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.API 510 EIGHTH ED., JUNE, 1997 ADDENDA # 1 DEC. 1998, #2 DEC. 2000, # 3 Dec. 2001 and ‘Aug. 2003, REVIEW QUESTIONS Section 1 - General Apy |. The primary code for the inspection of pressure vessels after they enter service is? ay 1 + The APISI0Code 2. Relative to presse vessels, when does API 510 apply? | ap + Only applicable to vessels after they have been placed in service. 3. What does the API inspection code cover? an ' + Maintenance inspection, repair, alteration, and re-ating procedures fox pressure vessels used by petroleum and chemical process industies. 4. What type of pressure vessel is exempt from periodic ins 22 requirements? + Pressure vessels on movable structures covered by other juisdictional 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 - De ns 5. What is an alteration? + Apphysical 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 thee situations should not be considered alterations? Bn ‘© Comparable or duplicate replacement ‘* Audition of reinforced nozzle less than or equal to existing reinforced nozzles ; + Alldition of nozzles not requiting reinforcement 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APIEXAMS.ORG7. Inwhat situation would the term “applicable requirements of ASME Code" he used? 62 » When the ASME Code camot be followed because of its 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 ingpeetion code rather than to the ASME Code. If an item is covered by requirements in the ASME Codle and this inspection cexle 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 foverthe ASME Code As an example of the intent of this inspection code. the phrase "applicable requitements of the ASME Code' hnas heen used in this inspection code instead of the phrase “in rnccordance with the ASME Cod 8, What is an Authorized Inspector or Inspector? 3) © Anemployee of an Authorized Inspection Agency who is qualified and certified to perform inspection under this inspection code. 9. List 4 examples of an Authorized Inspection Agency ery Inspection o: ganization of the jurisdiction in which the pressure vesse! is used of; Inspection organization of insurance company which is licensed or registered to write and actually writes pressure vessel insurance, ‘+ Anowner 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 10. Define "construction code". ‘©The code or standard to which a vessel was originally built, such as APVASME, API, ot State Specialinon-ASi IL What does the term "inspection code" refer to in API 510? ‘= Shortened tile for API 510 used in this publication. 12, Define Suisdictions, ‘+ A legally constituted government administration, which may adopt rules relating to pressure 89) 13, Define Maximum Allowable Working Pressure (MAWP) as it telates 1o API'S10. and (Sect VII UG-98) +The maximum sage pressure permitted at the top of a pressure vessel in its operating position for a designated temperature tat is based on calculations using the rminimum (or average pitted) thickness forall critical vessel elements, not including corrosion allowance or loading other than pressure 08/04 Rev 9 FAST TRACK ‘TECHNICAL 281.482.2253 Ww -APTEXAMS.ORG"7 When determining Minimum Allowable Shell Thickness. what must be considered when making. caleulations? Temperature. pressure, and all loading, ‘What type of inspection uses nondestructive examination procedures to establish the suitability of pressure vessels for continued operation? On-strean Inspe ‘What isthe key clement of an On-strenm inspection? Because the vessel may be in operation while an on-stream inspections being canied out. the vessel is not entered for internal inspection. ‘What isa Pressure Vessel? (3.12) and (Sect VIN U-1 (ay) 18. BB) 20 B15) 08/04 ‘A container designed to withstand internal or external pressure, which can be imposed by an external source, by the aplication of heat from a direct er indict source, or by any combination thereof This definition includes unfired steam generators and other vapor generating vessels, which use heat rom the operation of a processing system or other indirect heat source. Specific Timits and exemptions of equipment covered by this inspection code are given in Section! and Appendix A.) ‘Who shall be a pressure vessel engineer? Shall be one or more persons or organizations acceptable to the owner-user who are knowledgeable and experienced in the engineering 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 2s a composite ofall entities needed to properly assess the technical requirements. ‘What is the definition of quality assurance as given in API 5102 All planned, systematic, and preventative actions required to determine if materials, equipment, or services will meet specified requirements so that equipment wil perform satisfactorily in service The contents of a quality assurance inspection manual are outined in 43 ‘What is a Repair? “The work necessary to restore a vessel to a condition suitable for safe operations at the design cond * design temperature or pressure changes dite to restoration, then re-rating equizements shall also be satisfied Rev 9 FAST TRACK TECHNICAL 281.482.2253 Wa. APLEXAMS.ORG2. Bin 24 G18) 25, G19) List the four examples of a Repair Organization ‘The holder of a valid ASME Certificate of Authorization forthe use of an appropriate ASME Code symbol stamp An owner or user of pressure vessels who repairs his own equipment in accordance with the APL 510 code. A contractor whose qualifications are acceptable to the owner or user of pressure vessels andl ‘makes repaits in accordance with this inspection code. ‘A repair concetn that is authorized by the legal jurisdiction What is re-rating?” A change in either the temperature ratings oF the maximum allowable working pressure rating of a vessel. ora change in both. The maximum allowable working temperature and pressure of a vessel may be increased or decreased because of a re-ating, and sometimes a re-rating requires a combination of changes. De-rating below original design conditions is a permissible way to provide for corrosion. Whew a te-rating is conducted in which the maximum allowable working pressure oF temperature is increased or the minimum temperature is decreased so that additional mechanical tess 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 docs not evaluate the results of those examinations in accordance with API ‘510, unless specifically wained and authorized to do so by the owner or user “The examiner need not be certified in accordance with API 510 ot be an employee of the ownet or user but shall be. trained gad 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 tempering of the underlying Iheat affected zone (HAZ)in the base metal. Various contrtled-deposition techniques, such as temper-bead (tempering of the layer below the current bead being deposited) and half-bead (requiting removal of one-half of the first layer), are included. Controted-deposition welding requires contol ofthe entire welding procedure including the joint detail, preheating and post heating, welding technique, and welding parameters 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APTEXAMS.ORG‘Section 4 - Owner-User Inspection Organization 26. What are the education and experience requirements For hecoming an inspector? (42 goo Appendix B) + Degree in engineering & | year experience in the design, construction. repair, operation. or ingpection of boilers or pressure vessels. + 2-year cettificate in engineering or technology from a technical college & 2 years of experience in the design, construction. repair, operation, or inspection of boilers or pressure vessels + Equivalent of a high schoo! education plus 3 yeats of experience. (and) ‘+ Five years experience in the inspection of boilers or pressute vessels. 27, Who will be responsi to the owner-nser when alterations. inspections. oF repairs are performed? a4) +The APE authorized pressure vessel inspector 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WH! APIEXAMS ORGSection 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, 29. What guidelines must an inspector follow to enter a vessel that las been in service? 61) + OSHA Regulations regasding Confined Space Entry 30. Explain the safety precautions and procedutes that should be taken when performing an internal inspec 6) Isolate vessel from all sources of fiquids. gas or vapors. Drain, purge. efean and ventilate, Gas test Wear protective equipment as sequired Warn all persons working around the vessel that inspection personnel are inside. ‘Warn all inside the vessel of work that is done outside the vessel. Check all tools and safety equipment needed hefore inspection, 31. When developing an inspection plan for vessels that operate at elevated terperatutes (750 to 1000 TE) what things should be considered when assessing the remaining life ofthe vessel? 62 (Creep deformation and stress rupture. Creep ciack growth, Effect of hydrogen on creep. Interaction of creep and fatigue. Possible metallurgical effects including a teduetion in ductility 32. Locations where metals of different thermal coefficients of expansion are welded together are susceptible to what? © Thermal Fatigue 33, The actual or estimated levels of what four items must be considered in any evaluation of Creep? © Time © Temperature = Suess + Material Creep Strength 34, At ambient temperatures, carbon, low alloy, and aller ferritic steels may be susceptible to what? 62 © Brite Failure 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APEXAMS .ORG35 (52) 38 64) (34) Define Temper Embrittlement. A loss of ductility and notch toughness due to PWHT or high temperature ser degrees F (370 degrees C) ‘What kind of steel is prone to Temper Embritulement? Low alloy steels, especially 2 1/4-Ci-1 Mo ‘What three methods may be used to determine the probable rate of corrosion? Caleutate rate from data collected from same or similar service Estimate rate from owner-user experience or from published data on comparable sevice. ‘On-stream deter n after 1000 hours of service using a suitable corrosion monitoring Sevice of 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 anid requirements of the latest edition of the ASME Code to establish the design temperature and pressure. In corrosive serviee, the wall thickness used in the MAWP calculations shall he the actual thickness obtained by inspection minus __. Twice the estimated corrosion toss before the date of the next inspection, except as modified in section 64 What is the most important and the most universally accepted method of inspection? (Careful visual examination ‘What determines the parts of & vessel that should be inspected? The type of vessel and its operating conditions, For proper visual examination, what surface preparation is requited? ‘The type of surface preparation depends on individual circumstances, tt surface preparation stich a wire brushing, blasting, chipping. grinding, or a combination of these may be required. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APLEXAMS .ORG43, If distortion is suspected diving the inspection of a pressure vessel what isthe proper course of action? 65) ‘+ Tfany distortion of a vessel is suspected or observed. the overall dimensions of the vessel shall be ‘checked to confirm whether or nat the vessel is distorted and, if i is distorted, to determine the extent and seriousness of the distortion, The parts of the vessel that shoud be inspected most carefully depend on the type of vessel and its operating conditions. 44. What type of examiners shall the when the owner/user tequites inspection for detection of interior surface breaking planas flaws? 65) ‘+ Industy-qualified UT Shear Wave examiners. 45, List the inspections. which inchude the features that are common to most vessels and that are most important 66) + Examine the surfaces of shells and heads carefully for possible crac signs of deterioration ‘© Examine welded joinis and the adjacent heat-affected zones for service-induced cracks or other defects. ‘+ Examine the surfaces ofall man ways, nozzles, and other openings for distortion, cracks, and other defers 46. Name two reasons why itis necessary for the API 510 inspector to examine flange faces, 66) blisters, bulges, and other * To look fordistortion + To determine the condition of gasket-seating surfaces 47. Corrosion may cause what two forms of loss? 6.7) ‘© Uniform loss - a general, relatively even wastage of a surface area * Pitted appearance - an obvious, inegular surface wastage. 48, Name tee ways the minimum thickness of a pressure vessef can be determined. 6D ‘Any suitable nondestructive examination Measurements taken through drilled test hotes Gauging from un-corroded surfaces in the vicinity ofthe corroded area, 49. For a comroded area of considerable size in which the circumferential stesses govern, the least thickness along the most cttical element of the area may be averaged over a length not exceeding what? 6D ‘+ For vessels with inside diameters less than or equal to 60 inches (150 centimeters), one half the vessel diameter oF 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. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WW. APEEXAMS . ORG50 67) 31 67) 10 ‘When can widely scattered pits be ignored? [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! inches. When should the design by analysis methods of Section VIII, Division 2, Appendix 4, of the ASME Cole be used? ‘To determine if components with thinning walls, which are below the minimum required walt thicknesses, are adequate for continued service. ‘To evaluate blend ground areas where defects have been removed, ‘What do you tse to determine ifthe thickness at the weld ot remote from the weld governs the allowable working pressiwe when the surface at the weld bas 2 joint factor other than 1.0? For this calculation. the surface at a weld includes | inch (2.5 centimeters) on either side of the weld, of twice the minimum thickness on either side of the weld, whichever is greater. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 whi. APTEXAMS .ORG3 67h) 54 G7h 35 67h) 56. (57) 37 68) 11 Describe the govern toisphetical heads. :ness when measuring the corroded thickness of ellipsoidal and ‘The thickness of the knuckle region with the head rating cal formula ‘The thickness of the central portion ofthe dished region, in which case the dished region may be consideied a spherical segment whose allowable pressure is calculated by the code formula for spherical shells ed by the appropriate head ‘What isthe spherical segment of both eli ‘That area located entitely within a ciicle whose center coincides withthe center ofthe head and whose diameter is equal to 80% of the shell diameter. (On torispherical heads. what is used as the radius of the sph sl segment? Radius of the dish, “The radius of the spherical segment of ellipsoidal heads shall be considered to be what? “The equivalent spherical radius KD, 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’? API RP 579 Sections 4.5 and 6 Section 6 - Inspection and Testing of Pressure Vessels and Pressure-Relieving Devices 38 on 59 6) 62) 08/04 ‘When isan internal field inspection of new vessels not required? ‘When the manufactures’ data report (UI) assuring thot the vessels ae satisfactory for their intended service is available. [Name two factors to be considered when inspection intervals are being deter ‘The risk associated with operational shutdown and start-up and the possibility of increased corrosion due to exposure of vessel surfaces (o air and moisture. ‘What are the essential elements ofa risk based assessment inspection? ‘The combination of likelihood of failure and the consequences of failure Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS.ORG6 (62) a 62) ! 63) 64 63) 08/04 12 \ ‘What other factors should be considered in a RBI program? Approptiateness of the materials, vessel design conditions relative to operating conditions, ippropriateness of the design codes and standards utilized, effectiveness of corrosion monitoring programs; and the quality of inspection / quality assurance and maintenance programs ‘What aetion shoul be taken after an effective RBI assessment has been finished’? Choose the most appropriate inspection tools and methods based on the degradation expected. ‘Sel the appropriate frequency for internal and extesnal and on-stream inspections, Determine if pressure testing vill be required based on damage or after repairs Decide on prevention and mitigation steps to reduce the likelihood of s vessel failure, How often should each above ground vessel be given a visual external inspection? Each vessel aboveground shal be given a visual external inspection. pefetably while in operation, at feast every 5 yeas ora the same interval as the required internat or on-steam inspection, ‘whichever is less ‘When making an extemal inspection, what shat! the inspection include? Condition ofthe exterior insulation Condition ofthe supports Allowance for expansion General alignment ofthe vessel on its supports Buried vessels shall be periodically monitored to determine their external environmental condition. What shall the inspection intervals be based on? Conosion sate information obtained during maintenance on adjacent connecting piping of similar material Inform material Information from representative portions of the actual vessel Information from a vessel in similar circumstances. jon from the interval exami {ion of similarly buried conosion test coupons of simitar ‘What isthe minimum interval for checking the insulating system of outer jacketing of vessels tha are known to have a remaining life of over 10 yeass or that are protected against external Byery 5 years and repaired as needed. What is the maximum period between internal or on-stream inspection? ‘The maxinnm period shall not exceed one half the estimated temaining corrosion-rate life or 10 years. whichever is less Rev 9 FAST TRACK TECHNICAL 281.482.2253 WhiW. APTEXAMS .ORG13 68. Ifthe remaining safe operating life of a vessel is less than 4 years, what is inspection interval? 64) + Ineval may be the full remaining safe operating life up toa maximum of 2 yeas, 69. Under what 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 {0 years be exempt from an internal inspection and inspected externally instead? 64) ‘+ When size, configuration, ot lack of secess makes vessel entry for internal inspection physically impossible © When the general corrosion rate of vessel is known to be less than 0.005 inch (0. 125 milfimeter) pet year and the estimated remaining life is greater than 10 years, and all ofthe Following conditions ase met: ‘+ The corrosive character ofthe contents. including, the effect of trace components, has been established by al least 5 years of the same or comparable service experience withthe type of ‘contents being handled. [No questionable condition is disclosed by the external inspection specified in 62. ‘The operating temperature of the steel vessel shell does not exceed the lower temperature limits for the creep-ruptute range of the vessel material ©The vessel is not considesed to be subject to environmental cracking or hydrogen damage from the fluid being handled. Alternatively, a RBI assessment, as permitted in can be performed to termine thatthe tisk associated environmental cracking or hydrogen damage is acceptably low ‘nd that the effectiveness of external inspection techniques is adequate for the damage mechanism, ‘This assessment should include a review of past conditions and likely future process conditions. +The vessel is not strip-tined or plate-ined, 70. Write the formula to be used when determining the safe remaining fife of a vessel 4) {actual -t required Remaning. Life Yrs Corrosion rate Where: tactual = the thickness, in inches millimeters), measured atthe time of inspection for the limiting section used to determine the minimum allowable thickness. minimum = the minimum allowable thickness, in inches (millimeters) forthe limiting section or zone 71. There are two kinds of conosion rates to be considered when calculating the remaining life of a vessel. What are these types? (6.4) ‘© Short Term and Long Term rates, 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Ww. APLEXAMS.ORG65) 2B 65) ™ 65) 15 : 66) 16 (66) n : 7) 08/04 14 2. When conducting a pressure fest as part ofa periodic inspection. what shall the shell temperature bbe during the test? “To minimize the risk of brittle fracture during the es. the metal temperatune should be m at feast 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 test lemperature need not exceed |20°F (50°C) unless there is information on the brite characteristics ofthe vessel material indicating that a lower test temperature fs acceptable or hnigher test temperature is needed. ‘When should pneumatic testing be done and what ate 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 telief valves ever be removed from a vessel during pressure testing? ‘Yes, ifa pressure testis heing 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 is allowed to make this repair? ‘Testing and repairs shall be made by a repair organization experienced in valve maintenance, The repair organization shall have a written quality control system with the minimum requirements a5 listed in 45 of the API 510 code and maintain a uzining 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 sefvice concerned. Test or inspection intervals on pressure-relieving devices in typical process services should not exceed 5 years, unless service. experience indicates that longer interval is acceptable. For clean (non-fouling), non-corrosive seivices, maximum intervals may be inereased to 10 years, Pressure vessel overs and users are fequired (o maintain permanent and progressive revords of their pressure vessels, What things are included in these records? Construction and design information, Operating and inspection history. Repair; alteration, and re-ating information. Fitness-for-service assessment documtentation Rev 9 FAST TRACK TECHNICAL 281.482.2253 WW. APLEXAMS.ORG15 Section 7- Repairs, Alterations, and Re-rating of Pressure Vessels 78, Who must approve any repairs or alterations? mi +All epairand alteration work must be authorized by the authorized pressure vesse! inspector ‘before the work is started by a repair organization (see 3.13). Authorization fr alterations to pressure vessels that comply with Section VHT, Divisions I and 2, of the ASME Code and for repaits to pressure vessels that comply with Section VIII. Division 2, ofthe ASME Code may not bre given until a pressure vessel engineer experienced in pressure vessel design has been consulted bout the alterations and repairs and has approved them, The authorized pressure vessel inspector will designate the fabrication approvals that are required. The authorized pressuve vessel inspector 1 may give priot general authorization fot limited or routine repairs as tong asthe inspector is sure that the repairs are the kind thot will not require pressure fests 79, Who shall approve all specified repair and alteration work? my +The API authorized pressure vessel inspector. after the work has been proven to be satisfactory and any required pressure test has been witnessed 80. What must be removed from base material prior to welding? i ‘© Surface invegularities and contamination 81, All repair and alteration welding shall be in accordance with what code? 2) © ASME Code, except as permitted in 72.11 2 Wi 123) ‘must be done before Preheat or Controlled Deposition Welding is used in fieu of PWHT? + Prior to using any alternative method a metallurgical review must be conducted to determine ifthe proposed alternative is suitable for the application 83. Name the materials allowed when using the alternative preheating method when notch toughness | testing isnot required. 231) ‘+The materials shall be limited to P-Nos P-No. | 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 Controtled-Deposition Welding Method. { (7232) ‘+The materials shall be limited to P-No. 1, P-No. 3 and P-No 4 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Wh. APLEXANS .ORG16 85. Can local post weld leat trestinent (PWHIT) be substituted for 360 degree banding? 725) ‘+ YES provided the following conditions are met: ‘+ Application is reviewed and procedure developed by engineer experienced in pressure vessel design & PWHT requirements ‘+ In evaluating the suitability of a procedute, all applicable Factors (base metal thi properties, ete ) are considered + Preheat of 300 degiee or higher per WPS is maintained + PWHT temperature is maintained for distance not fess 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 kness, material 86. What considerations must be given to the repat of stainle s? 726) eel overlay and clad # Consideration shall be given to factors which may augment the repair sequence such as stress level, P number of base material, sevice 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, Filler Weld Patches, Overlay Patches, Flush patches © BUTT JOINTS - shall have complete 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 desi repairs Also it must be true that; n considerations, they are temporary (a) The fillet-welded patches provide design safety equivatent to reinforced openings designed according to the applicable section of the ASME Code. () The fillet-welded patches are designed 10 absorb the membrane stain of the parts so that | in accordance with the rules of the appticable section ofthe ASME Code, the following result: ‘+ The allowable membrane stress is not exceeded in the vessel parts or the patches. ‘+ The strain in he patches does not result in fillet-weld stiesses that exceed allowable stresses for such welds + OVERLAY PATCHES - shall have rounded corners. + PLUSH (insert) PATCHES shall have rounded corners and be installed with full penetration batt 1 joints 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Wild. APIEXAMS -ORGWw 88. Summarize the rules for the use ofa full encixclement lap band on a pressive vessel + A full encirclement lap band repair may be considered a tong term sepais if the design is approved. and documented by the pressure vessel engineer and the authotized API pressure vessel inspector and the following requirements are met: ‘The repair is not being made to a crack in the vessel shel. i ‘© The band alone is designed to contain the full design pressue All Jongitidinal seams in the repair band ate full penetration butt welds with the design joint efficieney and inspection consistent with the appropriate code. ‘+ The circumferential fillet welds attaching the band to the vesse! 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 of the original shell material covered by the band. + Fatigue of the attachment welds, suel as fatigue resulting rom diffetentiat expansi relative to the vessel shell, should be considered if applicuble. ‘+The band material and weld metal are suitable for contact with the contained fluid atthe design conditions and an appropriate corvosion 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 ofthe repair. Non-penetrating nozzles, ‘including pipe caps attached as nozzles) may be used as long term repairs for otber 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 ofthe ‘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 corrasion allowance shall be. provided 89. Describe the material suitable for making repairs or alterations 728) . + 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 ste! 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? 7.29) + NDE techniques that are in accordance with the applicable sections of the ASME Code or another applicable vessel rating code. 9}. After repairs or alterations, isa pressure test required? (7.210) ‘© Repairs - pressure test only applied if inspector believes one is necessary. ‘+ Alterations - pressure test are noumnally required. Subject to the approval of the Jurisdiction (where the jurisdiction's approval is requted), appropriate nondestructive examinations shall be required where a pressure testis not performed) Substituting nondestivetive examination procedures fora 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 heen consalted 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APLEXAMS.ORG18 92. Write the API 510 Test pressure formuta 7210 + Test Pressure = | 3 MAWP X Stress at Test Temp/Siress at Design Temp 93. List the minimum tensile strength requirements for filler metals used on vessefs weld repairs and the details ofthis method of tepai 2 + The filler metal used for weld repairs should have minimum specified tensile strength equal to ot greater than the minimum specified tensile stength of the base metal. Ifa filler metal is used that hhas a minimum specified tensile strength lower than the minimum specified tensile strength of the hage meta the compatibility of the filler mefal chemisuy with the base metal chemistry shall be considered regarding weld ability and service degradation. In addition, the following shall be met: ‘= The tepait thickness shall not be more than 50 percent of the required base metal thickness, excluding corrosion allowance ‘+ The thickness of the repair weld shall be increased by ratio of minimum specified tensile strength of the base metal and minimum specified tensile ofthe filler metal used for the repair. The increased thickness of the repair shall have rounded comets and shall be blended into the base metal using a 3 to I taper The repair shall be made with a minimum of two passes, sments associated with re-rating a pressure vessel. ‘+ Calculations from either the manufacturer or an owner-user pressure vessel engineer (or his designated representative) experienced in pressure vessel design, fabrication, ov inspection shall Justify re-ating. Il be established in accordance with the requirements of the construction cade to ‘which the pressure vessel was built or by computations that are determined using the appropriate formulas inthe latest edition of the ASME Code if ail ofthe essential details comply with the applicable requirements of the code being used. If the vessel was designed to an edition or addendum of the ASME Code earlies than the 1999 Addenda and was not designed to Code Case 2200 ot 2278, it may be re-rated to the latest edition/addendum of the ASME Code if permitted by ‘+ 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 obiained 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 lew of testing. ‘+The pressure vessel inspection and ve-sating is acceptable 1 the authorized pressure vessel Inspector 08/04 Rev 9 FAST TRACK TECHNECAL 281.482.2253 Wal. APTEXAMS.ORG19 95. When isthe re-sating of a pressure vessel considered complete? 73) = When the API authorized pressue vessel inspector oversees the attachment of an additional hhameplate or additional stamping that carsies the following information: Rerated by: Maximum Allowable Working Pressure — psi at__degrees F. Date. AP] RECOMMENDED PRACTICE 576 SECOND EDITION, DECEMBER 2000 REVIEW QUESTIONS Section 1 - General i 1. What is the general scope of API RPS76? o : ‘+ To describe inspection and repair prac used in the oil and petrochemical industsies for automatic pressure-relieving devices commonly Section 2 ~References 2 What document should be referenced to determine the appropriate size for a pressure relief device? © RP520 Sizing, Selection, and Installation of Pressure Relics 1g Devices in Refineries Section 3 ~ Definitions 2. Describe a pin-actuated device, 1 1.3) © Anonreclosing pressure relief device actuated by static pressure and designed to function by Duckling or breaking a pin, which holds a piston or plug in place. 4, Whit isa huddling chamber? 622 + Anannutar pressure chamber located downstream of the seat of a pressure relief valve For the purpose of assisting the valve in lifting } 5. Describe “rated rel 336) ‘+The relieving capacity use as the basis for the application of a pressure vessel reel deviee determined using the applicable code of rezutation, 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APIEXAMS.ORG20 Section 4 ~ Pressure-Relieving Devices 6, What is the function of pressie-telieving dev ay 5? © To protect refinery equipment and personnel by automatically opening at predetermined pressures, 7. Name common examples of pressure relieving devices. or ‘+ Direct spring loaded + Pilot PRV = Rupture disks Weight loaded devices Pressure/Vacuum vent valves 8, Name the five types of pressure relief valves 4243.44.46.47) © Safety valve © Relief valve © Safety relief valve + Balanced Safety Relief Valve + Pilot-operated safety relief valve 9. Describe a safety valve, (4.2ySeetion VIII UG-126 foot notes) ‘© Actuated by static pressure upstieam of a 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? 42 + Corrosive refinery services + Any hack pressure service + Whee discharge is piped to remote locations. Where escape of lading fui around blowing valves is nt desirable + Inliquid serviee ‘As pressure conttol or bypass valves H. Describe a relief valve. (4.3\Section VII UG-126 foot notes) © Actuated by static pressure upstream of a valye ‘+ Lifts in proportion tothe increase in pressuve. + Usually veaches ful it at either 10% or 25% overpressure, 12. Why do relief valves have closed bonnets? 43) To prevent the release of conosive, toxie, flammable or expensive fluids, 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 We. APIEXAMS. ORGal 13. Relief valves should not be used in what situations? 432) #Insteam, air. gas, ot vapor service + Inservices piped to an enclosed header unless the effects of any constant or variable backpressure have been accounted for # As pressure contrat or bypass valves. 14. There ate two types of safety relief valves What are these two types? 45,46) ‘© Conventional & Balaneed 15. Deserihe a conventional safety elief valve a5) * Opening pressure, closing pressure and refieving capacity are affected by back pressure ‘© Has aclosed bonnet vented to the downstream side. 16. Where ate conventional safety relief valves used? asi ‘+ Refinery process industries that handle flammable, hot, of oxic materials. 17. May a conventional safety relief valve be used on boiler steam drums or super heaters? sy + No 18. Describe balanced safety relief valve, 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: “ey ‘+ Balance safety relief valves are normally used in applications with flammable, hot or toxic materials, where high pressures are present atthe 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 controled by a self-actuated pressure relief valve (called a plot valve. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WW! APTEXAMS .ORG22 21 What are some applications of pilot-operated safety relief valves? am ‘Where a large relief area andlor 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 shott blow down required. Where back pressure is very high and a balanced design is required. Where the process requites the sensing of pressure at one location and the relief of fluid at another Whore inlet and outlet frictional losses are high Where in-situ, in-service, set pressure ver jon is desired 2 Name some limitations on the use of pilot-operated safety velief valves 72) © Where fluids are dinty. ‘© Thick or viscous fluid service. ‘© With vapors which polymerize in the valve. 23, What are the three basic categories of pressure and/or vacuum vent valves? 43) © Weight-toaded pattet vent valve ‘© Pilo-operated vent valve ‘© Spring and weight-losded vent valve 24, What are the applications and limitations of pressure and/or vacuum vent valves? (48 1 and 2 + They are designed to protect atmospheric and low pressure storage tanks and are not generally used in applications requiring set pressures above 15 tbifin® 25, Desetibe the parts of a Rupture Disk Device. (9) ‘+The combination of a capture disk and rupture disk holder is known as a rupture disk device 26 Name the types of tupture disks. 9) Conventional Rupture Disk. ‘Scored Tension-Loaded Rupture Disk. Composite Rupture disk. Reverse-Acting Rupture Disk. Graphite Rupture Disk. 27. What is one advantage of the 91s) raphite uisk over metal disks? +i gh conosion resistance 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW APTEXAMS.ORG23 28, What is usually the service life of pre-bulged metal rupture disks installed so that pressure acts against the concave side? 93) + One year- If not replaced periodically they can rupture under normal pressures without warning. 29. Nonmally the operating pressure of a system protected by a pre-bulged rupture disk is from 65% (@ 850 of the disk's predetermined bursting pressure. What determines this pressure range? 493) ‘©The exact percentage depends on the disk's type. 30. What precaution should he taken when a rupture disk is used in combination with another relief Uevice and removed for any reason and will be reused? 93 » They should he handled with care to avoid damage which might cause premature rupture See ~ Causes of improper Performance 31 What is the basic cause of many the difficubties encountered with pressure relief devices? 6.) © Corrosion 32, What effect can the severe over sizing of a relief valve have? 62) + Damaged valve s 33. Li the major causes of improper perforn nce in pressure-relieving devices. 6) Corrosion Damaged seating surfaces Failed springs Improper seating & adjustments Plugging and sticking Misapplication of materials Improper location, history, or idemtfication Rough handling Improper differential hetween operating and set pressures Improper piping test procedures 34. To prevent leakage of the fading fluid, what must be maintained in the flatness of seating surfaces on pressure relief valves? 52) + Anoptical precision on the order of 3 light beads/hands 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WH. APTEXAMS.ORG24 35. What are some reasons for damaged valve seats? + Corrosion + Foreign particles getting into valve + Improper or lengthy piping tothe valve inlet or obstructions in the Line © Careless handling during maintenance, Leakage past the seating sutfaces of a valve after it has been installed. Improper blow down ting settings. Severe over sizing 36. What almost always eauses broken springs in pressuse relief valves? i 63) ' + Conosion (Note: two types - surface & stest) 37. What chemical frequently causes stress-corrosion spring failure in petrochemical plants? (53) { + Hydrogen sulfide (HS) 38. What may be done to prevent spring failure due to cowrosion? 63) ‘© Spring material which can resist the action of the corrosive agent ) = Spris ‘+ Spring coated by a coating that can withstand the operating temperature and environment. 39, What medium shoutd be used to set the following pressure relief devices? 64) Safety relief valve - air or other gas. ‘Vapor service valve ~ air or inert gas. " ‘+ Steam service valves - steam but air may be used if suitable corrections are applied. + Liquid service valves ~ water 40, What is ecormended for lubticating sliding pats and threads on valves to prevent fouling? (55) ‘+ Valve parts should be lubsicated with a material that is compatible with the service and temperature 41. In general, what should be considered in determining the material to be used for pressure- telieving devices? © Temperature © Pressure: © Coirosion resistance requirements 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Ww. APTEXAMS.ORG25 42. Why should relief valves be shipped in an upright position? © When relief valves ate laid on their sides. she springs may not exert the sisne Force all around the seating surface 43. What is one important aspect of the work done fo PDs in the maintenance shop? 58D + Rough handling should be avoided such as the application of excessive hackpressine to hellows, type valves: 44, IF RV inlets and outlets are not covered during shipment what provisions should be made? 683 ‘+ Provision should be made for such covering during all future shipments, 45, What risks are incurred when a hydrostatic test of discharge piping for a PRD is performed? 6.19) «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 hack flow of the fluid. Section 6~ Inspection and Testing 46, Name two types of inspections 6») + Shop inspections! overhauls and visual on-stream inspections 47. When a relief valve is removed for inspection or overhauls winat additional inspection should be made? 62) ‘+ Inlet and outlet piping should be inspected for inteinal deposits and records made of their conditions 48. After a PRV hs been reinstalled what should be checked? 20 + After reinsialling the elated piping should be checked to ensure that itis not imposing fonds 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 he maintained and should include what? (623) * Information on upsets and their effects on the valve. © Theextent of any leakage that has occurred in operation © Any other evidence of malfunctioning. 08/04 Rev 9 FAST TRACK TECHNECAL 281.482.2253 Wl. APLEXAMS .ORG26 50. When a relief device is removed from a system that is in operation, name a necessary step to prevent an unexpected pressure release. 624) ‘+The space between the relief valve and the adjacent black valve should be vented to release all pressure 51. What must be done to valves in hydrofluoric acid sex (625 ice as soon as they are removed? © They must be correctly neutralized immediately after removal 52. 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 fine any major blockage or fouling? 626) ‘© Radiogiaphie Inspection, 53. What 626) fl inspection ofthe piping after the removal of a PRD ine + The condition of the process piping whose interior is not visible. 54. Why should caution be used with the rigging to remove a large PRD for maintenance? 2 ‘+ Prevent auxiliary piping and pitot assemblies from being damaged. 55. Priot to performing the as received pop test on a PRD what should be inspected and checked? 6.28) + Check that the seals are intact on the pressure set screw and the blow down sing screw cover 56, When may the as received pop pressure test be waived by the owner/user? (628) + When the valve is extremely fouled and the test may damage the valve. 57. When uinusual corrosion, deposits or conditions are noted upon receipt of a PRD at te shop what should be done? (629) ‘+ The inspector should participate inthe shop inspection ofthe PRD 5B_ When is it not necessary to disassemble at PRD at the shop? 16210) + Ifthe valve has been tested atthe appropriate API 510 interval and the as received pop test shows, the valve to be operating properly disassembly is not mandatory. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS ORG27 59. List atleast four of the steps in the inspection of a relief valve upon disassembly 62.11) Measure each part's dimensions. ‘Check components for wear or corrosion Seating surfaces should be checked for roughness or damage. Springs should be checked for eracking. 60. During re-assembly of a pressure relief valve what should never he done? 62.12) ‘+ The nozzle and seating surfaces should never be oiled. G1. Aftet e-assembly of a relief device how should any blow down rings be set? (62.13) + Inaccordance with the manufacturer's recommendations. 62. Why do some manufactures recommend atleast three pop tests before relea installation? 62.14) ing a relief device for ‘+ This believed that the first pop test helps to align all of the components and thatthe successive tests verify the actual set pressure. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Ww APTEXAMS.ORG.28 63. Once the valve is set to pop at its CDTP (cold differential test plessute) it should he checked for _ (62.15) ‘+ Leakage and seat tightness by increasing the pressure on the (est 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? (6217) +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. us 65. May a pilot operated pressure relief valve be tested in place if no block valve exists beneath it? 6219) ‘= No, it may be inspected and sepaired only while the vessel is out of service 66. Where isa wel 1m vent used” (6.2.20) 3 Tonded pressive and/or a va * Onpresswe storage tanks we 67. What type of fail ave pressure and/or vacuum vent valves prone (0? (6220) Sticking. 68. Is it permissible to reinstall a rupture disk once it has been unbotted and removed from its holder? 6220 ‘+ No, it may not be possible to get a tight seal and unreliable performance is probable 69._ What are the objetives of a visual on-stream inspection of relief devices? ae 6.3) ¢* + Make sure the correct device is installed, that the correct pressure can be determined, that there are not any blinds oF gags installed, that the seals are intact and that the valve isnot 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 dischas ge piping is supported, valve body drains and vent stacks are open. any requited 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 it is 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? (ay +The perfon mance of the device ina particular service. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS ORG29 71. How isthe frequency of shop inspection or overhaul normaly determined? (6401) + By the operating experience in the valve's present service. corrosion service would be more frequent for example, Section 7- Records and Reports ‘72. What is the principal objective in keeping records on pressute-relieving devices? am ‘= 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-teliving device include? (72) * Its specification data and a continuously accumulating record of its tests and inspections results 74, Which of the following per API S76 might be expected to initiate a work cequest on a PRD? The API inspector or the Process Unit Operator? a) = Process Unit Operator 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APLEXANS .ORG30 API RECOMMENDED PRACTICE 572, SECOND EDITION, FEBRUARY 2001 RIEVIEW QUESTIONS Section 1 - General we the mai points covered in API RP 572? Descriptions ofthe 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 repots. Sections 3, 4 § 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? an ‘+ To determine the physical condition of the vesse! ‘© Determine the type, 1ate and causes of deterioration. 3. List atleast four addi (74,72) nal reasons For inspections. + Safety maintained ‘+ Periods of operation without shutdown extended - well planned maintenance program + Rate of deterioration often reduced ‘© Future repair and replacement requirements estimated Section 8 - Causes of Deterioration 4. List the 4 general forms of deterioration, (sa) + Electrochemical + Mechanical © Combination ofall three 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APTEXAMS.ORG8 6 wt) 82) 08/04 31 List the 4 general classifications of things that cause deterioration upon con vessel suiface into contact with a Organic & inorganic compounds Contaminated or fresh water Steam Atmosphere Name 6 factors, which accelerate the rate of deterioration, Temperature Suess Impingement High velocity Degularity of flow ‘What is the prime cause of deterioration in a pressure vessel? Corrosion ‘What are the most common internal corrodents in refineries? ‘Sulfur Sall(Chioride compounds Define e “The removil of surface mat or cavitation, caused by numerous individual impacts of solid or Hiqui ind where in a vessel? Exosion is typically f Downstream of eonttol valves Downstream of orifices ‘Downstream of pump discharges At any point of flow direction change, such as impingement baffles Rev 9 FAST TRACK TECHNICAL 281.482.2253 WW. APIEXAMS.ORG(823) RD. (824) 13, (825) 14 826 Is. 20 08/04 32 Problems with envitonmenial cracking have been experienced of high hardness, areas of high stress or both. Examples ofthis include. CChioside stress corrosion cracking of austenitic stainless steels due to moisture under insulation, Polythionie acid stress corrosion cracking (PSCC) ‘Caustic stress corrosion also know as caustic embrittlement ‘Arnine stress corrosion cracking in non-sttess relieved vessels. Carbonate sttess corrosion cracking in alkaline systems, Wet hydrogen sulfide siress cracking, hydrogen induced eracking, and hydrogen blistering. Consosion beneath refractory linings ean eause what? B gf the refractory ‘What does fatigue cracking ina vessel result from? Excessive cyclic stresses the are often below the yield strength of the material such as; Pressure stresses Mechanical stresses ‘Thermal stesses Creep damage may be difficult to detect until Significant damage has occured ‘What factor inereases susceptibility to high temperature hydrogen attack: in a vessel's mate Increasing carbon content of the materials Inthe absence of |! _ sulfide corrosion tates of are relatively low at metal temperatures below "1 Water 450°F ‘When buried vessels are equipped with adequate eathodic protection when will excavation be required for inspection? ‘When evidence of coating os wrapping damage is revealed What ate the most important microorganisms that directly inf 10) ences the rate of metallic Sulfate reducing bacteria found in may soils Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APTEXAMS .ORG33 What causes titanium alloys to fose dctitity? “Absorption of hyd ‘Many of the problems that may develop in pressure vessels are traceable to what? aulty material or fabrication Poor welding, improper hest weatment, fabrication with dimensions outside tolerances allowed by ASME Code, improper installation of internal equipment, and assembly of flanged or thrended Joins are examples of what problem? Faulty fabrication List several consequences of improper welding teclniques. Incomplete penetration Lack of fusion Cracking Undercutting Slag inclusion Porous welds igh sesidual stresses near welds affecting the physical properties and corrosion resistance of the matal is caused by what? Improper heat treatment mensional intolerance can lead to what? ‘Stress concentrations and subsequent failures ‘What are the consequences of improper installation of internal equipment? Inefficient operation Blockage of passages Displacement of internal equipment with pressure surges 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WW. APLEXAMS .ORG34 26. Improper fitting or tightening of flanges or Unveaded joints may lead to what? 856) Leaks and possible failure Section 9 ~ Frequency and Time of Inspecti 27. What are the important factors when determining the frequency with which a pressure vessel should be inspected” © The ate of deterioration © The remaining corrosion allowance event can provide and oppentunity for an inspection? 29. What occasional check may locate the cause of functional deterioration? 92) © Accheck of a vessel's operating record 30. What are the most 0.3) portant issues when scheduling a unit for inspections? ‘© Sofety and reliability Section 10 Inspection Methods and Limitations 31. Before starting inspection of a pressure vessel, what are some basic things the inspector should do? 0.1) = Determine pressure and temperature conditions under which the vessel has operated since last inspection ‘+ Ascertain the character of the vessel contents and the function the vessel serves in the process 32. Name at least § types of tools required by an inspector to inspect a pressure vessel. 102.2) Portable fighis Thin bladed knife Broad chisel or scraper Minors Calipers Slee! tape measue(50 feet) Hammer Notebooks and pencils 33, Whete should the external inspection start? ‘= Esternal inspection should start with ladders. stairways. platforms, or walkways connected to or heating on the vessel. The condition of most parts ean be determined by hammering 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APTEXAMS .ORG36 43, Isatting of a vessel has occurred, what should be cheeked for distortion and 1038 © Nozzles 44. What is the recommenced resistance for grounding connections? (1039) + Soohuns or less, not to exceed 25 obims 45. Unchecked vibrations on suailiary equipment such failure? 103 10) as gauge connectors can ca Ise What type of + Fatigue failure 46. What type of inspection is usually sufficient for protective coatings and insulation? (103.1) © Visual 47. At what operating temperate does CU] become a concern on externally insulated vessels subject to moisture ingress? (oat © Betiveen 25 t0 250° F 48. What are the normally tequited measurements on external metal surfaces of a vessel? (103.12) + Under normal conditions, atleast one measurement in each shell ring and one on each head. If no history exists for a vessel, then get areading in each quadiant ofeach shell ring 49. What types of corrosion are found on exteinal surfaces of vessel?” (10313) + Atmospheric + Caustic Embritilement + Hydrogen blistering + Soil corrosion 50. Vessels containing acidie corrodents are found in the vessel? (103.13) inject to hydrogen blistering. Where is this normally © 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 ean occur ton the outside surface as well 51 What should a vessel be checked for if a caustic is stored in it? 03.13) + [ acaustic material is stored or used ina vessel, the vessel should be checked for caustic embrittlement. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APTEXAMS ORG37 52. Evidence of white salt 103.13) seeping through exacks will indicate what type of material? + 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 buly (103.13) ws or buckling on a vessel in service. ‘+ By measuring the changes in circumferences or hy making profile of the vessel wall. Profiles are made by taking measurements from a fine parallel to the vessel wall. A surveyor’ transit or a 180 degree optical plummet may also he used 55, The degree of surface preparation needed for internal inspection will vary with several factors Foremost among these are: (10.4.2) + Type of deterioration expected * Location of any deterioration 56 Chacks in vessels are most likely to occur where? (1043) + Inplaces where there ate sharp changes in shape or size or near welded seams, especially if «high sess is applied 57. What may preliminary inspections reveal? (10.43) + Unsafe conditions, such as those due to loose internals that may fall or due to badly corraded or broken internal ladders or platforms ‘58. A detailed inspection should start al one end of the vessel and work toward the other end and include what? (o4aay + A systematic procedure to avoid overlooking obscure but important items 59. What should all parts ofa vessel be inspected for? (0.44) © Conosion = Erosion © Hydrogen blistering = Cia = Laminations 60. Some times the depth of a pit can be estimated by ust 044) ‘what simple method? ‘© Extending the lead of a mechanical pencil 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APIEXAMS.ORG38 61. What types of methods are used For det 044) mining the extent of cracks? Dye penetrant Magnetic-particle (wet or diy) © Ulirasonic shear-wave 62, Explain the difference in appearance between erosion and corrosion (1044) ‘+ 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 focal aren © Corroded areas ate not often smooth of bright 63. Shells and heads of vessels should be inspected for defor +o. v4 deformation? (aay jon. Which is more likely to suffer The shell of a vessel 64. How do you chect bulging? ‘or (a) small distortions, (b) bulging or buckling (c) out-of-roundness or (1044) + Small distortions - by placing a straight edge against a vessel ‘+ Bulging/buckting - measuring the changes in circumference or by profile (measuring from a line strung parallel to the vessel) ‘© Qutof round/bulge - by measuring the m sectional area and comparing the two. imum and maximum internal deviation at the cross 65. What is the best method of locating suspected deformations? 04a) ‘© Ditect a flashfight beam parallel to the surface to check for shadows in depressions and on the non-light sides of internal bulges. 66. What is the most sensitive method of locating surface cracking? (044) ‘Fluorescent Magnetic Particle Method. 67. What is the difference between cracks and laminations? 04a) ‘+ Laminations rum ata stant to the plate surface ‘© Cracks run at right angles to the suiface. 668, Name three important factors inthe inspection of metallic linings 045) ‘+ That there is no corrosion. ‘© Thai the linings are properly installed ‘+ That no holes or cracks exist 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APIEXAMS .ORG39 69. Explain how the Corrosive Tab Method is used to determine the metal loss on vessel linings, 1045) ‘© Small [ by 2 inch tabs of lining that form a right angle are welded onto the lining with one Tez extended into the vessel. During inspections the thickness of the protruding leg 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. pl concrete, and cartvan block oF brick. 046) © Forthe most part all of the above will be visually inspected for discontinuities or physical damage. + Specifies ‘+ For paint, glass. plastic, & rubber fining the spark tester method is used to locate holidays. For ile, oF refractory lining the hammer testing method is used to locate lack of 71. Name the factors to consider when selecting tools for thickness measurements (ios) ‘+ Accessibility from both sides ‘+ Desire for NDE methods + Accuracy desired. + Time available i + Economy 72. What isthe primary means of obtaining thickness measurements? (105) » Ultrasonic instruments 73. To analyze defects in welded seams that are not visible on the surface of the metal, what two. methods are used? 06) | © Radiography ‘Shear-wave Ultrasonie 74, How does the Hammer Test function in supplementing visual examination of a vessel for the inspector? (ogy + "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 nings and lack of ond in concrete ‘eale” - Remove scale accumulations for spot inspections 08/04 Rev 9 FAST TRACK TECHNICAL 261.482.2253 Wi, APIEXAMS .ORG40 75. When is use of the Hammer Test not recommended? 08 1) © When vessels are under pressure ‘© On piping upstream from a catalyst bed. 76. Whatis pressure testing? (2082) ‘+ Filling a vessel with liquid or gas and building up an internal pressure to a desived level 77. Which is the preferred method, pressure or vacuum testing, and why? (10.8.2) ‘+ Pressure testing. Leaks from an internal pressure source arc more easily focated. With vacuum testing you will know if there ave leaks, but the location is not evident. ‘78. What should an inspector examine before applying test pressure to the shell side of an exchat 0083) ‘+ He should inspect the tube walls tobe sure there is sufficient wall thickness to withstand external pressure, 79, Iman exchanger where the cooling water the lower pressure stream and a hyocarbon isthe higher pressure steam, what i possible way o detect a leak? (1083) + Temay be possible to assess the hydrocarbon content upstream and downstream of the suspect exchanger. 80. Name the wo most limits of corrosion or other deterioration that must be known by inspection. (109) + The retiring thickness of the part considered «The rate of deterioration \ Si, Often vessels have excess thickness above that required or presstne When aking credit fortis ences thickness what must alvays be considered? 199) ‘+ Insome eases the excess thickness of the shell or lead plates was used by the designer to compensate for nozzle openings. 1 82, Before deterinining the limiting or retiring thicknesses of parts of any pressure vessel, what must be known? © Which Code and edition of that Code i is to be rated under Are there specific regulations regarding limits and allowable repairs. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WNW. APLEXAMS ORG41 Seetion 11 - Methods of Reps 83, When is it required that a repait concern making welded repaits to a vessel have a National Board R stamp? an ‘+ When the jurisdiction dictates thatthe these repairs ave to made by only R stamp holders 84. When is a pressuwe test of a vessel normally a requirement? ay © After an alteration Section 12 - Records and Reports sort file should cont 85. A complete r ay n wht thnee types of information? ‘+ Basic data ~ manufacturer's dfawings, data reports and specifications, design information, results ‘of any material tests. ld notes - notes and meast ingpected and repairs required. Continuous file - all information on the vesset’s opetating history, previous inspections, corrosion rate tables, records of repairs and replacements. ments recorded on site including record of condition of all parts: 86. When making reports recommending repairs, who should receive these reports? 2.2) ‘+ All management groups. This would normally include engineering, operation, and maintenance {depaitments, Reports should include the location, extent, and reasons for recommended repair. Appendix A - Exchangers 87. Why should bundles be checked when they ate frst pulled from the shells? (agty +The color, type, amount, and location of scales and deposits often help to pinpoint conosion problems 88, A distinctive Prussian bh (A92) on bundle tubes ficates the presence of what? + Feniferrocyanide 89. Coils in open condenser bnses and double-pipe exchanger shells should be inspected according 10 what API Recommended Practice? 4A 10) © RESTA 08/04 Rev 9 FAST TRACK TECHNECAL 281.482.2253 WWW. APTEXAMS ORG42 CHAPTER TI CONDITIONS CAUSING DETERIORATION OR FAILURES SECOND EDITION, 1973 201 General |. What are the modes of failure that can he found in efinery equipment? 2012) * Fatigue Failures - caused by stress reversals. (In machinery these cracks start atthe susface 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 briile fracture at ambient temperatures anc! below. (A number of tank failures have been aitributed tothe brittle condition of steel at low temperatures, combined with high loads that have been imposed by thermal stress set up rapid temperature changes.) Excessive Metal Loss - may result in fate if cemaning wall thickness settings. This isa rare occurrence. © Wrong Material or Wrong Gaskets - may lead to fale 1s below safety valve 202 - Corrosion 2. Covrosion problems in refining operations guoups? (2024) bed ded into three major g ups. What are these ‘+ Corrosion from components present in crude cil. + Corrosion from chemical used in refinery processes. + Environmental connsion 3. Name the corrosion compounds found in crude of (20201) ‘+ Hydiogen Chloride and organic/inorganic chloride. ‘Hydrogen sulfide, meteaptans, & organie sulfur compounds. © Carbon dioxide. ‘Dissolved oxygen and water © Organic acids. Nitrogen compounds 4. What is hydrogen chloride? When does it become a costosion problem in process streams? (202022) ‘+A dty hydrochloric acid (normally not corsasive in process streams), It bevores corrosive when water is available to form hydrochloric acid 5. What do all crude oils contain? (202022) = Salt 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW, APTEXAMS ORG43 6. What is the most active ofthe sulfur compounds in causing corrosion in refinery equipment? (202.023) + Hydiogen Sulfide 7. At what temperature range does accelerated hydrogen sulfide corrosion occur in refinery equ (202.023) ment? Between 450 ani 900 °F 8. What makes earbon dioxide corrosive? (202.024) © When itis combined with water. i hecomes earbonte 9. Where is conrasion by catbon 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. 11. When are organie acids very corrosive? (202.026) #Attheirboiling temperatures. The most severe form of corrosion occurs upon condensation 12, What wo forms of corradents are formed wien nitrogen is cracked in a cracking or catalytic cracking unit? (202027)] ‘+ Ammonia & Cyanide 13. What is phenol and what is it used for? (202.033) © Carbolie acid - Used in refinery oper fons in the manufacture of lubvicating oils and aromatics, 14 What is caustic and what i it used for in refinery operations? (202.035) ‘+ Sodium Hydroxide - Used for the neutralization of acid components and for prease 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 genetal metal loss and stress corrosion cracking will occur. How may thi be identified? (202.037) attack *» By the appearance of « blue salt deposit on the metal's surface. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Whi APIEXAMS. ORG44 16. What are the primary uses of ammonia in the rfini (202037) © Asarefrigerant © For neutalization of ac cracking units fe components in overhiea 1 pipe stills, and 17, What materials is ammonia harmful to? (202037) ‘© Copper base alloys. 18, What is chlorine used forin refinery operations and when does it became very corrosive? (202038) ‘+ Used for treating cooling water and for the manufacture of sodium hypochtorite for treating oils, Iwbecomes very corrosive in contact with small amounts of moisture 19. Aluminum Chloride - What is i used for? What does it form inthe presence of water? How does it affect carbon stes! and stainless steels? (202.039) ‘© Used as a catalyst in isomerization units. It forms hydrochloric acid in the presence of water. Hydrochloric acid causes severe pitting covrosion in carbon steel and intergranular and stress corrosion cracking in stainless 20. What is the term applied to atmospherie corrosion? (202.041) + Galvanic 21, What is needed to prevent atmospheric corrosion? (202.081) + Eliminate water from the surface ofthe metal by means of a protective barrier oF coating 22. At what temperature does hidden corrosion take place unde insulation and fireproofing if moisture penetrates through cracks inthe insulation? 2 (202.042) ‘+ In vessels 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? (202053) ‘+ Because the steam may be decomposed to hydiogen and oxygen, and the flee oxy severe scaling sn ay cause 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APLEXAMS.ORG45 25, Vanadium oxide corrasion does not take place below winat temperature? (202054) + 1.100° 26, The extent corrosive attack by hot sulfur compounds (sulfu dioxide. hydrogen sulfide) depends on What thtee things? (202055) # Concentration, tempetature. and oxidizing power of the envisonment 27, At what temperature does all gray strength, scaling, and growth? (202.056) cast iron begin to deteriorate, resulting in extreme brittleness. loss of = 800 28. Growth of cast iron results from what two things? (202056) + Graphitization & infiltation 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 i products, leaving the graphite intact. 30. In what material do you find graphitic corrosion and at what temperature docs it occur? (202063) # Incast iron at temperatures below the dew point of water 31. How can you recognize gi (202.063) saphitic corrosion? * By the sofi porous stiueture that remains inthe areas where it occurs 32. What materials is mercury harmful to? (202064) * Monet and copper based alloys (stress corrosion cracking) * Aluminum alloys 33. Define Stress Corrosion Cracking, (202064) + The spontaneous failure of metals by crack ned action of cotrasion and tensile stress 08/04 Rey 9 FAST TRACK TECHNICAL 281.482.2253 Wa. APTEXAMS ORG46 34, What is dezincification? ‘+ Atype of comosion that can occur in copper- zine alloys (lasses) containing less than 85%% copper and used in water service. 35. What are three types of dezincification? (202066) ‘+ Plug - occurs in localized areus + Layer - covers large areas ‘¢ Inforerystalline - 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? (202.067) ‘+ An electrochemical type corrosion that occurs when two different metals are electrically connected, ether 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 atthe point of contact or in a crevice between a metal and rnonmetal or between two pieces of metal in the presence of a corrodent 39. What is biological corrosion? (202.069) + Comosion influenced by primitive organisms 40. What ate te most important microorganisms that directly influence the rate of metallic corvasion? (202.069) ‘© Sulfate eeducing bacteria found in many sos 203 - Erosion 41, Erosion is frequently a problem in equ principle? (20302) he Muidized - solids principle. What is this ‘© Ia gas steam of sufficient velocity is passed through a mass of finely divided solids, such as a powder, the mass of particles will behave very much like a true liquid 42. What method of deterioration does cavitation induct (203022) + Erosion. Cavitations erosion is associated with the formation and collapse of cavities ina liquid aL the metal to liquid interface. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APTEXANS.ORG47 204 - Effects of High Temperatures 43, Define creep (204012) ‘+The low 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? (04018) + 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? (204022) +n granular corrosion, 46. When feritc steels ae heated above a certain temperature (above 1.100" F for mild steel). how does this affeet the material? (204022) + Leads to general lowering of the tensile strength 47. What i incipient melting (burning)? (204.022) ‘When fenitic stels are heated above approximately 2,600 °F, melting and oxidation will begin at the grain boundaries, The steel is called "burned" and will be very weak and britle upon cooling. 48. What is Graphitization? (204022) + A.stuctural change in certain frit steels that have operated fora long period of time between 825 and 1,400 °F. Carbide is unstable in that temperature range and may decompos (enite) and graphite (carbon). 49. What are the two gener types of Graphtization? (204.022) + Random Graphitization - graphite distiboted uniformly throughout the steet + Localized Graphitization - graphite highty concentrated in local regions ‘50. What is Sensitization? What happens to sensitized steel when exposed to conedents? (204.022) ‘+ When Austenitic stainless stecls are exposed to tempetatures of 750 to 1680 °F, precipitation of complex clromium carbides at the grain boundaries takes place. When the sensitized stee! is exposed to cotrodents, intergranular corrosion takes place 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WWW. APLEXAMS .ORG48 41, What is decarburization? (204034) ‘+ The loss of carbon from the surface of a fesrous alloy as 2 result of heating in a medium that reacts with earbon. 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 stee¥emaperature limits for hydrogen service? (208.035) © Nelson Chart 208 - Subnormal and Ambient Temperature Effeets 54. Define notch toughness (a property of metals) (20501) ‘+ The amount energy necessary to cause fracture inthe presence of a sharp notch or suess concentrator 55. Britle facture can be recognized by several characteristics, Wh: (20501) are these characteristies? Cracks propagate at high speed. * There may be a loud report or sharp rending sound There is almost 2 complete lack of ducttity +The fractured surface has a brittle or faceted surface 206 - Excessive Pressure 56, What is (206.01) excessive pressure? ‘+ 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 bb Blocking off against a pressure source ¢ Thermal expansion of a trapped liquid Hydraulic hammer or resonant vibration 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 wal. APTEXAMS.ORG49 207 - Overloading 58. What are some indications of everloadi (207 92) of equipment? + Visible distortion # Change of shape * Change of position Appendix 1 59, Stee (ferrous alloy) is an alloy of iron and carbon. What is the carbon content range? (App 1A) + 0.01% to 1.7% (Max. carbon content of weld able steels for Code purposes is 0.35%) 60, Usually for refinery consteucton stels have Fess than whal percent carbon? (App 1 A) © Less than 1% 61. Steels for welding| (App 1A) ave a maximum of what percent carbon content? + 0.35%. 62. There ate two general types of steels. What are these? (App 1A) ‘© Ferritic Steel - ordinary carbon steel, ow and intermediate alloy steels, and high alloy steets (straight chromium ‘+ Austenitic - chromium - nickel stainless steels 63. Nonferrous metals and alloys contain what percent iron? (App 1B) # Less than 50% 64, What isthe only commen copper nickel alloy and what is i used for? , ‘App 1B) © Monel 11 is used for relatively low temperature corrosion resistance. 65. What are the major uses of commercially pe copper in refineries? ‘App 1B) + Electrical conductors, gaskets, and corrosion resistance. 66, What are the major uses of aluminum and its alloys in refineries? iApp 1 Bb + Corrosion resistance and for structures which lightweight is a necessity. 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 Wahl. APTEXAMS.ORG50 ‘CORROSIVE MATERIALS AND THEIR USES IN THE PETROCHEM INDUSTRY ‘+ Sulfuric Acid and Hydrogen Fluoride - used in alkylation's units as a catalyst, Concentrations of 85% to 959% for sulfuric acid and above 659% for hydrogen fluoride. ‘+ Phenol (Carbolie Acid) - used for the manufacture of lubricating oils and aromatic hydrocarbons ‘+ Phosphorie Acid - used fora catalyst in polymerization units, = Cans So m Hydroxide) - used for neutralization of acidic components, + Mercury - used in instruments # Ammonia - used asa refiigerant and for the neutsa ization of acidic components, © Chlorine - used to treat cooling tower water and for the manufacture of sodium hypochtorite used 0 ueating oils © Aluminum Chloride - used as a catalyst for isomerization units 08/04 Rev 9 FAST TRACK TECHNICAL 281.482.2253 WwW. APLEXAMS .ORG