API-510 INSPECTOR EXAMINATION PREPARATORY COURSE FINAL CLOSED BOOK API-510 Examination Preparatory Course Final: Closed Book Page | of 18FINAL - CLOSED BOOK NAME: DATE: Please note: There is only one (1) correct answer to each question. Math problems may be ‘worked in this workbook. Assure you mark the correct question on the answer sheet, 1. Whatis the maximum period between internal or on-stream inspections? @) They shall not exceed on third the estimated remaining life of the vessel based on corrosion rate, or 10 years, which is less. b) They shall not exceed one half the estimated life of the vessel based on corrosion rate, or 10 years, whichever is less, ©) They shall not exceed one fourth the estimated life of the vessel based on corrosion rate, or 5 years, whichever is less. @) They shall not exceed on half the estimated remaining life of the vessel based on corrosion rate, or 5 years, whichever is less. 2. Lowenergy results on a Charpy impact test indicate 2 a) High ductility b) _Brittieness ©) High tensile strength d) None of the above 3. API-510 Authorized Pressure Vessel Inspectors must be recertified every years? a 5 b) 4 3) 3 a2 API-S10 Examination Preparatory Course Final: Closed Book Poge 2 of 18A vertical vessel has been in service for 4 years. The vessel service and has an MDMT of -20°F. during UT examination, the shell was found to have an actual thickness of 1.20". The original thickness of the vessel was 1.25” and the design thickness is 1.0392". Find the remaining life of the vessel if the corrosion rate is 0.0125" per year. used in lethal a) 16.8 years b) 12.86 years ©) Ayears 4) 14.5 years Prior to inspection of a pressure relief device, an operating history of the valve should be obtained. This history should include upset information. (True or False) Carbon or alloy steel with a carbon content exceeding % shall not be welded on? a) 0.25 b) 0.30 ° ©) 0.35 4) 0.40 Fillet weld patches are never allowed in API-510 repair work? (True or False) In Liquid Penetrant per Section Vill, Div.1, only indications with major dimen: greater than___shall be considered relevant? a) 132" b) 1s" V8 4) What makes safety precautions more important in vessel inspection than inspection of any other type of equipment? a) The height of the vessel ») Potential rotating equipment ©) Limited access and confined spaces d) Internals API-510 Examination Preparatory Course Final: Closed Book Page 3 of 1810. i. 12. 13. A safety relief valve that incorporates a bellows or other means for minimizing the effects of back prescure on its operational characteristics is known as a Valve? a) b) °) d) Conventional Balanced Safety Relief How often should each vessel above ground be given a visual external inspection? a) At least every 5 years or at the same interval as the on stream or internal, whichever is less. b) At least every 5 years or at the same interval as the on stream or internal, Whichever is more. ©) Atleast every 10 years or at the same interval as the on stream or internal, whichever is less, d) Atleast every 10 years or at the same interval as the on stream or internal, whichever is more. Where is cavitation most likely to occur? a) The first elbow downstream of a pump b) The first flanged connection downstream of a pump ©) The nearest flange upstream of a pump d) The suction side of a pump impeller Under what conditions may Magnetic Particle examination be performed on a part with a coating such as paint left on the part? a) » °) d The paint cannot be left on the part. It must be demonstrated that indications can be detected through the maximum coating thickness applied. Paint thickness may not exceed 2 mils Paint thickness may not exceed 3 mils API-510 Examination Preparatory Course Final: Closed Book Page 4 of 1814, 15, 16. 17. 18. In what Article of Section IX are procedure qualifications requirements found? a) Article 1 b) — Aticle It ©) Article IIL 4) Article 1V ‘examination is the most important method of examination? a) Radiography b) Careful visual ©) Ultrasonic 4) Hydrostatic Chemicals used in refining are not a variable when considering metal loss? (True or False) What directly affects the operating characteristics of a conventional safety relief valve? a) Changes back pressure on the valve. b) Changes in upstream pressure ©) Spring setting d) Disk tightness A minimum of specimens must be broken for each Charpy Impact Test? a) 2 d) 3 . 4 d 5 API-5 10 Examination Preparatory Course Final: Closed Book Page 5 of 1819. 20. 2 22, 23. When may widely scattered pits be ignored? @) _No pil depth is greater than % the vessel wall required thickness. b) No pit depth is greater than % the vessel wall required thickness, ©) _No pit depth is greater than 1% the vessel wall required thickness, d) No pit depth is greater than % the vessel wall required thickness, Under normal conditions, how many thickness checks should be taken on a vessel as a minimum? a) One on each shall ring and one on each head. b) — Twoin each shell ring and one on each head. ©) One on each shell ring and two on each head. d) Two oneach shell ring and two on each head. Name a type of corrosion that may be found on the external surface of a vessel a) Hydrogen embrittlement b) Caustic embrittlement ©) Erosion-corrosion d) — Sulfidic corrosion You are called out to review the final package for the repair of a 3/6" thick vessel fabricated from P-1 carbon steel material. The vessel is in a amine service and was post weld heat treated during original construction. You notice no PWHT was performed on the repair but a preheat of 200°F was used to make the repairs. \Wnat must be done? a) __ Nothing, the preheat temperature is satisfactory of this repair. b) The entire vessel must be PWHT'd again. ©) Localized PWHT must be performed on the repair areas. d) The vesse! must be taken out of service as repairs to vessels in this service are not allowed. If after calibration, Magnetic Particle equipment is stored for over a year, it must be calibrated prior to the next use? (True or False) API-510 Examination Preparatory Course Final: Closed Book Page 6 of 1824, 25. 26. 27. When may widely scattered pits be ignored? a) The sum of their dimensions along any straight line within an 8" circie does not exceed 1” b) The sum of their dimensions along any straight line within an 8" circle does not exceed 2” ©) The sum of their dimensions along any straight line within an 8” circle does not exceed 3” 4) The sum of their dimensions along any st not exceed 4” ight line within an 8" circle does AP Number a a) _ Is assigned based on the usability characteristics of electrodes b) Is assigned based on comparable base metal characteristics such as composition, weldability and mechanical properties ©) _ Is assigned based on an as deposited analysis of the weld metal d) __ Is assigned based on impact properties of the base metal After API-510 repairs are completed, when should a pressure test be applied? a) Aiter all repairs b) Pressure tests atter repairs are not necessary ©) When the API-510 Authorized Inspector believes one is necessary 4) As required by the ASME Code How are penetrameters of different materials distinguished? a) _ Different notches on the edges of the penetrameter b) Tho material number is stamped on the edge of the penetrameter ©) The material number is identified on the penetrameter with lead letters d) The thickness of the penetrameter differs based on different thickness of materials API-510 Examination Preparatory Course Final: Closed Book Page 7 of 1828. 29. 30, 3. 22 ‘A welding procedure qualified on plate may be used to weld a) b) °) ¢) Plate and pipe Plate, and pipe over 6 inches in diameter Plate only Plate, and pipe over 24 inches in diameter Laminations in vessel plates have an appearance similar to 2 a) b) °° o Slag Cracks Porosity Lack of fusion A vessel with a corrosion rate of 0.0215"iyear has 2 measured thickness of %4' The limiting thickness of the vessel is /6". What is the remaining life? a) b) ©) d) 48 years 7.1 years 6.5 years 5.8 years When in accordance with API-510 may a pneumatic test be substituted for hydrostatic test? a) At the owner's request b) At the request of the Authorized Pressure Vessel Inspector ©) When a hydrostatic test is impractical due to temperature, foundation or process reasons @) —Allof the above On-stream inspections require entry of the vessel. (True or False) API-S10 Examination Preparatory Course Finel: Closed Book Page 8 of 1833. 34. 36. 36. 37, Define RT-4 a) ) °) d) When the complete vessel satisfies the requirements of UW-11(2)(5) and when the spot radiography requirements of UW-11(a)(5)(o) have been applied When the complete vessel satisfies the radiographic requirements of UW- 14(b) When only a part of the complete vessel has satisfied the radiographic requirements of UW-1 1(a) or where none of the other RT markings apply. Radiography of only circumferential seams During the turnaround inspection of a pressure vessel that has been in service for 7% years since the last thickness measurements were taken, ultrasonic thickness measurements were taken and revealed the current thickness to be 0.801". Inspection records indicate the last measured thickness as 1.09". What is the cortosion rate based on these two inspections? a) .2.85"/year b) —0.265"year ©) 0.0268"!year 4) 0.00265"/year Monel is alan alloy. a) Iron-based b) _ Copper-based ©) Nickel-based d) —Aluminum-based What are the two major factors that affect the amount of surface preparation needed for internal inspections? Service medium and operating temperature Type of deterioration expected and the location of the deterioration Corrosion rate and remaining life Equipment available and personnel qualifications Safety valves are normally used in steam or air service. (True or False) API-S10 Examination Preparatory Course Final: Closed Book Page 9 of 1838. 39, 40. 4 A pressure vessel shell has been in service for 3 years. The original thickness of the vessel was 3.625” and the actual thickness of the vessel is 3.58". The vessel is designed for 500psi, has an inside diameter of 20ft and an allowable stress value of 17,500psi. The required thickness of the vessel is 3.488" and the corrosion rate is 0.015" per year. Find the remaining life of the vessel. a) 3.7 years b) 4.2 years c) 5.6 years ad G1 years Define jurisdiction as it relates to API-510. a) The limits or boundaries of API-510 b) The occupational Safety and Health Administration cc) The Environmental Protection Agency @) A legally constituted government administration that may adopt rules relating to pressure vessels. A vessel has been in service for 15 years. The original thickness of the vessel was 2¥!'. The vessel was inspected § years ago and its thickness was 2.15" Measurements on the vessel now indicated a thickness of 2.08". What is the corrosion rate of this vessel? a) ote b) 0.017%yr 6) 0.014%/yr dg) 0.007"%/yr Define alteration a) A change jn the temparature rating or the maximum allowable working pressure rating of a vessel or itis a change in both. b) A physical change in any component or a rerating that has design implications that affect the pressure containing of a pressure vessel beyond the scope of the scope of the items described in the existing data reports. ©) The work necessary to restore a pressure vessel to a condition suitable for safe operation d) The addition of a reinforced nozzle less than or equal to the size of an existing nozzle, API-510 Examination Preparatory Course Final: Closed Book Page 10 of 18,42. 49. 44. 45, 46. 47. 48. Who is responsible to the Owner/User for determining that the requirements of API- 510 on inspection, examination, and testing are met? a) The National Board Commissioner Inspection employed by the insurance company. b) The jurisdiction ©) The API Authorized Pressure Vessel Inspector 4) The AWS-CWI employed by the Ownerluser. Most welding procedures, with the exception of GMAW short-arc, can be qualified using radiography. (True or False) How do mechanical fatigue failures start in machinery? @) From laminations beneath the surface b) Lack of fusion between weld pass ©) Notches on the surface of the metal 4) The failure is rapid and is accompanied by a loud sound A vessel is in service for 7 years has an unexpected shutdown. It was decided to perform inspections during the shutdown, including thickness measurements. The original thickness of the vessel was 1.5" and the measured thickness two years ago was 1.41". The design thickness of the vessel was is 1.22". Measurements now indicate a thickness of 1.374". When should the next inspections take place if based on the thickness measurements taken during the shutdown? a) 4.25 yrs b) 5.6 yrs. ©) 3.75 yrs ) 24yrs You are called to witness a hydrostatic test of a pressure vessel alteration, The MAWP for the vessel is 500psi and the test pressure is 750psi. You notice the gauge being used had a range of 0 to 4000psi. The test is acceptable. (True or False) Galvanic corrosion is an electrochemical type of corrosion. (True or False) Air used to test safety relief devices for set pressure and leaks. (True or False) API-510 Examination Preparatory Course Final: Closed Book Page 11 of 18,49. 50. 51. 82. 53, ‘A welder may deviate from the parameters specified in a WPS if they are a nonessential variable. (True or False) Define flaw. 2) Arejectable discontinuity ») An indication cue to an error by the NDE operator ©) An imperfection or discontinuity that may be detectable by NDE and is not necessarily rejectable d) An imperfection or discontinuity thet may be detectable by NDE and is rojectable Atmospheric corrosion usually increases with: a) b) ° d Higher humicity Higher operating pressure Higher temperature Higher elevation Steel is and alloy of: a) lronand silicon b) Iron and copper ©) tronand carbon @) Iron and molybdenum Openings in shells 2 a) Cannot exceed 24” in diameter b) Cannot exceed 30” in diameter ©) Cannot exceed 60" in diameter d) Have no limit on diameter provided the opening is properly reinforced API-5 10 Examination Preparatory Course Final: Closed Book Page 12 of 1854. 55. 56. 87. 58. Define RT-2 a) When the complete vessel satisfies the requirements of UW-11(a)(5) and when the spot radiography requirements of UW-11(a)(5)(b) have been applied b) When the complete vessel satisfies the radiographic requirements of UW- 11(0) ©) When only a part of the complete vessel has satisfied the radiographic requirement of UW-11(a) or where none of the other RT markings apply 4) Radiography of only circumferential seams Why are buried vessels monitored? a) To detect any shifting b) To detect cracks ©) To detect any leaks d) To determine their external environmental condition. Demagnetization of the part is always required after required Magnetic Particle ‘examination? (True or False) ‘Anew WPS is being written by a repair concem to weld repair to a pressure vessel. A PQR qualified in 1978 by the repair concern is found that addresses all the essential variables of the new WPS. May the new WPS be supported by the 1978 PQR without re-qualification and be used to repair the vessel? a) No b) Yes ©) Yes if the vessel was built in 1978 4) Yes if the PQRis revised and dated to the same date as the WPS. Multi-layer construction is sometimes used on heavy walled reactors and vessel subject to high pressure? (True or False) API-510 Examination Preparatory Course Final: Closed Book Page 13 of 18,59, 60. 61 62, 63, ‘Temporary repairs using fillet-welded patches to vessels, ) Must be replaced with permanent repairs during the next avaliable maintenance opportunity b) May remain in place for long periods if approved by the pressure vessel engineer ©) May remain in place for long periods it approved by the API-authorized pressure vessel inspector. d) May remain in place permanently if approved by the pressure vessel engineer and the API authorized pressure vessel inspector Normally, heads are more likely to suffer deformation than shells. (True or False) The nondestructive examination method to be used for a particular inspection should be determined by the: a) Availability of certified NDE examiners b) Length of time since the last inspection ©) The age of the component to be inspected d) Type, location and orientation of the expected flaws In planning for an intemal inspection of a vessel that has contained acidic corrodents, what type and location of corrosion would you expect to find on the vessel shell away from the welds? a) Hydrogen blistering in the vapor space b) Hydrogen embrittlement in the vapor space ¢) Hydrogen blistering near the liquid level d) Hydrogen embrittlement below the liquid level A pressure vessel has been in service for 15 years. The original nominal thickness was 0.75 inches and the design thickness was 0.609". In a recent shutdown tho actual thickness was determined to be 0.661 inches. When should the next inspection be scheduled for this vessel? a) Syears b) 4years °) 3 years 4) 2years API-S10 Examination Preparatory Course Final: Closed Book Page 14 of 1865. 66. 67. 68. 69. 70. Ultrasonic search units may contain single or dual transducer elements? (True or False) Per Section Vill, Diy 1, the maximum temperature of the PWHT oven prior to placing a vessel in it is? a) GOOF by) 700°F ©) ROOF 4) 900°F A pressure vessel has been in service for 12 years and has @ history of corrosion over its eervice life. The original thickness was 1.9375" and the current thickness is 1,405”. What is the corrosion rate of this vessa\? @) 0.044 inches per year b) 0.089 inches per year c) 0.266 inches per year 4) 0.532 inches per year Full RT per Section Vill means all butt welds are radiographed throughout their entire length (True or False) Information in a continuous file includes a) Basic data and filed notes b) Measurements recorded on site, and a record of repairs required ©) All information on operating history, descriptions and measurements from previous inspections, corrosion rate tables if any, and records of repairs and replacements, 4) Drawings, data reports, design information and the results of any material testing Carbutization of austenitic stainless steels can sometimes be detected by a magnet because normally non-magnetic steel can become magnetic when carburized (True of False) Cracks in foundations or supports caused by high temperature or temperature changes appear as hairline cracks. (True or False) API-510 Examination Preparatory Course Final: Closed Book Page 15 of 181 72. 73, 74, 75. In Section Vill, Div 4, it is not allowed to weld a non-pressure part over a pressure retaining weld. (True or False) Define Safety valve 2) A safety valve is a spring-loaded pressure-relieving device that is popped ‘open by enough static pressure in the huddling chamber and kinetic energy of the gas or vapor to overcome the spring force on the disk as itis lifted, to provide full opening and allow minimal overpressure. b) A spring-loaded pressure-relieving device for liquid service that begins to ‘open when the inlet pressure reaches set pressure, overcomes the spring force and begins to lift the disk off the seat and that continues to open as inlet pressure and the lft of the disk increase allowing the flow of the liquid to increase. ©) A spring-loaded pressure relief valve that acts like a safety valve when used in gas of vapor service and as relief valve when used in liquid service ¢) One that incorporates a pressure-balancing bellows, piston or both, to minimize the effects of back pressure on its operational characteristics. ‘A magnetic particle, DC yoke must be able to lift pounds at the maximum pole spacing? a) 10 pounds b) 20 pounds ©) 30 pounds @) 40 pounds The responsibility for the functions of the authorized inspection agency per API-510 rests with? a) The jurisdiction b) API ©) The insurance company that insures the pressure vessels d) The Owner/User When some chlorides are mixed with water and heated, they form: a) b) eo d) Sulfuric acid Sodium hydroxide Hydrochloric acid Calcium hydroxide APL-S10 Examination Preparatory Course Final: Closed Book Page 16 of 1876. 7. 76. 79. 80. A vessel profile is used to detect: a) Cracks b) Porosity ©) Laminations 4) Bulging or buckling Spark testing is used on: a) Stee! lined vessels b) Vessels lined with non ferrous metal ©) Insulation 4) Non metallic lined vessels Spring failure is almost always due to corrosion. (True or False) The minimum required hydrostatic test pressure for section Vill, Div.1 vessel for new construction is? a) 1.5 (MAWP) (Stress at test temperature) _ (Stress at design temperature) b) 1.5 (MAWP) (Stress at design temperature) (Stress at test temperature) ©) 1.3 (MAWP) (Stress at test temperature) (Stress at design temperature) 4) 1.9( MAWP) (Stress at design temperature) (Stress at test temperature) A vessel has a measured thickness of 0.43 inches. The vessel has been in service for 10 years and had an original nominal thickness of 0.6". The design thickness is 0.275". What is the remaining life of this vessel? a) 10 years b) 13 years ©) tTyears d) 22 years APL-510 Examination Preparatory Course Final: Closed Book Page 17 of 1881 82. 83. &4, 85. Localized corrosion may result from any of the following except? a) b) 9 9 Under-deposit corrosion Crevice corrosion Microbiological corrosion Thermal fatigue ‘The most common corrodents found in refineries are sulfur and chloride compounds. (True or False) Combining the assessment of likelihood of faillure and the consequence of failure are essential elements of which of the following? a) b) ° d) Planned Maintenance Inspection Planned Maintenance Shutdown Risk Based Inspection Risk Based Maintenance If local post weld heat treatment is to substitute 360-degree banding, who is required to develop the procedure? a) b) ¢) d) ‘The API 510 pressure vessel inspector ‘The Owner/User The repair organization A pressure vessel engineer experienced in the appropriate engineering specialties During the hydrostatic pressure test of a vessel at 1300psi, when should the Authorized Inspector examine the vessel for defects? a) b) ¢) The Authorized Inspector is not required to witness the final pressure test ‘The Authorized Inspector should conduct the examination at a pressure not less than test pressure divided by 1.3, The Authorized Inspector shall conduct the examination at 1300psi The Authorized Inspector is not required to examine the vessel if there is no significant drop when the pressure source is removed from the vessel API-510 Examination Preparatory Course Final: Closed Book Page 18 of 18,