal be forvarded wo tbe owner of the vessel 1, Us] Form 2, Material Test Report and the Form U-2 or U-2A. 3. Cerificate af Conformance and the Form U2 oF U-2A 4. Form U2 or U-2A) 40. Safety, safety relief, and reieFvalves shall be of the | talons etpansion ype \SRRSSRSRseRnen 2. Gaston loaded ps 5nd ong oe ps 4 dad weigh ope 41. The set pressure tolerances, plus or minus, of pressure relief valves shall not exceed __ psi for pressures up to and including 70 psi and for pressures above 70 psi 12,394, Set 7 2.55% 3.13% anim aA pressure relief valve netuated by inlet state pressure and characrerzed by rapid pening or pop action. A is pressre cle valve atuted by inlet static pressure which opens in proportion othe increase in preasre over the opening presse. A apresure rele valve ‘haraeterized by rapid opening of pop action or by opening in proportion to the increas in pressure ever the opening pressure, depending on application. A. fa pressure relief valve in which the major ‘elioving device is combined with and is controlled by aselFactated ausliary pressure relief valve. 1 satay cli valve ~ safety valve rlict valve lt operated pressure rele vals, 2 safety valve «reli valve salty rele valve = plo operated pressure lie valve 5. plot operate pressure rele valve ~ say rele valve say valve rei valve Lelie valve = safety valve= pio operstedpressre reli valve ~ softy sit valve aA {sa pressure relief device which is designed foreclose and prevent the further Now of uid afer rsrmal conditions have been restored, tla bow contol valve 2 atu veal 5 perce alel , eee Ror icon ig pi aii. {Carmen USE Garin UG ome) -(GGamewluaesemen44, A rupture disk device be use as the sole pressure reliving device on a vessel Lemay not 2. may under certain circumstances 3. my, Senn nent CAE TET 4. can ifapproved by the owner 45. In accontance with Section VIII Div.1 liquid relief valve ean be no smaller that __ in pipe size i) 1.304 ine, 21 inch 3.5/8 inch 46. Carbon or low alloy tee! having carbon content of more than __by heat analysis shall not be used in \welded construction or be shaped by oxygen cutting (except as provided elsewhere in this Division), 1 oss, a 447. When radiographic examination is required for butt welded joints by UCS-S7, joins of Categories _ and __ (ee UW-3) shall be of Type No. 1 or No.2 of Table UW12, LBandc 2. Aand D 3Aandd._ nee veer CEU TSE) 4.CaneD 48, Shells of pressure vessels may be made from seamless pipe or ubing sted in Table 1A of Section i, Part D provided the material of he pipe is manufactured by the process |. Open‘eart, basi oxygen, or let fumace! 2 Open earthy reducing oxygen. 3. Closesearth, basic oxygen, o lecrcfomce process. 4. Basic oxygen or cece race process Cannan US a 49, Elipsodal, torspheriel,hemigpherice, nd conical heads having pressure onthe convex side are also Ara Mawel teeta leh etca enalal scan dc pagal ot |. satisfictory weld procedure qualifications ofthe procedures 1 be used] _-- Cae) 2. satisfactory heat treatment tests ofthe procedures to be used 3. chemical and mechanical tests ofa production coupon 4. survey ofeurent ASTM requirements51. The aperation of postweld heat treatment shall be carried out by one of the procedures given in UW-40 in accordance with the following requiremens, - |The tempernture ofthe face sill noexceed 00°F athe ime the paris ced int. 2. The temperstre ofthe free stall ot exesed 400% a th tine the pats plaed int 3. The tempers ofthe furnace shall not exceed GOOF athe time the pat placed int 4 The emperatre ofthe frase sal ot exes 30°F at th ime te parte placed init 52. During dhe heat treatment holding period there shall not be a greater difference th Iighest and lowest temperature thoughout the portion of the vessel being heat treated, Teween the 1 100°F 2.250°F 3, 150°, ASOT 53, As concer Impact Testing exemptions for a material that is2 inches thick and assigned to Curve C in the tables of Seetion VIII Div. the coldest Minimum Design Metal Temperature allowed is thout impact testing, disregarding any other exemption? 1664 2oxF sat Lor 54, Section VII Div.1 paragraph UCS-67() stnes that welds made with filler metal shall be impact ested in accordance with UG-84 when any of the following apply: |. When both base metals require impact testing 2. When either ofthe base metals requires impact testing) 3. When the vessel wil be in lethal service 44 When the vessel will hea non-stationary vessel 455, Welded joints shall comply with UW-2(b) when the minimum design metal temperature ix colder than unless the coincident ratio defined in Fig. UCS-66.| is less than 0.35, 1..20°F 2. 55 SSH 3 20F 56. Carbon and low alloy steel plates shall___formed cold by blows, 1 nott tbe 3. may be ‘not be unless post wed heat rested after fering 57. The rls in Part UHT are applicable to pressure vesels and vessel pars that are constructed of feriie ‘Sicels suitable for welding, whose tensile properties have been enhanced by 2 | foming wil ned othe over tensfomaton temper, 2. eaten : 3. mechani lw fll by ha ical 4. Fomingat te upper usformion perature and Meat tng ‘Comment abe USS (Comments UoseT Comer Cea omen USS Comment Ge58, Part UHT states that impact test procedures, and size, location and orientation of the specimens shall be the same as required by ___ except that fr plats the specimens shall be oriented transverse tothe final direction of rolling and iSretreular forgings the specimens stall be oriented tangential to the circumference 1. ucs.6s 2 ucs-sk 3uc42 auasd (Game oine z 59. A cylindrical shell ifto be rolled and welded and is mode of SA-S17 Grade A plate. The nominal thickness of te shell course is 1.0". Which of the following isthe heat treatment temperature range? 1. 1025-1085 °F 2, 1000-1100 °F, 7 [oa Soe 7 (Comment Take UTS 3.950 -1100 °F : 41025-1125 °F 60. Which ofthe following UHT materials can be exempted fom production impact tests oF the weld metal in accordance with UG-847 BsAasy evenness eect CGT, 2SA-517 3.84724 484933 61. The requirements of UW-35(a) and UW-51(b) shall be met except that for_ materia the ‘maximum weld reinforcement shall not exceed 10% of the plate thickness or tia: @.2 mm), whichever is less. LsA-Ta4 2SA553 3.SA-517] {Comments Ora, 484-685 62. Radiographic indications with a maximum length of tree times the width or lesson the radiograph are defined as ications. These indications may be circular, eliptieal, conical, or irregu shape and way have tails When evaluating the sizeof an indication, he til shall be inelnded. The indication may be ftom any imperfection inthe weld, suc as porosity, slag, or tungsten. Longa 2 vanmene 5S roanded TT 4 tips 663. The maximum size ofa ndom rounded indication ona radiograph in US customary units fora thickness of 12" is, ae eae a(4, linear indication when using magnetic particle testing is described as one [having @ width greater than two times te length 2. iaving a length greater than four times the width 3 having a length greater than three times the width 4 ving a width greater than three ies the length 7 ~ (camamnants Aopen 65, Afier repairs to a detect found by the use of magnetic particle testing have boon made, the repaired ew stall be blended into the surrounding surface so as to avoid sharp notches, eeviees, or comers snd reoxamined by the magnetic paniele mthod and by all other methods examination that were originally required for the affected area, except that, readiogrephy may be omitted. 1. when the dep of repair more than the radiographic scshvty requlred 2. when he dept of eal i ess than te magoete sensitivity required 3. when de depth of tear i ess than de raiograie sensitivity quired 2. when the depth of repair more than the magnetic sensitivity required - Carnaiant pee 666, An indication of an imperfection found using the dye peneaat technique may be larger than the imperfection that causes it; however, the size of the indication isthe basis for acceptance evaluation, Only indications with wajor dimensions greater than__in. shal be considered relevant 67. These penetrant accspsance standards shall apply unless olber more estctve standards are specified for specific materials or applications within this Division. All surfaces tobe examined shall be flex; 1. relevant rounded indieations greater duan 1/16 in 2. relevant rounded indiations greater than 1/8 in 3 relevant rounded indications greater than 1/6 in 4 relevant rounded indications greater than 316 in, (68, Section VII iv. 1 states that when performing ultrasonic examination of weld that imperfections Which producea response greater than ____ ofthe reference level shall be investigated to the extent that the oper en dtemsine the shape, isn, and foration ol such emperetions Loft 210% 3.20% a) a imott 69, Openings in vessels not subject to apd Auctions in pressure dono rere reinforcement lhe than that inherent in the construction under te fllowing conditions: 1. The vessel will not contain a lethal substance. 2. The vessel will not have arated MAWP greater than 15 psig 5, Section VII Div listed sie thickness combinations arent exceed, ED 4. The vessel will not be constructed to Part UT so Section VIM Div. 170, Section VII Di. | states that no two isolated openings, shall have their centers closer to each other than the sum of teir diameters, 1. uninforoed, 2 reinforced 3. beveled 4. filet welded TL. All pressure vessels for use with and those subject to internal corrosion or having parts subject fo erosion or mechanical abrasion, excaptas permitted otherwise inthis paragraph, shall be provided with suitable mankole, kandbole, or other inspection openings for examination and cleaning. 1. sul cid 2 ater 4, hydrogen chloride ‘Seompresed ai 72, As regards the Section VIII Div. formule forthe ealevlation of uastayed fat heads when determining the variable C, a value of m mast first be found, this done by finding the ratio of thickness of the 1 - 1 shall to dhe head 2 thickness equred of seamless shel othe acta thickness of the hl 3 thiskness equred of seamless shel fo dhe nominal thickness of te shel 4 any long est join fone nthe shell and that oF cae sel 73, Seetion VII Diy. 1 states that fr formed head that = lowest efficoney of any jain in the head; for ‘hemispherical heads this includes head-to-shell joint; for welded vessels, use the efficiency specified in LUW-12, what category of weld joins do all hemispherical heads contain? Lame 2.Bonly 3.AandB 4A on 174, The required wal thickness for tubes and pipe under external pressure skal be determined in decordance with the ules in Lua-29, 2uw28 3. UCS.28 sue 75. Sestion VII Diy. allows that in some cases its desirable to pressure test vessels when partly filed With Tiquids. For such vessels s combined hydrostatic and pneumatic test may be used as an alternative t0 ‘he pneumatic test of this paragraph, provided the liquid level set so that dre maximum stess including the stress produced by paeumatie pressure atany polat inthe vessel (usually near Une bottom) or in the support attachments, does not exczed 1.3 times the allowable sress value ofthe material rultiplied by the |. rato of material's sires t test and desig temperatures. 2 applicable joint eficieney, 3. material sess allowed at design iemperaiure. 4, material stress allowed at tes iemperature ~~ (Caiainant UG et eens