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API 510 – FINAL MODEL EXAM (OPEN BOOK

)
1.

A PQR was qualified in 5G position using a new welder. But production welding is to be done by the same
welder in 2G position. Which of the following are applicable as a minimum.
A.
B.
C.
D.

2.

A procedure is required with preheat temp = 250ºF. Two WPS were made based on this PQR. All other
parameters being same WPS (A) showed preheat temp = 280ºF and WPS (B) showed preheat temp = 145ºF,
will you,
A.
B.
C.
D.

3.

Qualify new PQR with E 7015 electrodes.
Revise only WPS showing the change from E 7018 to E 7015 and submit WPS as a new revision.
Revise only the PQR document showing the change and resubmit for approval.
Revise both WPS and PQR showing the change and resubmit for approval.

A PQR in GTAW process was qualified with PWHT with A 516 grade 70 material, ¾ inch thick. The thickness
for production welds is 1.0 inch, but without PWHT. Manufacturer claims that same PQR will be O.K. What is
your assessment?
A.
B.
C.
D.

5.

Reject (A) & (B)
Accept (A) only
Accept (B) only
Accept both

In a certain PQR for SMAW, the electrodes used for all passes were of AWS classification (E 7018).
Corresponding WPS also showed filler materials as E 7018. Now the manufacturer proposes to change the
filler material in WPS to E 7015. Will you ask manufacturer to:
A.
B.
C.
D.

4.

Both procedure and welder shall be re-qualified in 2G position.
The qualified procedure can be used ,only welder needs to be re-qualified in 2G position
The welder is qualified, but the procedure needs re-qualification
Both procedure and welder need not be re-qualified.

It
It
It
It

qualifies required conditions hence no new PQR is required
qualifies thickness but not It does not qualify “no pwht” condition, hence new PQR is required.
qualifies “no pwht” condition, but not thickness. New PQR is required.
does not qualify both thickness and “no pwht” condition, hence new PQR is required.

For 515 gr 60 material, following results were obtained for two tensile test specimen in PQR qualification.
·
·

Specimen T1 : failed in B.M. at 57,400 psi
Specimen T2 : failed in weld metal, at 59,500 psi

Your assessment is
A.
B.
C.
D.
6.

PQR
PQR
PQR
PQR

A procedure is qualified with Base metal thickness = 20mm. Two WPS were made based on this PQR. Other
parameters being same, WPS (A) showed Base metal thickness = 38 mm and WPS (B) showed B. M. thickness is
6mm. What will you do?
A.
B.
C.
D.

7.

Reject (A) & (B)
Accept (A) only
Accept (B) only
Accept both

Calculate estimated inspection period for external and internal inspection for a vessel whose remaining life is
estimated as 12 years.
A.
B.
C.
D.

8.

test is ok since both are within acceptance criteria
test is rejected as both T1 and T2 are not within acceptance criteria
is rejected because T1 is ok but T2 has failed
is rejected because T1 is failed although T2 is ok

Internal
Internal
Internal
None of

= 6 years, external = 10 years
= 6 years, external = 5 years
= 5 years, external = 10 years
the above

A 2.0 inch thick vessel data-sheet shows MDMT= 50 deg. F. The minimum pressure-test temperature for Hydro test
to be carried out after alteration shall be:

API 510 Final Model Exam-Open Book

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Welding electrode = AWS E 6015. None of above 14. 1 ¾ " thk SA 285 grc plates. C. None of above API 510 Final Model Exam-Open Book Page 2 of 6 . B. This PQR will qualify which of the following combinations. Following combination of Base metal and welding electrode was qualified by a certain PQR. 2. D. 70 deg F 80 deg. C. D. D. Which of the following is / are to be undertaken in case the Service conditions of vessel are changed A. 15. C.0 inch thick. C. Specify impact testing if Pressure vessel engineer feels it is necessary. The vessel shall be hydro tested only The vessel shall be internally and externally inspected before it is re-used The allowable conditions (MAWP.4mm 1. A. C. C. This procedure can be used with SMAW for weld thickness of: A. B. MDMT specified was +20ºF and material of Construction used was SA 515 Gr 60.2mm None of above 13. Vessel does nor undergoes temperature / pressure fluctuations or cyclic loading during service. C. Impact testing is not required.A. After repairs. D. Based on code requirements. rating) for new service shall be established and the next period of inspection shall be established for the new service. D. B. For vessel 1. 5 to 0 to Any 0 to 32 mm 16 mm thickness 32 mm 12. Impact testing need not be specified Specify impact testing if API 510 inspector feels it is necessary. C. E 6013 electrodes. Smaller of : One half of the remaining life of the vessel and 10 years 5 years The lesser of “a” and “b” The higher of a. A procedure qualification test was carried out for a groove weld on a plate with weld metal thickness of 16mm thickness by SMAW process. F 60 deg. 3/4" thickness. D. B. B. A insert type patch repair is proposed to be carried out. D. 1" thk SA 515gr 60 plates. B. E 7018 electrodes.0mm 2. Following is full scale pitting pattern as observed on inside surface of a pressure vessel during the recent planned inspection vessel thickness required = 7/8” including C. vessel will be hydro-tested but not stress relieved. 1 ¼ thk plates plates SA516gr70.A = 1/8” (See diagram on last page) Your assessment is: A. and b. F None of above. will you specify impact testing of repair plate. A. The period between External inspections for vessels (remaining life > 4 years) shall not exceed which of following A. B. E 6013 electrodes. Base Metal = SA 285 GrC Plates. Temp. For a vessel which is planned for internal inspection after 8 years what should be the minimum remaining corrosion allowance in the vessel if corrosion rate is 150 microns per year. Pitting Pitting Pitting Pitting pattern pattern pattern pattern is is is is not harmful hence acceptable unacceptable too scattered for correct assessment too close for proper assessment 11. Specify impact testing. 9. A. 10. D. The test was found satisfactory. B.

D. D. Your assessment is: A. 28 years D. D. The same procedure is restricted to maximum of 15 0C only C. (corrosion allowance = 0) and (S = 20000 psig) was inspected. 1 inch thick 1. A. Calculate the remaining life of a vessel given the following data: Actual thickness = 0. D. C. 10 mm 12mm 14mm none of above 20. For given configuration. 1 18000 psi 15000 psi 350 psig 260 psig 312 psig none of above 23. C. Minimum thickness required = 0. B. The same procedure is qualified to the temperature from 10 0C to 52 0C B. It is decided to carryout a surface NDT method.015 inch A. C. C. B. B.25 inch thick 0. 20 years B.787 inch Thickness at pervious inspection 5 years prior to present inspection = 1. C. or b depending on joint efficiency Data is not adequate 21. A vessel with seamless 2:1 Ellipsoidal head 60 inch ID. But the weld is in vertical position. The same procedure shall be applied to 5 0C to 10 0C D. 1 shall be: A. Available thickness of only 5/8” was observed on the crown portion. 400 psi design pressure. D.955 inch.16 In liquid Penetrant Testing. Pick up a correct statement. The minimum thickness available for a seamless tori spherical head for following data are as given in options. The requirement of radiography to be incorporated in repair procedure shall be:. correct minimum weld dimension (x) required as per ASME sec. a procedure is qualified to a temperature of 15 0C. Design Pressure Design temp Material of construction (M. B. Safe stress 17500 psig and internal diameter is 96 inches and has no corrosion allowance provided. Choose correct hydrostatic test pressure from given options for a vessel with following data. A. B.C) Allow stress (Ambient) Allow stress (675ºF) A. VIII Div. Choose a suitable NDT method. A.1) is to be repaired by using insert plates. None of the above 18. B. C. The Knuckle thickness was found to be adequate. The temperature measured at a weld layer for a magnetic material is around 45 0C.75 inch thick 1. Penetrant testing wet developer Magnetic particle testing with wet particles-prod type Magnetic particle testing with dry particles-yoke type API 510 Final Model Exam-Open Book Page 3 of 6 . Select suitable head thickness for a new construction of vessel with design pressure 200 psig. Full radiography Spot radiography May be a. A.O. = = = = = 200 psi 675º F SA 537 Cl. A pressure vessel constructed according to ASME Sec VIII Div 1 with shell thickness 7/8’’ (Material of Construction SA 387 gr 11 cl. Head thickness in crown portion is still ok for operation Thickness is inadequate. Depends on the opinion of third party inspector Depends on the opinion of API -510 inspector 22. 14 years C. The same procedure shall be applied to temperature more than 15 0C 17.125 inch thick 19.

70 (normalized) Plates of 1 inch thick were impact tested at -35° F. 28. Pipe in the overhead position 6” O. A. your advise is: A. B. A procedure qualification test was carried out for a groove weld on a plate of 16mm thickness by SMAW process. C. C. 5mm to 32 mm 5mm to16 mm Any thickness 8 mm to 16mm 27. D. Pad size is 6. C. Resistance must be reduced to 25 Ohms maximum. C.5 inch and with no C. Accept. B. Nozzle I. SA 516 Gr.D. D. 30. Your assessment is: A. C. D. Nozzle is adequately reinforced Reinforcement is inadequate Data is inadequate. observed resistance of electrical grounding connections for Pressure vessels was 42 ohms. 25-4T hole 30-2Thole 35-2T hole 40-2T hole 32. in 1G position. Shell thickness provided is 0. The test was found satisfactory. Tensile testing of equivalent sized bolts Hammer testing UT All of the above 25. Data is inadequate. Decide which of the following are applicable in the present case.D. pipe in the horizontal position API 510 Final Model Exam-Open Book Page 4 of 6 . B. Shell thickness is not ok Data not adequate. D. D. B.D. C. The penetrameter designation should be A. A pressure vessel (M.D. D. ½” O..Design shell thickness must be given. D.O. O.4 in. Depends on opinion of electrical engineer. Thickness of pad is 0. Acceptance of shell thickness depends on opinion of vessel engineer 29. If the vessel was not given PWHT earlier now receives PWHT. C. This procedure can be used for welding A. Shell thickness is ok. B. 24 None of above If anchor bolt corrosion is anticipated for vertical vessels what testing methods are recommended? A. A. Resistance must be increased to 25 Ohms minimum. B. C. Shell thickness is 0 . B.C. Jacket temperature 3500 F) the vessel OD 36 inches. May be still used for new MDMT Needs fresh impact test at new MDMT.D. B. is 3. 6” OD pipe in 1G only 2” OD pipe in 1G only Any Æ pipe in any position Pipes smaller than 2” OD in 1G only 26. 70) has external jacket spread over 72 inches length of the shell. C. 516 Gr.A. (Jacket pressure 200 psig. A welder qualifying by making a groove weld on pipe with an O. Now the MDMT is changed to –50° F. For a certain nozzle to shell joint (No corrosion allowance is required) following data is presented. In one of the External inspections. A weld procedure is qualified on pipe OD=2”. of ¾” in the 5G position is qualified to weld groove welds in : A.42 inch.2 in. B.. A weld with a nominal thickness of 1.D. This procedure can be used with SMAW a thickness of: A. D.42”. Pipe in the vertical position ¾” O. Did not require impact testing in case of both MDMTs May be still used for new MDMT only if E=1 (Full Radiography) 31. D.75 inch is to be radiographed using a film side penetrameter.Nozzle thickness must be given.

are same. D. 76. For procedure qualifications with the GTAW process _______ is Non-essential variable. C. C. yes . For procedure qualification. B. a pressure test A. C.5 years 5 years None of above 36. the test can be performed in any position. 42 A welder performing procedure test is also qualified in that position. Welder can be qualified by conducting Tensile test. One PQR was qualified for Austenitic Stainless steel plates in GTAW process. B. Authorization for which of the following approval from pressure vessel engineer is not mandatory A. 39 Must always be conducted Shall be applied if the authorized pressure vessel inspector believes that one is necessary Must never be conducted Shall be conducted only if repair is done on pressure parts. C. B. both a and b 41. D. D. This PQR will support a WPS made with Austenitic Stainless steel plates but process changed to SMAW A.4 inches All of the above 35. An ellipsoidal head has an internal diameter of 80 inches and depth of 22 inches (including a straight face dimension of 2 inches). D. B. D. Change of S No Groove Design 34. external inspection shall be performed not later than: A. 60” 30’’ 54’’ 48’’ 38. B. B. D. No. C.Provided The material thickness is within the range qualified yes . None of the above 33. Identify incorrect statement from following A. 10 years 12. The crown portion for tori spherical head ( ID=40 inches) may be considered as the portion lying entirely within a circle whose center will be same as head center and diameter will be A. Change of P No Change of F No. For 2:1 Ellipsoidal head (ID=75 inches). 36’’ 40’’ 32’’ 200’’ 37. B. as the position is not essential variable for procedure qualification. All supplementary essential variables become essential variables when impact test is specified. B. Repairs for vessels that comply with sec VIII Div 1 Alterations for vessels that comply with sec VIII Div 1 Repairs for vessels that comply with sec VIII Div 2 Alternations for vessels that comply with sec VIII Div 2 40. C. After completion or repairs.9 inches 72. C. What should its spherical (crown) radius be? A. C. The maximum permitted reinforcement on circumferential welds with plate thickness up to 1 inch will be: API 510 Final Model Exam-Open Book Page 5 of 6 . A.D. B.0 inches 68. D. The crown portion would lie within similar circle of diameter A. C. D. D.Provided The material P Nos. For non-continuous corrosive service with remaining life 25 years.

C. C.05 inch 0. B. B. D. The variation of density over the examination area on film was 3. A PQR was qualified by GTAW process using Austenitic Stainless Steel plates (ss304) this PQR will quality A. 50. B. B. B.0 “ at Set pressure Water Bubble test with water head = 0. D.532 inch inch inch inch per per per per year year year year 45. dia. B. 0. C. C.06 inch 0.5 “ at the Set pressure. 8 inches 16 inches 20inches 30 inches 47.266 0. B. = 48'' and height ( tan-tan) =98 ft.089 0. Rejected. the value for Density at the IQI is beyond the acceptable range. D. the upper limit of range is above specified upper limit Acceptable.5. The Hydrostatic heead for bottom dished head (2: 1 Ellip type) will be A. Base metal SS 316 SS 316 L base metal SS 304 L base metal NONE of above. Vessel 60“ ID.A. D.3 psi None of above 44. C. Water Bubble test with water head = 1. Water Bubble test with water head = 0. B.6 psi 42.5 “ at 90% of the set pressure NONE of above 46. D. what length will be taken for corrosion averaging is taken for corrosion analysis A. C. 0.4 psi 43.044 0. Rejected. A.6.006 inch 0.9375 inches. The original thickness was 1. a nozzle opening of finished opening = 8 inches was present in thinned out patch on inside surface and lying close to a reinforced nozzle with R.6 inch 48. 40. What is the corrosion rate for this vessel? A. A. The film shall be A. API 510 Final Model Exam-Open Book Page 6 of 6 . D. the lower limit of range is beyond specified lower limit Rejected. D. C. API 2201 API Recommended practice 572 API Publication 576 None of above. pad OD=8”.F. C. 49. Which of the following documents referenced in API 510 addresses the Hot Tapping requirements. Radiographic density obtained for a radiograph at the IQI (2T hole) was 3. B. What will be total thinning (metal loss) up to next inspection due after 10more years if Corrosion rate is 6 mills per year (mpy). D. 1/8” 1/16 3/16” ¼” 43 For a vertical with column int. Leak tightness of the relief valves is tested by conducting : A.2 to 4. the current thickness is 1.405 inches. C. D. A pressure vessel has been in service for 12 years and has a history of corrosion over its service life.