ag Suojssie enmiGns eowouoo3 ubjsap aids 7oaT ABUT OUI SHEL SHUE TES J9n09 PewUsIeNA sue, Aovotiow3 SoURITSHUTE SET SON pabewep seunsse,di@A0 YS|H) qu23@|0) aK aunssosd 381Ng 0},.68099 sieiedo ueD suopeyeisul mou 20) 3SN LON OG sip 1n9 22p104 SIP UI SepeIa BUY, swigoid eames pinbrs peBewep j! ainssaidieno soyeeu8 ye yung Aeyy quesat0) aah aunssaid sing 40.%06~ 0} dn ajesedo UES S\Nae J0pUN soomues pani 0 soden, seunsseud ysang pay] queIsis@) Uo}s0I09 ATYBIH, S,AMd J80UN LON SBOIAIBS UO}SOLIOD, yydesé peuyoeny = ysig eumidn ; amssaud Hos jo %08~ 1e aje10d0 KUO paBewep fuses auesquIsNy Sea001d seoues jo eBues pin SunuowBey-u0N, S\Add J2pun ‘SEOIMIES pinby 30 10dan, ‘se8001d uy sjees euesquieN aunjey {a1/SU9} Os}U09 YSIP UI SIOIS aysodwog 81g eumidnay ainsseid ‘SAbid RUN ION ‘SeO;IES 10 s0den une UoIsueL,API 510 A.L/Engineers Responsibilities Exercise Read the API 510 Code and determine the responsible person(s) Aetivity AY] Bue [ALAND Eng.or Cor. Specialist? ‘Assure owner that testing, nspeation, and examination activities meet 510 Code Evaluate and accept NDE examination resulls Review inspection plan for elevated temperature equipment inspection ‘Approval of thickness measurement procedure fo determine actual thickness is greater than that on the data report for use when determining MAWP. Review and approve RBI approach that extend inspection beyond 10 years Determine if on-stream extemal inspections may be substituted for internal inspections Determine most appropriate corrosion rate long term or short term Determine fa pressure test is required ‘Approve all methods of design, materials, WPSs, NDE and testing ‘Authorize ait vessel Te) Authorize all repairs to Division, 2 vessels ‘Authorize al alterations ‘Approve all repair and alteration work al completion of work Designate hold points for fabrication inspection and approval ‘Authorize the repair welding of cracks ‘Authorize the repair welding of cracks athigh stress points Review the use of Preheat in lieu of PWHT. Review the use of controlled deposition welding In lau of PWHT Review the use of fo PWHT | PWHT in place of ful encirclement Review the repair procedure for Stainless Steel cladding Monitor the repairs made to cladding ‘Approve the use of filet-welded paich repairs Allow temporary welded repairs to remain in place (until next fepair opportunity) ‘Approve use of lap band repair ‘Approve substituting NDE for a pressure lest after repairs ‘Approve alternative NDE to ASME requirements after repairs or alterations Perform calculations for re-rating ( unless performed by manufacturer) Oversee the aitachment of a nameplate aller re-ralingSaaS oT ULF J0jeanssosdiono 400, ‘uo sainssaud 08 way eiqeyene saz eoyo eae] reaqwoucos + sypien ‘fa pepwerd cain) Gunees + s0owes ejdonsns y Supoy6s06nxenue%o « ‘ugyedwco esmeseduoy ‘BIEOUALD 3 Sp00B YOS + ‘sounssaid 28 ed og eroge aIgeIEASION TROBE pus amnssardiero (ews + feunssexd ypeq 0} eNSLES ION) + Arges amnssard ys wry qwowobuerewtendeg + seowns ajgydeoens ‘uy Buynoysibind equ} + Aejqednoo exryeseduoy 13 JeoRWeLp yu SpO08 YOS « ‘WROD, ue onssaidiona Joes enesaxd ‘emsseudypeq 0} engsue5 ON + Y2s.0)50509 ayed0 ueD + Tsuetceie apavoRENSS > ‘anssaud ‘auep sjoquco amen + ‘aie 6upsoe seppaid eunssaid soi) + paBewep sq ube sueeg + ‘onsuadro ciow Ayei0u9g + Sema ey woy papojadseuoyy) + + | seovues prio 0dens0j poo « ‘Augneded aumerediey » OWA SPAN = sopues ston :0;poodeN =» s80pv28 Pb POOH TON + ‘sons sedan 105009 + funssaxtyoeq oj annysues = 248 40de8 0) po00 oN + rowoueeg + peje ye oinssaidano gz + ‘eumssaidiano oyevoqvodasd yi 9s + Sobesiehpy ‘SOunyeOS OMIT rere TaBtl ieee] Utste) pereye |IRC ‘ASME IX AND V TEST copYRIGHT 2900. IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED 00 NOT cOFY OR DISTRIB! QW-482 (Back) ws Rev Mo [POSITIONS (QW-405) [POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove: __ALL temperatuie Range Hetng Progression: Up__X down x | Time Range. aa Positions(s) of Filet Scorer erereereceeeeear PREHEAT (QW-406) GAS ((QW-408) Preheat Temp Min: __ 100° MINIM Percent Composition | interpass Temp Max ___650° MAXIMUM Gasies) (Mature Flow Rate Preheat Maint Shielding: _YES 00% AR___10-15 CEH ‘Trang: NONE. ERR Nig POR INT ‘Backing: YES TSARI25CO2 __2.CFH ELECTRIGAL CHARACTERISTICS (QW-408) Current AG or DC _DC Polarity_REVERSE ‘Amps Range _ 100-120 Volts (Range) _24-27 ange ardels ange SOU be read foreach tered se Penge shea eT rforaton say belie 3 ‘Sr trm sma at hown betow ) Tungsten Electrode Size and Type ‘Pare Targaan Be Thad Ge SPRAY OR SHORT ARC. Boray are. show creung are cre) Mode of metal Transfer for GMAW Electrode Wire feed speed range ‘TECHNIQUE (QW-410) String or Weave Bead STRING Orifice or Gas Cup Size 412" peer esnd interness Cleaning (Brushing, Ganding, ete) BRUSHING AND GRINDING Mathod of Back Gouging ‘AIR AR Oscillation REVERSE Contact Tube to Work Distance ia ‘Multiple or Single Pass (per side |_____MULTIPLE. Multiple or Single Electrodes SINGLE {SIEM - 30 1PM. NONE Travel Speed (Range) Peening Other ae i | ie 7 Type | wera Da Polar ame | j_tevera | Process Case ange lL aL Gina | ERSOS BF) TAB -ST_ | CRP ea) Tea FM L SPRAY i c i t 7 £ t i T i r L i C i cOPYRIOGHT 2i- IRG?SCHINDLER & ASSOCIATES - ALL FIGH HTS RESERVED -00 NOT COPY OR DIgpuucacacooansacomsosanageasonoeeann ASME IX AND V TEST IRC COPYRIGHT 2000-IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘API 510 COURSE ASME V AND IX TEST ANSWER SHEET COPYRIOGHT 1 RC7SCHINDLER & ASSOCIATES -ALL RIGHTS RESERVED -00 NOT COPY OR OISTRIBUTScage aR ASME IX AND V TEST IRC COPYRIGHT 2000: IRCISCHINOLER 2 ASSOCIATES _ALL RIGHTS RESERVED. 00 YOT COPY OR DISTRIBUTE ‘QW-483 (Back) PQR No: GMAW-SP-1 Tensile Test (QW-150) eee Type of 1 Specimen | Total Loaa Faiuro & No. Width | Thickness | Area) bb. ra HA [soa DIA) tg7__| 4.200 DF-HAZ acer NA “500 DIA. “186 | 12.000 DE-HAZ : t i = C L I i i Guided Bend Tests (AW-160) ype and Figure No. Result FACE Wis" GRACK OK ROOT ‘CORNER CRACK OK FACE NO INDICATION OK ROOT 1ia° CRACK OK Toughness Tests (QW-170) innpact Values specimen | Notch | Specimen | Test scien | Not | reise. | Temp. | Fetbs. | %Shear | mils | Drop Weight Break (VN) | i | T 1 1 t Comments: Fillet Weld Test (QW-180) Satisfactory: Yes: No: Penetration into Parent Metal: Yes: No: Result Macro ~- Results’ z Other Tests Type of Test: Deposit Analysis: Other: Welders Name: _JOE BLOW JR. Glock No. ‘Stamp No.: Tests conducted by: _ XYZ COMPANY. Laboratory Test No: _1234 We cortty thatthe statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer: _ XYZ COMPANY. Date: By: _JOE BLOW SR. COPTRIGGRT UT IRGTSGHINDLER & ASSOCIATES -ALL RIGHTS RESERVED -DO NOT COPY OF DISTRIBUTEoe ASME IX AND V TEST IRC COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT GOPY OR OISTRIBUTE ‘QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boiler & Pressure Vessel Code) Company Name: __ XYZ COMPANY. By:__ JOE BLOW SR Welding Procedure Spec. No.: _GMAW-SP-1 Date: Revision No: _0 Date; _2-2-92 Welding Process(s):_GMAW-SPRAY ARC _ Typet JOINTS (QW-402) : eras Joint Design:_SEE PRODUCTION DRAWINGS. Backing: (Yes) _X wo) _X. Backing Mateflal: (Typey WELD METAS, if USED ‘Refer fo both backing & retainers) XMotal | Nonfusing Metal ) should be 16" c @ should be 1/16" - 500° should be 3/16" = 2° 29 The preheat temperature shawn on the WPS. is acceptable should be increased to 20°F should be decreased to 50°F ‘should be increased to 180°F COPYRIOGHT 2)-1RC7SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRISUTE31 32 33 36 ASME IX AND V TEST COPYRIGHT 2000- IRC/SCHINOLE! ‘Tha tension iests shown on the PC! 22 acceptable 2= shown ‘are dimensionally unacceptable to the Code ‘The bend tests shown on the POR: are acceptable 2s shown should be all side bends are unacceptable because the root bend has a corner crack none of the above goce ‘The ultimate stress shown on the POR: a. is unacceptable for T-2 1B, is unacceptable for T-1 @ is too high for both specimens @ should be at least 75,000 PSI for both specimens ‘The joint design specified on the WPS is: acceptable as shown, ifthe drawings show the required details should show only a single vee groove weld should not address backing should be drawn on the WPS as a sketch nord ‘The POR is unacceptable because: the position of welding does not match the product welded the gas backing mixture does not match the WPS: the joint design is not shown as a sketch on the POR: the travel speed is too fast ‘The A# shown on the WPS and POR: is acceptable as shown ig unacceptable because ait should have been used a 5) is unacceptable because it does net correlate to chrome filer metal d ts unacceptable because A-t filler metal requires PWHT per ASME IX COPYRISGHT U- RC?SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBU IRC RASSOCIATES -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE.ASME IX AND V TEST IRC IRCISCHINDLER & ASSOCIATES -ALL RIGHTS RESERVED .DO NOT COPY OR DISTRIBUTE “GW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PGR) (See QW-200.2, Section IX, ASME Boiler and Pressure vessel Code) Record Actual Conditions Used to Weld Test Coupon Company Name: _XYZ COMPANY Procedure Qualification Record No.: _ GMAW-SP-1 Date: 2-29-82 |AW-SP-1 (GMAW (SPRAY ARC) ‘ute ‘SEMEAUTO. JOINTS [aw-402) Groove Deigna! Test Cosson ( oreoronation qusfcasons the daosiag wos meal edness sa be cored ft ach er mete proves use} [BASE METALS (GW-403) POSTWELD HEAT TREATMENT (QW-407) | Material Spec.:__SA 387 CL.4 ‘Temperatu: Type or Grade: GR 22 Time: NONE, P-No. 5A ‘to P-No: 5A Other ‘Thickness of Test Coupon:, 500 Diameter of Test Coupon: __N/A aoe Other: COMPOSITION - 27/4% CHROME, 1% MOLY PASS THICKNESS 1/5” GAS [QW-A08) Percent Composition FILLER METALS (QW-404) Gas(es) (Mixture) Flow Rate SFA Specification: _5.8 | AWS Classification: ER 90SB2 Shielding: _YES 400% ARGON 20-30 Cf Filler Metal F No:: 6 Trailing: _ NONE Weld metal Analysis No 1 Backing: YES 00% ARGON 10-48 CPHL Size of Filler metal: _1/8 ELECTRICAL CHARACTERISTICS (QW-408) j Other: 2 114% CHROME Current:___DC | FILLER METAL Polarity: REVERSE Weld Metal Thickness: _.500 Amps.:___128 Vents: 24 Tungsten Electrode Size: NIA FOsTION(aw4s)SS—~—~SN othe: eee te Position of Groove: 6G Weld Progression (Uphill, Downhill): UPHILL TECHNIQUE (W470) Other: |_| Travel Speed: _12 1PM String or Weave Bead: STRING. Oscillation REVERSE, ae Preheat Temp. 250° Multipass or Single Pass (per side):__MULTIPASS Interpass temp.; 650° MAX Single or Multiple Electrodes:__ SINGLE - Other: SOLID WIRE ONLY, NO SUPPLEMENTAL — | Other: POWDER, FILLER, OR FLUX USED PREHEAT (QW-406) COPYRIGHT TI IROTECHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTEead APIS%0 FINAL EXAMINATION 1 - OPEN-BOOK ec COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES = ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE apisio FINAL EXAMINATION #1 OPEN BOOK DATE, NAME. Suet eee Questions 4-10 analy to WPS 11 ang Susoorting POR #15, attached on back. Ht The P #'s shown on the WPS are: F A. qualified by the POR B should be changed to P3 to P3 only should not show P #4 D- should show P1 to Pt only 2. The AWS Classification shawn on the WPS: a, A. should be changed to & 71T1-4 B is acceptable as shown Cig a 90,000 tensile electrode 1. is acceptable ff the "T” was changed to “S" 3 The base metal thickness range shown on the WPS: A, Is correct as shown B. should be 1/16" = 1/2" CC should be 3/16" = 1/2" ©. should be 3/16" 1" 4 The pestweld heat treatment condition shown on the PAR: ‘A. is not acceptable to the Code Bis acceptable to the Code © should be changad to show PWHT was done 1D should show the required pre-heat 5 ‘The ges mixture shown on the WPS is unaccepteble because! ao A. the CO2 was not property qualified 5 the Argon was not properly qualified C. the flow cate is beyond the range allowed 0 bon S&C above 4 6 The tensile test results shown on the POR are: -eptable as shown 8 ‘otable - the tensile strength on 7-1 is too low © unacceptable - the load on T-2 is too low D. unacceptable - the area calculations are incorract on ‘The bend test results shown on the PQR are: acceptable as shown Unacceptable - side bend #1 has unacceptable porosity unacceptatle - not snough specimens were tested both B & C above vam» |S ASSOCIATES - ALL FIGHTS RESERVED -0O NOT COPY OR OISTRIGUTE COPYRIGHT 20¢0 = 1RCISCHINO10 2 COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIAT APIS10 FINAL EXAMINATION 1 - OPEN BOOK IRC “ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE The POR should be A, notarized B legalized © rormaiized D certified The pass restriction of QW 403.9 is: acceptably addressed on the WPS only acceptably addressed on the POR only acceptably addressed on both the WPS and PAR unacceptably addressed on both the WPS and the POR o0n> ‘The A# range shown on the WPS is: unacceptable - should show A-t only ‘unacceptable - should show A-2 only ‘unacceptable - should show A-3 acceptable as shown comp A pressure vessel has been designed using SA516 - 60 material (32,000 yield). Totallength of ‘support is 8 feet. The stamped MAWP (external )is 180 psig @ S00°F. Theod is 48°. Can this vessel be safely operated If the thickness has correded down to 250"? A yes. this vessal is safe down to 250" 5 no. this vessel is not safe for 150 psig CC. not enough infarmation provided to solve the problem Dyes. this vessel could actually be operated at 250 psig ‘An existing vessel is inspected on a given year end found to be 500” thick in the shell and heads. The next inspection is performed 3 years later, anc the thickness of the shell and heads is shown to 2 310° (uniform) The vessel minimum thickness is calculated to be 200°. From this information. the Remaining Life (RL) and internal inspection Interval (1) on this vessel is approximately 13 A. Syears RL. 10 years LI B 7 years RL. 15 years | © 173 years RL 173 years I DB tO years RL. 10 years L MOMT of -38°F. (not ‘niuch wail require 'cact testing? ‘An ammonia processing vessel is stamped for an MAWP cf 50 asig with ‘examoted per UG-201) Various materials have cracked and/or coi welded recairs Which of the following materials, if any. will require © A. SA 537 Class 1, 3/4” thick BSA 387 Grade 21 normalized and tempered, 4/8" thick © SA 516-70 normalizec thick’ none of ne above will require impact tests A full size (or standard) Charpy impact specimen is: A ue xe B 10mmx 10mm © temx 10cm D 3eex tem ERVED 00 NOT 79 OR OISTAIBUT: NGHTS Fi COPYRIGHT 2000 IRCISCHINDLER & ASSOCIATES - A17 18 20 API 510 FINAL EXAMINATION 1 - OPEN 300K IRC COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIGUTE. ‘Avvassel shell is 66° .O and is made from material with a stress value of 13.200 psi. The vessel has Category A Type 1 buttwelds and is stamped “RT-2". Ifthe thickness has corroded down to 285° thick, what MAWP can oe allowed on this vesset? A. 400 esi B. 190 psig © 250 psig D139 psig ‘Awire 10! with a diameter of 020° would be found in an ASTM SET A a c D cour ‘A fat unstayed circular head with a diameter of 14” is operating at 360 PSI @ S00*F. The stress value Is 17,500 PSI with an efficiency of 1.0 and aC Factor of 33. Can this head be operated with @ corroded thickness of 1.25"? A. yes, can continue to operate B. na, cannot be operated . °C" Factor is incorrect for design D. circular heads cannot be use at 1 25° ‘Avvessel has @ nozzle installed as shown In Figure UW-16 Sketch (using two equal size fille welds The shell thickness is 3/4” and the nozzle wall thickness is 7/16". Using equalleg fillet welds, wnat eg dimension is required on these welds, rounded up to the next 116°? A gne B 76" coune 0 3a" In visual examination. the procedure is qualified by using @ test methed thet allows resolution of a fine fine that is __" or less in wath. A132 Be C18 Dove Gna 1" thick piece that will be MT tested by procs. the soacing Setwsan the prods wil ‘ct amp range fer this spacing would be: 4900 - 2000 ames 150 - 300 amps 106 -125 ames 500 - 825 amps A © D An ASME vessel is to be repai stamped °RT-3". and the total length of the buttw Complete the work on both patches How many radiographs will be 10 API S10? nas to the shell The vessel is ‘One waider wil be used to Wired. f the work is core sw Aus is willbe by adding wo cour OPY OR OISTRISY COPYRIGHT 2000 ~IRCISCHINDLER 8 ASSOCIATES ~ALL RIGHTS RESERVED 00 W'23 24. 25 28 2 28 wz 2 ‘API510 FINAL EXAMINATION 4 - OPEN BOOK IRC COPYa:GH? 2000 IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY C2 DISTRIBUTE ‘An exampie of 2 ‘siandard pressure par on a pressure vessel would be: A. apiece of 1 nick piss &. a welded elliptical head. C. a pipe fitting (Forged) 3 22 length of SA-106 B pipe 9 A radiograph is produced to “full RT requirements Thrae elongated slag inclusions are seen the radiograoh that are measured individually at 1/2" long, 3/4" ong. and 3/8" erg. Tne weic 1s 3 1/2" thick The interpretation of this radiograoh i See eee : B. unacceptaole C. slag inclusions are not a factor in RT D. none 6f the above ‘A standard seamless torispharical head has a skirt od, of 56" and a correded micxress of 1.27" The material stress value is 16,100 psi, and the head is atached to the bottom cia vertical ves: that {5 20' tall ful of water. Ifthe vessel is stamped "RT-2", what approximate MAV/P would be allowed on this vessel? Sea A. 600 psig 8 402 psige-~ C704 psig D302 psig Aweld repair is made on P-4 material, 3 1/2" o.d. pipe, 3/8” thick, carbon con minimum preheat of 200°F is maintained. Is PWHT mandatory on this repair? A no Byes ©. depends upon servic: D depends upon joint efficiency 10%. anda A2" thick carbon steel pressure vessel is to be postweld heat treated, The re: (ebove 300°F up to 1100*F) on this vessel shall nat exce: A. 400°F ne B g00*Fmr 200°Fihr ‘A vessel is ultrasonically inspected when itis new and cold in June 1987 anc thick in the shell. The next inspection is done in June 1995 and the vessel is teu": 50° thick. If the minimum thickness by calculation is $10", when (approxime: I or on-streem inspection be scheduled, per API 5107 wary 1989°~ 8 November 2010 ©. June 2005 © October 2002 An example of a “double wall exposure, double wall view" would b: A, ellicical exposure (ellips®) 5 suermposed exposure C_ single wall exposure (sour D both A&B above in middle of cylinder) CosvaiGHt 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OF 2ISTRI23 30 1 32 33 API510 FINAL EXAMINATION 1 - OPEN BOOK IR COPYRIGHT 2000 ~IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE A welding cperator is qualified by making a radicgraph of her first production wele an 2 spot (R7- 3) vessel that is 1/2" thick. The weld shows several rounded incications that are 1/4” diameter tnat are interpreted as gross porosity. This welder would be: A. accepted to weld in production 5. accepted 10 wela in progucuon, put on: © not accepted to weld in production —~ ©. automatically requalified by welding two more test coupons 1 a 26 posicn ‘Acozzle is 1" thick and is attached to a pressure vessel 1 1/2" thick using a joint configuration waters Sig Wane # Geateh tak Tea af theags ar he sor curation (tc) wou" be ar 8 saute & sa Bt Reinforcing plates and saddles attached to the outside of a vessel with filet welds shall be provided with at least one tell-tale hole with a maximum tap size of NPS Auge 812 C13 Dt ‘A hydrostatic test is conducted on a vessel that is 60' tall, A pressure gauge is located 35° up from the bottom of the vessel. If the stress ratio Is 1.0 and the MAWP of the vessel is 100 Fsi, what zoproximate‘fressure should the gauge read to mest ASME Vil requirements? A. 141 psigh B 143 psig ©. 130: D188 psig ‘Awelder hes been qualified in the 6G position on 3/4” thick material, How many bend tests wit bee required? A, 4 side bends-~ & 2 side bends © 2 root bends no bend tests - tension tesis only All of the following statements conceming a “UM’ vessel are true xceat A. “UM" vessels are exempt from inspection by API 310 © “UM" vessels Mig. Data Raports are not signed by an Al ~ © "UM" vessels are exempt ay ASME Vill from the scope of the Code 1D “UM vessei manufacturer's must maintain an inspection agreement wits an AIA Atensicn tast specimen is made from welded plate, SA-299. The diameter of the turned: simen ig 300° and the load is 15 KSI. Does this specimen mast ASME IX requirements? A no B yes © tension specimens are nat required by ASME 1X D. the diamater of tne specimen does not mest Cace & ASSOCIATES - ALL RIGHTS RESERVEO -00 NOT COPY OR OISTRIGUTE COPYRIGHT 2000 ~ IRCISCHINOLFAPI 510 FINAL EXAMINATION 1 - OPEN BOOK IRC COPYRIGHT 2000 -IRCISCHINDLER & ASSOCIATES ~ ALL RIGHTS RESERVED -00 NOT COPY OR OISTRIGUTE, ‘QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boller & Pressure Vessel Code) Company Name: XYZ COMPANY, By JOE BLOW Welding Procedure Spec. No _11 Date: .57-82Supporting PR No. (s):_46 Revision No.:_0 Date: FCAW-SPRAY ARC TRANSFERType(s): _SEMI-AUTOMATIC Welding Procass(s) -SEMI-AUTOMATIC _ (Automatic, Manual, Machine, or Semi-Auto JOINTS (QW-402) = Details Joint Design:__ DOUBLE VEE GROOVE, ONLY Backing: (Yes) x. (No} Backing Material: (Type): WELD METAL ONLY (Refer to both backing & retainers) xXMetal + Nonfusing Metal + Nonmetalic + Other ‘Sketches, Production Drawings, Weld Symbols or Written Description ROOT OPENING - 1/16" - 1/8" ‘Should show tne general arrangement of the parts to be'welded. Where GROOVE ANGLE - 60° - 70° 2pplcable. the root spacing and the details of weld greove may be ecified Gettne option ofthe Migr, Sketches may be attached to Mustrate ont Gesign. weld layers. and the bead sequence, e.g. for notch toughness procedures. for multiole process orocedures, etc.) TBASE METALS (QW-403) Z P-No.___3 Group No. 1 to P-No. Pd. 3.1 Group No. 1 oR Specification type and grade to Specification type and grade oR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness range: Base Metal: Groove: _1/16" Pipe Dia. Range: Groove: ALL Other:_NO PASS GREATER THAN 1/2" THICK Fillet: ALL ALL TFILLER METALS (QW-404) Spec. No. (SFA): SFA 5.29 ee AWS No. (Class): __E81T4 (1.2.3.4) TS Filler Metal F-Nos 6 ne Chem. Comp. -A No TOR2 ee Size of Filler Metais: ALL a Weld Metal Thickness range Groov: Te MAX —————— Fillet ALL oO Electrode-Flux (Class): Flux Trade Name: Consumable Insart: oe Other, _NOSUPP. FILLERS OR PeReeeeeere eee eeeeee POWDERS TO BE USED = Zach base metabfiler metal combination should be recorded individually {VEB 00 NOT COPY OF DISTRIBU COPYRIGHT 7000 = IRCISCHINOLER § ASSOGIATES “ALL RIGHTS1 Scalia etme ir tn Aa ET EN BOOK IRC =DO NOT coPY OR DISTRIBUTE API 510 FINAL EXAMINATION 1 COPYRIGHT 2000 - IRC'SCHINOLER & ASSOCIATES ~ALL RIGHTS ‘Qw-482 (Back) WPS No: Rev Nos [ POSTTIONS (aw-405) | POSTWELD HEAT TREATMENT (W607) 1 Position(s) of Groo ALL Temperswure range 1130 = 1200¢ Welding Progression: Up __X Down | Time Range 1 HR PER INCH, 15 MINT MINIMUM Positions(s) of Fillet__ALL | | GAS (ance) Parcent Composition 1p Min.:200° MINIMUM Interpass Temp Max:__650° MAXIMUM Gas(es) (Mixture) Flow Rate Preheat Maint: NONE. Shielding ARGONICO2 _75%-25% __ _10-20 CEH ina Traling? ; Backing: _O2 700% 5.10 CF Ta We MGs Ee TE ET ELECTRICAL CHARACTERISTICS (QW-408) 7 =, ‘Currant AC or DC —_DC. Polarity_REVERSE ee ‘Amps Range __ 100-150" Volts (Range) _18-25, {Amps and vls Tage should Be recorded for eat elecade SB. positon, and ikness, ete. This information may be std in {ular form sia to rat show below.) ‘Tungsten Electrode Size and Type, ‘Pars Tongaien, Be Thersied. we] Mode of metal Transfer for GMAW SPRAY ARC TRANSFER ONLY ‘(Soray ae anor rearing we ee) oo Electrode Wire feed spaed range FECHNIQUE (QW-410) String or Weave Bead _BOTH. Orifice or Gas Cup Size iz _ Initial and Intergass Cleaning (Brushing ie. ) BRUSH AND GRIND BY USING MANUAL METHODS af Method of Back Gouging ___ CARBON ARC Oscillation _NONE _ Contact Tubs to Work Distance 1/4" = 1/2" Multiple or Single Pass (per side)_MULTIPASS a or Multiple of Single Siectrodes: SINGLE. a es Peerage Reece Teen cee Sree eae ALLOWED otner | RE ar ae 7 1 i veg. seman reve, | Sonmane met f wate Spee d years) | Prats | cess Renae q ALL ALE DCREV_ 100-150 a 1 | amo Pare r T L 1 i T EB 190 NOT COPY OR DISTRIBU GASSOCIATES - ALL RIGHTS RESERVE! COPYRIGHT 2000 ~IRCISCHIND.API 510 FINAL EXAMINATION 1 - OPEN 800K IRC COPYAIGHT 2000 = IRC/SCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED .50 NOT COPY OR DISTRIBUTE ‘OW-183 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (POR) (See QW-200.2, Section IX, ASME Boiler and Pressure vessel Code) Record Actual Conditions Used to Weld Test Cougon Company Name:___XYZ COMPANY n Record No.: 44 Date: 8-31-82 Welding Process(s): FCAW (TUBULAR) — Types (Manual, Automatic, Semi-Auto. ): __ SEMILAUTOMATIC SPRAY TRANSFER, JOINTS (Gw-202) Groove Design of Test Coupan (For combination quaifcations, the deposed wold metal thickness shall be recordad foreach Mer metal of process used.) BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407) Material Spec: __SA 302. ‘Temperature: _NONE USED Type or Grade: __ GRADE 5. Time: 2.No: __3 to PN 3 Other: Thickness of test Coupon:__/2 THICK E Diameter of Test Coupon: ___N/A= PLATE Other. NO PASS GREATER THAN 1/8" THICK GAS (QW-408) FILLER METALS (GW-404) Percent Composition SFA Specification: _SEA- 6.29 Gas(es) (Mixture) Flow Rate AWS Classification: _E7iT1-4 Shielding: _CO2 100% 42.18 CEH Filler Metal F No. € Trailing: __NONE. Weld metal Analysis No. A2(80,000 TENSILE). Backing: NONE Size of Filler metal: _1/8"___ ELECTRICAL CHARACTERISTICS (QW~403) Other: NO SUPPLEMENTAL FILLERS OR Current: _ DIRECT POWDERS USED. Polarity: REVERSE rece Weld Metal Thickness: __ 1/2" THICK Amps.:____130 Volts: 28 Tungsten Electrode Sizer __ Other: : POSITION (QW -405) Position of Groove:__ FLAT Weld Progression (Uphill, Downhill: NIA TECHNIQUE (aW-10) Other: Travel Speed: __15 12M String or Weave Sead: _ WEAVE Oseillation: NONE Multipass or Single Pass (per side):_MULTIPASS Interpass temp! Single or Mu Other: Other: PREHEAT (W205) Preheat Temp.:___400°F le Electrodes:_SINGLE ___ ‘caPYRIGHT 20¢0 ~IRG:SCHINO! RIGHTS RESERV: ‘API 510 FINAL EXAMINATION 1 - OPEN BOOK IRC (COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 09 NOT COPY OR DISTRIBUTE QW-483 (Back) PQR No: __14 Tensile Test (QW-150) | | [ _Uitinaie’ | Gisate | Type of Specimen Total toad | unit stress | Falture & No. | Width _| Thickness |__Area_ | tb. |__Lecation we | ae se [OG | SRBASE | | METAL [eae | besASe METAL i 1 1 T i 1 I I i [os I i Guided Bend Tests (QW-180) 7 Type and Figure No. Result = | [SEBEND HT ow-622 POROSITY - Ge" DIA) - ACCEPTABLE | [SIDE BEND #2 - QW. 462.2 ‘CORNER POROSITY - 1/8” DIAM. - ACCEPTABLE Toughness Tests (QW-170) Impact Values = Specimen | Notch | Specimen | Test No. | Location ize _|Temp.| Ft.Lbs. | %Shear| mits | drop Weight Break (YIN) = { Comments: Fillet Weld Test (QW-120) Result — Satisfactory: Yes: No: Penetration into Parant Metal: Yes:_No:_~_ Macro — Results: Other Tests Type of Test: Deposit Analysis: Other: Welders Name: JOE BLOW JR. GlockNo: A Stamp No __4 Tests conducted by: __ BILLS TEST LAB. Laboratory Test No.:_123. We cartify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Cade Manufacturer: ___XYZ COMPANY. 8/31/92 a By! _JOE BLOW SR. COPYRIGHT 2000 ~ IRCISCHINOLER 2 ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OR CISTRIBUTEASME IX AND V TEST IRC SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE AP! 510/570 COURSE ASME SECTION IX AND V TEST (ALL OPEN BOOK) NAME DATE, 1. AWS s primary purpose is to: a qualify the POR qualify the WP sc, provide direction to the welder during production welding document all non-essential variables 2. APQR's primary purpose is to: sa,’ qualify the WPS qualify the WPQ cc. _ provide direction to the welder when making the test welds d— botha&c, above 3 AWPQ's primary purpose is to: a. _ chow ine ranges quid by 2 wolderopeator b show the actual variables used to qualify a welder/operator A Reet per eet & a all of the above 4 ‘The nan-desvucve examination tht wil be covered bythe AP 510/570 sxrinaton a # > F elton $e 5 What ypes of ane maybe detected by PT? ay sutece only B Mea ony c surface cracks. only Fee erty abeutace é—sanduest acceptance cite is specifedin Paragraph __ of ASME Seton ik 2 awass 2 Santee 2 Bates § Gkagh 7 Wanting the SMAW process a decrease of more han YOO" in the peseat temperature qualified is an variable Essential Non-Essential Supplementary Essential Not a variable COPYRIGHT 2/- IRCZSCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE10 " 12 13 14, 15 ASME IX AND V TEST IRe COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE SFA 5.28 's considered to be an Fi, per ASME IX. A penetrameter is used for? Judging RT flim density by Judging RT fim sensitivity ¢ Judging RT film exposure qd Judging UT acceptability ( ‘What is the minimum frequency range of ultrasonic instruments to be used for ASME Code examination? a 25 MHz b 18 Khz cc 8-10 MHz d. none of the above What is the difference between X and Gamma Rays? Xi a longer ray than Gamma ‘Gamma is a harder ray than X ‘Tne origination of the ray (source vs machine) Xis only used in alloy analysis MT using AG yokes is: acceptable to find all discontinuities acceptable to find surface discontinuities, only acceptable to find sub-surface discontinuities acceptable to find cracks, only What device or devices may be used to measure RT film density? 2 Calibrated density strip b Calibrated densitometer c Calibrated penetrameter @— Botha&b. above ‘Tension tests may be used to. a Qualify a welder b Qualify a walding operator c Prove the ductility of a proposed welding procedure: Qualify a welding procedure Essental variables must be addressed on a wes b PAR c¢ wpa d— Allof the above COPYRIOGHT 2)- IRC?SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTEEXAMINATION 1 - CLOSED 800K IRS IACISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE, copyaIGHT 20% = sessure test shail be p: 18 Ahar rapairs are completed to a pressure vessei [Atha repairs an alteration 3.) the API-510 inspector believes one is necessary C the Pressure Vessel Engineer believes one is necessary D. no NDE is done in iau of the pressure test 17 The ASME Code requires that safety valves be marked wit! A. tbine steam capacity (8) MAW of the valve C. valve supolier D bursting pressure Se {8) An exchanger that has a tube bundle that is free to move in the snaii, which pam \/ expansion and contraction with temperature changes is 2 Ax, Floating Tubesheet exchanger (B) Floating Head exchanger © Floating Body exchanger D. Fixed U Tube heat exchanger ‘The scope of API 510 includes: CA.) miniature vessels (UM stamped vessels) Coast Guard vessels C. vassals rated for 10 psig D none of the above 20. _Erasion problems would be more likely in which of the following concitions A, sampling lines (3 impingement point across from a vessel nozzle inlet T the battom of a fractionating tower ©. the bottom of a kettle-tyoe re-boiler Sensitization (or carbide precipitation) occurs in stainless steels when heated in the temperature range of °, and then slowly cooled ‘A. 2000 - 25000 5 Git D 22 Aprassure vessel is 4° thick and made from carton steel (P-1 material) This vessel will hav sired with a flush patch using a Category A butweld. Per ASME Vill. this recair will EA, szot radiographed © fully adiographed C radiographed, if 2 joint efficiency of 1 0 is used © Ulrasonically examined per UW-12 requirements COPYRIGHT 2000 ~IAGISCHINOLER & ASSOCIATES - ALL RIGHTS RESEAVEO - 00 NOT CO?¥ OR OISTRIE:API510 FINAL EXAMINATION 1 - CLOSED BOOK IRC COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OF OISTRIBUTE 23. Aradiograph that meets ASME V requiremients will have a density range of i produced with an X-Ray source A 20-40 18-40 13 (composi © 23-38 24 Amateriai test report is requires for au rai par ASME vin @rse and plate product pipe © fiting. D pressure-retsining 25 The allowable mill undertalerance an piping is B 12.5% : © 125% = 1s at D. 01" of 6% of ordered thickness: (2s ,) Acomman type of stress corrosion cracking that occurs in carton stee!s in petroleum refineries is that caused by sodium hydroxide This type is commeniy called: ‘A, chloride cracking ‘B.)caustic embritiement © erosion/carrosion © high temperature embrittlement 27 When repairing vessels with stainless steet weld averiay and cladding (vessels constructed of P-3 Pot. or P-5 base materials) the base metal in the area of repair should be examined for cracking by UT per ASME Section V This UT inspection should be made at least hours aiter repairs have been completed for equipment in hydrogen service. Fapedaly for chromium-molyodenum alloys that could be affected dy delayed cracking ANZ (Bye ‘C38 D 42 ® 28 For corrosion calculations the surface of the weld is considered to De! Bs inch en eter se ofthe wel orice the minimum heknes onan side of he sna wsicnave is greater whicneve 8 23 até o2 times the minimum biekness on ether side of viatea hisnaveriegrestar ee ee weld or ties the minimum tienes on "enet icneveris greater cee ene ee rea eld or 6 ies the minimum thickness on siter side of Sane michaves is greats: & er side o 28 Which of the following is not a tool for measuring thickness of vessel shells? A ecoustic emission transducers 'B ultrasonic instruments C radiography with step gages © corrosion buttons and depth drilling a & ASSOCIATES - ALL RIGHTS RESERVEO - DC NOT COPY OR DISTRISYAPI510 FIK COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES ~ ALL RIGHTS RESERVED . DO NOT coPY OR DISTRIBUTE 30 Vessel production i \JA) the base metal must be impact tasied 8 raculred by the Inspector CC the metal will be operated 2¢ -20°F ©. UHA St requires them to be performed 31 ita WPS shows a single "Vee" Groove weld is to be used and the POR was qualified witn a double "Vee" Grocve: A. the WES can be used without requalification 5 the WPS must be requalifie C, the POR must be retested ‘D> the WPS must be modified to show the A. itis always used in vapor service , itis always used in hazardous service : Circular Flat Unstayed q 1D. Hemispherical 40 Ifa steel has exceeded its yield point upon the removel of pressure and heat it wil ‘A. return to its original shape CB) contain a permanent deformation “6 spitrupture D be scrap 41 Of the lypes of stresses placed on a thin walled cylinder, the most severe is A) circumferential B longitudinal C compressive D radial rsile strength men is 15 KSI The ultima: 42 The ultimate load on a $10" diameter tensiie sp: on this specimen is approximately’ A) 73.528 psi 90.200 psi C 85 100 psi D 18.389 psi 43. The “Piezoelectric” effect is used in: 44 Onthe PH Scale 2 reading of 7 0 would be A. acidic yn C alkaline BD fatwlant 45 One of he most common welding defects abserved in the root pass of 2 welc Coe YRIGHT 2000 = IRCISCMINDLER & ASSOCIATES - AL! RIGHTS RESERVE™ AP} 510 FINAL EXAMEIATION { - CLOSED BOOK IRC IGHT 2000 ~ IRGISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DG NOT COPY OR DISTRIBUTE, A, porosity B. lack of penetration C tergster inc! D overies 48 _ Ifa probable corresion rate cannot de determined from reviewing data from ihe same or similar service vessels or estimated form published data, on-stream determinations shallbe made after approximately hours of service by using NDE methods anda corrosion rete is established @> 1900 Cc” 3000 © 10500 47 What datarminas the inspection interval af 2 pressure-reileving device? ‘A. The interval is determined by the authorized pressure vessel inspector 'B The interval is determined by the owner-user. Grain growth. D Graphitic corrosion. 64 —_In-cases where the remaining safe operating life is estimated to be less than 4 years, the inspection interval may be the full remaining safe operating life up to @ maximum of 8 (> mus be at least 20°F above MON 3 mended tobe a least 30°F above MOLT 63 “CREEP’is affected by: ep strength 09 HoT cory oF OIS TRIS COPYAIGHT 2006 ~ IRCISCMINOLER & ASSOCIATES - ALL RIGHTS RESER'/AP! 510 FINAL EXAMINATION 1 - CLOSED BOOK IRC COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE A guy wire is used for: ar QD sesing tetra wind lading) suppor to a tat vss $ooig Hon eo ut vee! uiding 2 level gauge through 2 tower © pre-placement of insulation over a corroded surface oak 68. _ The two NDE methods referenced by API 510 for measuring metal thickness ars (Ac REET 8) RT. UT UT, AET OD MiPT 6 Radiography of zirconium (P51 ~ P62 metals) for purposes of welder qualifications is: é permitted by ASME IX 6. 5} not alowed by ASME IX net addressed by ASME (X D acceptable per ASME Vil 70 Ralleving devices in a dirty, corrosive service must be removed and inspected at least every: A. 10 years B. year (E> 5 years oy 5 10 years if the Inspector approves 71 The primary difference between GMAW and FCAW is: B) the gas used the wire used D the power source used i 6 the wire feeder used 72 Ifthe ownership and location of a vessel are changed the vessel must oe: A. revregistered withthe state 3 tevheat treated after instalation G. cleaned before moving (Gdinsoected after instalation atthe new location should have 3 on the downstream side to indicate if leakage or rupture 73 Acupture has occurred (Bnscatng lasso ole ots é fr D alarm 74 Anameplate shell be attached to a vessel after 2 A repair _&, alteration (i erating D allof the above comYRGMT 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - D0 NOT COPY OR DISTRIBU)a API 510 FINAL EXAMINATION 1 - CLOSED BOOK IRC CCOPYaIGH? 2000 -IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRISUTE High temee: drogen attack wil usually ocxur at temperatures above A, 1900°F 8 10.000°F 20°F (D.450°F 76. When the temper-bead welding technique is used in lau of PHT per APi 510, the minimum praneat temperature shall be __ °F and the maximum wierpass i! shall be A, 350. 450 B 450.550 , 850, 750 D. 280, 380 17. Cathodic protection systems are normally supplied in either one of two ways: A, expressed current or impressed current (B) impressed current or sacrificial anode sacrificial anode or impressed anode D. sacrificial anode or artificial cathode 78 Before a hydrostatic test of an existing vessel is performed: (CAbithe vessel should be checked to ensure itcan withstand the lcadings frem the height of the water the vessel must be fully rauiographed C the vessel should be PWHT'd D the vessel should be purged of air by opening a connection at the lowest point on the vessel ina pressure vessal record file 78, The three types of information that should be retainex (according to API 510) are! A. crawings. caleulations, specications 2 permanent, progressive, historical © Sperating and inspection history. construction design and repair. alteration anc m_ferating information (basic deta, field notes, data accumulated in a “continuous file” 80 An Authorized API Inspectors duties may include: (A, “authori approve re-rating designs repairs & alterations 5 C periarm radiography D. install nameplates er SB fatigue © corrosion © brittle fracture COPYRIGHT 2000 ~IRC'SCHINOLER & ASSOCIATES -ALL RIGHTS RE!83 a4 8s, e6 ar 88. a3 API 5t0 FINAL EXAMINATION 4 - CLOSED 800K IRC (COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OF DISTRIBI Fer ASME IA, a welding operator may be Gualified by test plates (bend tests) production weld radiography Raciograohy of a tast pipe ‘D) all of the above Goer Which PT examination may not follow the other? (@ fuorescent my not follow visible visible may not follow fluorescent C. mutidicectional may not follow longitu D_ exponential may not follow subrotational ‘When conducting extemal vessel inspections, specific attention shoult be directed to: A tray support rings 8 downcomers . Cskirt attachment area ‘Dantivartex devices ‘The dish of a torispherical head will normally be than an elliptical head, and therefore will have to be thicker for the same pressure A, thinner |B. rounder ©) hater D_ more obround A pressure vessel that reduces vapor to liquid is called a: A, heat exchanger 8. seboiler (C) condenser “D. mutti hoon Per Ariicie 9. personnel perierming visual 2: A. be qualified to SNT-TC-1A B. have 20 years experience . have an annual vision testo J-1 Standards _¢&) have an annual vision test to 12 Stancarcs shall ‘An inquiry submitted to the AP! committee requesting an interpratation on an API S10 requirement should be composed so that the committee reply can be made in a format. ‘A Nes or no” B. legal ©. lengthy D. narrative When steel is heated to a high temperature followed by rapid cooling, the substructure becomes very hard This is caused by the formation of (martensite 8 austenite C bainite ©. pearite The scope A, vessels rated for less than 15 psig (Ep vores less nan carte non-stationary vessels (moveable vessels) over 15 psig D piping and {In checking a bbe oriented Ay parallel fired heaters wald fer longitudinal tothe cracks (8) perpendicular © aligned © similar .SME VII! includes which of the following: Jes using the MT method, the magnet field should Graphitization is @ phenomena that occurs when steels operate for 2 fong time in the. TSF - 100" 250°F - 504 gio w > cosvaicHt 2000 *F range }O°F range 11,000°C - 15.000°C range 25°F - 1.400°F range IRCISCHINDLER & ASSOCIA’ ALL RIGHTS RESEAVED - GO NOT COPY CR DISTRIEUTS