Part A PDF

Preparatory Course for
API 570
PIPING INSPECTOR EXAMINATION
Part A
Pre-course material
Document No.: API 570/2001A Rev.4 Dated 01.01.2019
By
Insight Quality Services, Pune

Faculty: Mr. D. D. Joshi
Contents:
1.0 Message to the participants

2.0 Documents applicable
3.0 Preparation recommended before joining the Preparatory course
3.1 ASME B31.3
3.2 API 570
3.3 ASME Sect. IX
3.4 ASME Sect V
“It is good to have Education, it is better to have Experience,

but it is Essential to have Training”
IQS/API 510/1001/A Rev.4 Dated 01.01.2019

Disclaimer
The information compiled here in is for Training purpose only and to be used for
understanding the codes and standards, however, for actual execution of work the
respective codes and standards must be referred.
1
FOR TRAINING PURPOSE ONLY. NOT TO BE REPRODUCED.
INDEX
Section Description Page No.

No.
1. Message to the Participant 3
2. Preparation of Study Material 5
3 Examination Information 6
4. Body of Knowledge 8
5. Publication Effectivity Sheet 17
6. Content Classification 18
7. General Information about Exam 22
8. ASME B31.3 28
9. API 570 34
ASME Sec IX 46
10.
ASME Sec V 51
11.
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Message to the participants:
Welcome!
It is a great pleasure to welcome all of you for this API 570 Preparatory program.
Before we enter into the preparation we must know the approach for this preparation.
It is expected that the inspector should be able to handle the day-to-day situation in
actual service inspection. Hence we have to equip ourselves with the knowledge and
skills required for fulfillment of the responsibilities of an API 570 Piping Inspector.
If you go through the document 2.1 e (final role…) you will understand and
appreciate the requirements of the piping inspector. At the end of this preparatory
module you should be in a position to demonstrate your role as a piping inspector.
I must inform you at this stage that this syllabus is covering the design principles as
well as inspection principles. Many times the inspectors will be having a practical
knowledge about actual inspection, however, may lack in design principles. Some
may be experts in welding but may not be comfortable with NDT and vice versa.
Some may not be comfortable with ASME B31.3 requirements. In order to have a
proper preparation before examination one has to identify his strengths and
weaknesses in context with the Body of Knowledge. Once you identify your pain
areas (areas where you have to put more efforts) start working on these areas. This
will add confidence during preparation.
The very idea of giving this pre course material is to give orientation to the
participants about the expectations of the examination. There are two examinations
namely Open Book and Close Book. The questions in both the examinations are
multiple-choice questions.
The open book examination is having about 50 questions to be attempted in 3 hours.

(In the last examination there were 58 questions) The questions are based on
applicable codes as per publication effectively sheet. One has to know where to find
the answer in the code and therefore for quick reference highlighting the important
areas underlining the key areas and small notes in margin will be helpful which is
allowed in the examination. (Refer 2.1 b).
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It must be remembered that the candidate has to go through all the areas of
open book examination at least once and have clarity of the contents and
applications.
The close book examination is having approximately 100 questions and 4 hours. (In
the last examination there were 92 questions on close book) The questions judge
your awareness of the topics and will be based on the definite principle given in the
material. Generally, the time given for the examination is sufficient.
While preparing for the examination one can start with ASME B31.3, and ASME Sec.
V and Sec. IX to know the manufacturing of new process piping l and to get clarity in
inspection principles. This will constitute approximately about 50 % of the total
questions. Then the candidate should go through API 570 code thoroughly and study
the service inspection principles. This will constitute around 40 % of the total
questions. Then API 574, API 578 and B16.5 can be taken which generally
constitute approximately 10 % of the questions. In each of the above area there are
numerical questions for which it is advisable to list all the formulae and try to solve
the examples based on the formulae.
As the preparatory course duration (6 days) is comparatively short we have made

this pre-course material which will be sent to the candidates 1 to 2 weeks in advance
and the candidates may orient themselves to the Body of Knowledge. The pre-
course material is giving you some basic principles of the topic and a questionnaire
to know the depth up to which you have to study the subject. One can read the
question and try to locate the answer by referring to the relevant code topics, which
will help in preparation.
We are sure that the candidates can make maximum out of this pre-course material.
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1. Documents applicable:
The following information is available on API website www.api.org .The candidates

are advised to go through the same before starting the preparation.
Preparation and Study Materials

Study Materials
Questions in the API 570 exam are derived from the publications listed below. You
should bring these publications to the exam with you.
i. API Standard 570, Inspection, Repair, Alteration, and Re-rating of In-Service

Piping Systems
ii. API Recommended Practice 574, Inspection of Piping, Tubing, Valves, and
Fittings
iii. American Society of Mechanical Engineers (ASME), Boiler & Pressure Vessel
Code
o ASME Section V, Nondestructive Examination
o ASME Section IX, Welding and Brazing Qualifications
iv. American Society of Mechanical Engineers (ASME), Code for Pressure Piping
o B16.5, Pipe Flanges and Flanged Fittings
o B31.3, Process Piping
API and ASME publications may be ordered through IHS Documents at 303-792-
2181 or 800-854-7179. Orders may also be faxed to 303-397-7935. More information
is available at http://www.ihs.com.
ASME publications may also be ordered through ASME’s publications department at

1-800-843-2763. In Canada, ASME publications are available through Power
Engineering Books, Ltd. at 1-800-667-3155 or 403-458-3155.
Please refer to the 570 Publications Effectivity Sheet to determine which editions of
the above documents are applicable for your exam.
Note: API and ASME publications are copyrighted material. Photocopies of

publications are not permitted at the exam.
5
Examination Information
1. The examination is administered at various sites by the participating members
of the National Board of Boiler and Pressure Vessel Inspectors and by the
Professional Examination Service (PES). Questions for the online
examination will be multiple choice with an open and closed book sections.
Total length of examination is 8 hours. Individual jurisdictions may charge an
additional sitting fee to take the test in their jurisdiction. Please contact the
jurisdiction you select for an exact amount. There is no additional sitting fee at
the locations where the test is administered by PES.
2. If you pass the examination, and all sections of your application are complete,
you will be certified and receive a wallet card and certificate approximately 3
months after the examination date
3. If you fail the test on your first attempt, you may retake it. You must notify API
in writing before the deadline for the next scheduled examination, if it is your
intention to register for that exam. A reschedule fee of $300 applies.
4. If you do not pass the test on the second attempt, you may submit an
additional $200.00 plus the $50.00 rescheduling fee. You must submit an
updated Employment Reference form. If the candidate is unsuccessful on the
third attempt, an initial application must be submitted with a new application
fee.
5. Test results will be mailed to you approximately 8 weeks after you have taken
the exam. DO NOT call API, PES, or your jurisdiction for test results; these
results WILL NOT be given over the telephone
6. What to Bring to the Exam
o No. 2 pencils;
o A non-programmable calculator (a calculator with only simple
functions);
o The applicable API and ASME reference publications. Highlighting,
underlining, page tabs, and notes written in margins of the code books
are acceptable. Loose pages inserted in the code books are not
acceptable. Note: API and ASME publications are copyrighted material.
Photocopies of publications are not permitted at the exam;
o Your test site confirmation letter
o A picture ID (i.e. driver’s license)
6
Pre‐test Questions for API510, 570 & 653 Examinations
The API 510, 570 and 653 exams contain 125 scored questions, plus 25
questions that are not scored, otherwise known as "pre-test". Pre-test
questions are usually newly-written or recently revised questions. These
questions need to be vetted by the candidates before being approved and
used for scoring.
Using pre-test items on an exam does not impact scoring or test taker
performance, since test takers are unable to identify which questions are
scored and which are not. Exam grading is based on the number of correct
responses. The minimum passing score is calculated based on the 125
scored items, and each scored item is worth 1 point.
API utilizes the statistical method of equating in order to maintain the same
level of exam difficulty. The equating process takes into account that 25 of the
test questions are “pre-test” questions and accordingly establishes passing
grade for all exams. The pre-test questions appear on all tests for all
candidates, so each test taker receives the same fair experience
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Content Classification
Final Role Delineation & Rubrics (content classification)
Piping Inspector Certification (API-570)
Activity areas (Domains)
Task Statements
Knowledge statements
Activity 01 -- Planning and Extent of Inspections - 570

Tasks:
0101 Review previous piping inspection reports
0102 Identify areas of special concern (e.g., dead legs, injection points, buried
piping)
0103 Determine and document any changes in service conditions (e.g., temperature,
pressure)
0104 Determine number and placement of thickness measurement locations (TMLs)
in piping systems
0105 Plan the piping inspection as regards types of deterioration (e.g., corrosion,
SCC, CUI, embrittlement, erosion, vibration)
0106 Plan the piping inspection as regards inspection techniques (e.g., NDE, impact
testing)
0107 Determine inspection techniques for large bore piping (>2" diameter)
0108 Determine inspection techniques for threaded and small bore piping (= 2"
diameter)
0109 Determine limits of scope of inspection (including jurisdictional requirements
and code applicability)
0110 Review and validate piping classifications (per API 570)
0111 Identify, locate, and document specialty items (e.g., expansion joints), noting
those which
need additional inspection
Knowledge of:
01 . .responsibilities of involved parties (e.g., inspectors, repair organizations)

02 .. major types of corrosion/deterioration mechanisms and where they are likely to
occur
03 . .areas of special concern as regards deterioration
04 .. applications/limitations of various inspection techniques
05 . . special considerations for buried piping
06 . .testing requirements
07 . .types of refractory and inspection methods
08 ..record keeping systems and requirements (e.g., including manual and computer
based systems)
09 . .scope of API 570, Piping Inspection Code
10 . .drafting conventions
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Activity 02 -- Inspection and Testing Practices – 570
Tasks:
0201 Assess potential safety hazards associated with conducting inspection & follow
all required safety permits, procedures, & provisions for proper personal protective
equipment
0202 Ensure all NDE equipment is properly maintained and calibrated
0203 Conduct external visual inspection of piping including pipe supports
0204 Conduct appropriate NDE inspection (including flaw detection and sizing)
0205 Ensure that inspection and data collection is done in accordance with approved
procedures
0206 Conduct thickness measurements
0207 Conduct internal inspection of piping
0208 Conduct inspection for corrosion under insulation (CUI)
0209 Conduct inspection of refractory systems
0210 Specify and witness pressure and leak tests including aboveground and buried
piping
0211 Specify and oversee necessary destructive examination
0212 Conduct inspection of piping insulation
0213 Inspect coating of above ground and buried piping systems
0214 Observe cathodic protection system (close interval potential survey) and obtain
report advice as needed
0215 Conduct external pipe inspection of buried piping
0216 Conduct visual surveillance of soil-to-air interface points of buried piping
0217 Inspect valves, fittings, flanges
Knowledge of:
12 ..safety requirements for inspection (e.g., Permit Required Confined Spaces,
Lockout/Tagout, elevated work)
13 ..personnel qualification for NDE per ASNT SNT-TC-1A
14 ..NDE procedures per ASME Boiler & Pressure Vessel Code, Section V
15 ..insulation and insulation inspection methods (including CUI)
16 ..refractory systems and inspection methods
17 ..leak and pressure testing procedures, requirements, and precautions
18 ..cleanliness requirements for inspection
19 ..maintenance and calibration requirements and methods for various inspection
equipment
20 ..applications/limitations of various inspection techniques (e.g., hammer testing,
strapping, PT, RT)
21 ..paint and coating systems
22 ..cathodic protection systems
23 ..requirements for non-destructive examination
24 ..requirements for destructive examination
25 ..material verification and traceability
26 ..piping components (e.g., piping, tubing, valves, fittings, expansion joints, pipe
supports) and pipe joining methods
27 ..special inspection requirements for buried piping
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Activity 03 -- Data Evaluation and Documentation – 570
Tasks:
0301 Determine minimum allowable thickness of piping components
0302 Determine MAWP
0303 Record inspection data
0304 Evaluate locally thinned areas or other indications (e.g., undercut, slag
inclusion,
porosity) in regard to need for repair or replacement
0305 Calculate corrosion rates on piping
0306 Evaluate change of service effects on inspection frequency and suitability of
continued
service
0307 Determine estimated remaining life
0308 Adjust the number and location of thickness measurement locations based on
inspection
results and deterioration mechanisms
0309 Document the evaluation in a record system
0310 Schedule the next inspection based upon frequency requirements and
estimated
remaining life
0311 Evaluate effectiveness of cathodic protection and/or coating for aboveground
and buried
Piping
Knowledge of :
30 .. corrosion rate calculation

31 .. remaining life calculation
32 .. establishing inspection frequency based on remaining life and service
33 .. maximum service intervals specified by codes and standards
34 . thickness measurement locations (TMLs) and their selection
35 .. requirements for documentation of results
36 .. deterioration mechanisms and their impact on suitability of continued service
37 . .maximum allowable working pressure (MAWP) calculations
38 .. minimum required thickness determination
39 .. evaluation of locally thinned areas
40 .. widely scattered pits
41 .. established inspection frequency for buried piping
42 .. cathodic protection systems and principles of operation
43 .. need for piping stress analysis
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Activity 04 -- Repairs, Alterations, and Rerating – 570
Tasks:
0401 Specify repairs and alteration work prior to commencement of work including
identification of inspection hold points
0402 Verify correct materials are used
0403 Ensure that all work complies with approved procedures and standards
0404 Ensure that a piping engineer has been consulted when appropriate
0405 Approve all repairs, rerating, and alterations when complete
0406 Document repairs, alterations, and rerating
Knowledge of :
44 ..procedures to evaluate competency of repair organization
45 ..ASME B31.3, Process Piping
46 ..ASME Boiler and Pressure Vessel Code, Section VIII Division I
47 ..material requirements and methods for positive material identification
48 ..inspection, testing, and documentation requirements
49 ..definitions of repairs and alterations
50 ..repairs and alteration methods and procedures (including temporary repairs)
51 ..hot tapping techniques and requirements
52 ..rerating requirements and calculations
53 ..fabrication techniques
5x ..repairs to buried piping
54 ..piping components (e.g., piping, tubing, valves, fittings, expansion joints, pipe
supports) and pipe joining methods
Activity 05 -- Welding – 570
Tasks:
0501 Approve welding procedure specifications (WPS) and Procedure Qualification
Records
(PQR) to assure compliance with applicable code
0502 Verify welders’ qualifications
0503 Ensure welding is performed according to approved procedure (including pre-
heat)
0504 Ensure correct filler metals are used and properly stored
0505 Ensure PWHT is performed according to procedure
0506 Ensure that alternatives to PWHT (e.g., temper-bead) conform to applicable
code
Knowledge of :
55 ..ASME Boiler and Pressure Vessel Code, Section IX-Welding and Brazing
Qualifications
56 ..impact testing requirements
57 ..WPS, PQR, and WPQ requirements
58 ..preheat requirements for various materials, thicknesses, and conditions
59 ..acceptable methods and temperatures, and precautions for PWHT
60 ..acceptable alternative methods to PWHT
61 ..methods of documenting welds (e.g., welders’ stamps, weld maps)
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General Information and Qualification Requirements
Introduction
The American Petroleum Institute (API) initiated the Piping Inspector Certification
Program (PICP) to provide a continued high level of safety through the use of
inspectors specialized in process piping; to improve management control of process
unit inspection, repair, alteration and rerating; and to reduce the potential for
inspection delays resulting from regulatory requirements. This program is based on
API Standard 570, Piping Inspection Code: Inspection, Repair, Alteration, and
Rerating of In-Service Piping Systems; and RP 574, Inspection of Piping, Tubing,
Valves, and Fittings. The program promotes self-regulation and establishes a
uniform program that will assist state and local governments in process piping
regulation.
Before Submitting an Application
1. You must be employed by or under contract to an authorized inspection

agency or owner/user organization as defined in API 570.
2. You must satisfy one of the combinations of education and experience for
The certification you are applying for.
Education Minimum Skills

Experience
Required
BS (or higher) in 1 year Supervision or performance of
engineering inspection activities of piping systems
as described in API 570.
2-year degree 2 years Design, construction, repair,
or certificate in operation, or inspection of piping
engineering or systems, of which 1 year must be in
technology supervision or performance of
inspection activities as described in
API 570.
High school 3 years Design, construction, repair,
diploma or operation, or inspection in-service
equivalent piping systems, of which 1 year must
be in supervision or performance of
API 570.
None 5 or more years Design, construction, repair,

operation, or inspection in-service
piping systems, of which 1 year must
be in supervision or performance of
API 570.
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1.0 Preparation recommended before joining the Preparatory course
ASME B 31.3
This process piping code is to be studies in line with the body of knowledge.
The students are advised to go thro the following pages to make some initial
preparations:
1)Page no. 5 : fluid services,
2) Page no. 9 Longitudinal weld joints Quality Factors
3)Page no. 19/20 Thickness Calculations
4) Page no. 29 Blank thickness calculations
5) Page no. 50: Impact testing curves
6) Page no. 54: Impact acc. Stds.
7)Page 68: Preheat requirmments
8) Page page 78: Acc stds
9)Page 84 Testing
10)Page 156 Basic allowable stresses.
The following information is for ASME SECTION DIV 1 .
THE INFORMATION WILL HELP THE STUDENTS TO GET AQUAINTED

WITH ASME CODE SYSTEMS.
1.0 Preamble
The Boiler and Pressure Vessel (BPV) committee of American Society of
Mechanical Engineers was set up initially in 1911.
1.1 Functions :
i. To establish rules for SAFETY governing design, fabrication and
inspection during construction of boilers and pressure vessels.
ii. To interpret rules when questions arise regarding their intent.
1.2 Incorporated in the rules are :
i. Needs of users, manufacturer's and inspectors of the pressure
vessels
ii. Reasonably certain protection to life and property
iii. Margin for deterioration in service to afford a long and safe period of
usefulness
1.3 Revisions :
i. Addenda covering revisions and errata, is annually on 1st July.
ii. Revised Edition is issued every three years.
Note : Current edition or revision of Code becomes mandatory after six
months of issue.
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1.4 Code Cases:
Code cases are applicable for Code-stamped vessels, in particular those
falling within jurisdictions of those States of U.S.A. and Canada which have
adopted one or more sections of the Code.
1.5 Coverage:
Rules cover materials of constructions, methods of fabrication & inspection,
and safety factors for given design, pressure and temperature conditions.
1.6 Code Sections complimentary to ASME Section VII Div. 1 :

ASME Section IX, Section II Part A, B, C & D, Section V
Note : Materials to ASTM specifications, unless adopted as a companion

ASME specification, and unless incorporated by relevant Code section for
use, should not be employed in construction of code stamped vessels.
2.0 Scope of the Code : ASME Section VII Div. 1 : 2001:
2.1 Definition of a pressure vessel as per Code:

Containers for containment of pressure (external or internal), obtained from an
external source, or by application of heat (through direct or indirect source), or
by combination thereof.
2.2 Scope : Exclusions
Following pressure vessels are not included in the purview of
ASME Section VIII Div.1
i. those covered by other sections.

ii. fired process tubular heaters.
iii. Pressure containers which are integral parts (or components) of
rotating machinery.
iv. Piping System [except pressure relieving devices.
v. Pipe fittings, valves, pipe components [e.g. strainers, flow meters] and
other accessories.
vi. Vessel containing water under pressure including those containing air,
the compression of which serves only as a caution when none of the
following limitations are exceeded:
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- a design pressure of 300 psi (2070 kPa)
- a design temperature of 2100 F (990 C)
vii. Hot Water Storage Tank with limitations
- heat input not exceeding 2,00,000 BTU/Hr.
- water temperature not exceeding 2100 F.
- nom. water capacity 120 gallons (545 Ltrs.) max.
viii. Vessels with incident loading of external or internal operating pressure
not exceeding 15 psi (No limitations on size).
ix. Vessels having inside diameter or width/height/cross section diagonal
not exceeding 6" (No limitations on length or pressure)
x. Vessels for pressures exceeding 3000 psi.
xi. Vessels for Human occupancy
2.3 Inclusions :
Following are included in the scope of this Code :
i. Pressure Relief devices (Refer to See ANSI/ASME-PTC 25.3)

ii. Unfired Steam Boilers (with pressure relief devices as per
ASME Sec. I)
Such as (a) Evaporators & Heat Exchangers.

(b) Process heat generated steam boilers.
(c) Directly fired steam boilers - which are NOT COVERED by
Section I, III & IV
(d) Gas fired jacketed steam kettles with jacket pressures 50 psi
and below (See Appendix 14 Clause 30)
iii. Small vessels not excluded by 2.2 above, not including 2.3 (ii)
above, and not exceeding following parameters :-
(a) 5.0 cu.ft. Volume & DP 250 psig. or
(b) 1.5 cu.ft. Volume & DP 600 psig.
Note : These do not require radiography and are not to be provided with
quick actuating closures.
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2.4 Battery Limits
(a) For external connections
i. Welding ends, for welded external connection
ii. Threaded joints for screwed connections
iii. Flange face for bolted connections
iv. Sealing surface for proprietary connections
(b) Weldment of pressure part to non-pressure part.
(c) Manhole and handhole covers - for vessel openings.
(d) Sealing surfaces for instruments, gauges, etc.
2.5 Responsibilities :
i. Manufacturer's :
(a) Compliance of all requirements of Code by himself, and by all others
(i.e. Vendors)
(b) Providing proper certification of materials and construction.
(c) Providing applicable design calculations.
(d) Establishing a mandatory Quality System.
ii. Inspector's:
(a) Monitoring quality control.
(b) Verification of design calculations.
(c) Conducting specified inspections.
(d) Code stamping
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SECTION I : Power Boilers
SECTION II : Material Specifications
Part A : Ferrous Materials

Part B : Nonferrous Materials
Part C : Welding Rods, Electrodes and Filler Metals
Part D : Material Properties
SECTION III : Rules for Construction of Nuclear Power Plant Components

(Section NCA, Div. 1 & Div. 2 & Div. 1 - NB, NC, ND, NE, NF,
NG, NH, Appendices, Div.2 & Div.3)
SECTION IV : Heating Boilers

SECTION V : Nondestructive Examination
SECTION VI : Recommended Rules For Care and Operation of Heating

Boilers
SECTION VII : Recommended Guidelines for care of Power Boilers

SECTION VIII: Division 1 : Unfired Pressure Vessels
SECTION VIII Division 2 : Pressure Vessels : Alternative Rules
SECTION VIII Division 3 : Alternative Rules for construction of High

Pressure Vessels
SECTION IX : Welding and Brazing Qualifications
SECTION X : Fiber - Reinforced Plastic Pressure Vessels
SECTION XI : Rules for In-service of Nuclear Power Plant Components
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Practice Quiz for ASME B31.3 (Pre- course)
There are 15 questions given below which can help you to have right direction of
study.
ASME B31.3 QUIZ - Closed Book
1. The requirements of the latest edition of ASME Code Section B 31.3 and any
subsequent Addenda :
1. Must be followed explicitly as soon as the latest edition is issued.

2. Are retroactive and all piping installed per earlier must be upgraded.
3. Are not retroactive & all piping installed per earlier additions need not
be upgraded.
4. May be used without regard to the acceptability of Code revisions to the
jurisdiction.
2. Clauses in the B 31 code are not necessarily numbered consecutively. Such

discontinues result from :
1. The age of the code and the number of changes that have been made.
2. Following a common outline, insofar as practical for all Code Sections.
3. No particular logic was followed in the original versions of the Code.
4. Practices followed by all Codes to make them difficult to reproduce.
3. Who has the responsibility of determining which Code Section is applicable to

piping installations, i.e. B 31.1, B31.3 etc?
1. Owner
2. Inspector
3. Jurisdiction
4. Engineer
4. Who has the overall responsibility for compliance with ASME

B31.3?
1. Inspector
2. Owner
3. Engineer
4. Jurisdiction
5. The intent of ASME B 31.3 is to set forth engineering requirements deemed

necessary for ____________ and __________ of piping installations.
1. Structural design, fabrication

2. Safe design, construction
3. Adequate fabrication, execution
4. Permanent existence, longevity
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6. ASME Code is not intended to apply to piping :
1. In the chemical Industry

2. That has been placed in service
3. In the agonomy industry
4. In the space industry.
7. Compatibility of materials with the service and hazards from instability of

contained fluids :
1. Is covered extensively by ASME B 31.3

2. Are not within the scope of ASME B31.3
3. Is addressed on a limited basis by ASME B31.3
4. Is the main scope of ASME B31.3
8. ASME B31.3 applies to piping for all fluids except for which of the below?
1. Tubes of fired heaters, plumbing and storm sewers

2. Raw, intermediate and finished chemicals
3. Petroleum products, fluidized solids and refrigerants
4. Gas, steam, air, and water
9. A pre-placed filter metal which is completely fused into the roof of a welded joint
and becomes part of the weld is called :
1. A depleted appendage
2. A pre-placed ligament
3. A consumable insert
4. A caulked joint
10. Define "face of weld "
1. It is the longitudinal view of a weld that has been split down the middle
for inspection.
2. It is the elevation view of a weld that has been cut out to show its cross
section.
3. It is the concealed weld surface on the side opposite from which the
welding was done.
4. It is the exposed surface of a weld on the side from which the welding
was done
11. fluid service that is non-flammable, non-toxic, and not damaging to human
tissue and its gauge pressure does not exceed 150 psi and the design
temperature is form - 20o through 366oF is known as a
category_____________fluid.
1. D
2. C
3. M
4. N
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12. A fluid service in which th<v potential for personnel exposure is judged to
be significant and in which a single exposure to a very small quantity of a
toxic fluid, caused by leakage, can produce serious irreversible harm to
persons on breathing or bodily contact, even when prompt restorative
measures are taken is known as a category fluid:
1. D
2. M
3. H
4. N
13. A fillet weld whose size is equal to the thickness of the thinner member
joined is called:
1. A butt fillet weld

2. A longitudinal fillet weld
3. A full fillet weld
4. A fillet weld with out backing.
14. The heating of metal to and holding at a suitable temperature and then
cooling at a suitable rate for such purposes as; reducing hardness,
improving machinability, facilitating cold working, producing a desired
microstructure, or obtaining desired mechanical, physical, or other
properties is known as :
1. Annealing
2. Normalizing
3. Quenching
4. Stress – relievin
15 Piping joint that for the purpose of mechanical strength or leak resistance,
or both, in which the mechanical strength is developed by threaded,
grooved, rolled, flared, or flanged pipe ends; or by bolts, pins, toggles, or
rings; and the leak resistance is developed by threads and compounds,
gaskets, rolled ends, caulking, or machined and mated surfaces is known
as a :
1. Bonded joint
2. Mechanical joint
3. fused joint
4. juke joint
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ASME B31.3 Answers - Closed Book
Q. ANS. REFERENCE
1. 3 ASME B 31.3 Introduction
4. 2 ASME B 31.3 300 (b) (1)
5. 2 ASME B 31.3 300 (c) (1)
6. 2 ASME B 31.3 300 (c) (2)
7. 2 ASME B 31.3 300 (c) (6)
8. 1 ASME B 31.3 300 1.1 (b)
9. 3 ASME B 31.3 300.2
10. 4 ASME B 31.3 300.2
11. 1 ASME B 31.3 300.2
12. 2 ASME B 31.3 300.2
13. 3 ASME B 31.3 300.2
14. 1 ASME B 31.3 300.2
15. 2 ASME B 31.3 300.2
32
1.1 API 570 PIPING INSPECTION CODE- INSPECTION, REPAIR,
ALTERATION, AND RERATING OF IN-SERVICE PIPING SYSTEMS.
Sr. No. Description

Section 1 Scope
Section 2 References
Section 3 Definitions
Section 4 Owner-User inspection organization
Section 5 Inspection and Testing Practices
Section 6 Frequency and Extent of Inspection.
Section 7 Inspection Data Evaluation, Analysis, and Recording
Section 8 Repairs, Alterations, and Re-rating of Piping Systems
Section 9 Inspection of Buried Piping
Appendices: A,B,C,D.
Section 1:
This gives the scope, applications and exclusions. It also gives fitness for service
concepts.
Section 2:
Section 2 is giving references.
Section 3:
Section 3 is giving definitions. The definitions of authorized inspection agency piping
circuit and piping systems Primary process piping and secondary process piping;
repair organization shall be studied and understood properly. Normally 3 to 4
questions are asked on definitions.
Section 4:
Section 4 is dealing with owner-user organization. It includes quality assurance
inspector’s manual. 1 or 2 questions can be asked on this.
33
Section 5:
Section 5 is giving inspection and testing practices.
5.1 It gives Risk Based Inspections.

5.2 This givers preparatory work details for inspections.
5.3 Corrosion and cracking
5.4 This gives types of inspection and surveillance.
5.5 This gives thickness measurement
5.6 This gives thickness measurement methods
5.7 This gives pressure testing details
5.8 This gives Material verification and traceability
5.9 This gives inspection of valves
5.10 This gives inspection of welds in service.
5.11 This gives Inspection of flanged joints.
Section 6:
This is for Frequency and extent of inspection and to be studied in details as this is
the core area of the code.
Section 7:
This is meant for Inspection Data Evaluation, Analysis and Recording You can
expect numerical problems from in this section
Section 8:This gives Repair , alteration and re-rating details.
Section 9 :
This section gives details of Inspection of Buried piping
Appendix A- Inspector certification
Appendix B- Technical inquiries
Appendix C-Examples of Repairs
Appendix D-External Inspection Checklist for process piping
34
Practice Quiz for API 570 (Pre-Course)
study. API 570 Quiz - Open Book
1. A 14" O.D. pipe has a corroded area on it. What is the maximum size of
a small repair patch that may be used to cover the corroded area ?
1. 3.5"
2. 7"
3. 5"
4. 6.5"
2. A NPS 4 Schedule 80 (0.337" wall) branch is welded into a NPS 12

Schedule 40 (0.406" wall) header. What size cover fillet weld (tc) is
required over the full penetration groove weld " (Express answer to
nearest hundredth)
1. 0.578"
2. 0.286"
3. 0.334"
4. 0.236"
3. A NPS 6 (6.6.25" od) seamless pipe made from ASTM A335 Grade P2
material operates at 800 psi and 600 oF. The conditions require that a
corrosion allowance of 0.125" be maintained. Calculate the minimum
required thickness for these conditions.
1. 0.294"
2. 0.343"
3. 0.631"
4. 0.524"
4. A NPS 14 (14.00" od) seamless pipe made from ASTM A106 Grade
A material operates at 300 psi and 600 oF. The pipe must
cross a small ditch and it must be capable of supporting itself
without a visible sag. A piping engineer states that the pipe must be
atleast 0.375" to support itself and the liquid product. He also states
that a 0.125" corrosion allowance must be included. Calculate the
minimum required thickness for the pipe.
1. 0.778"
2. 0.567"
3. 0.642"
4. 0.600
35
5. A 10' long carbon steel pipe is welded to a 10' 18-8 stainless pipe
and is heated uniformly to 475 o F from 70 o F. Determine its total length
after heating
1. 20.067'
2. 20.156'
3. 20.234'
4. 20.095'
API 570 Answers - Open Book
Q. ANS. REFERENCE
1 2 API 570, APP
2 4 B31.3, 328.5.4(c)
3 1 B31.3, 304.1.1
4 3 B31.3, 304.1.1
5 1 B31.3, Table C-l
36
API 570 Quiz - Closed Book
1. API 570 covers inspection, repair alteration, and re-rating procedure for
metallic piping systems that_______________________.
1. Are being fabricated

2. does not fall under ASME B31.3
3. have been in-service
4. has not been tested.
2. API 570 was developed for the petroleum refining and chemical process
industries.
1. It shall be used for all piping systems.

2. It may be used, where practical, for any piping system.
3. It can be used, where necessary, for steam piping.
4. It may not be used unless agreed to by all parties.
3. API 570 be used as a substitute for the original construction

requirements governing a piping system before it is placed in-service.
1. shall not
2. should
3. may
4. can
4. API 570 applies to piping systems for process fluids, hydrocarbons,

and similar flammable or toxic fluid services. Which of the following
services is not specifically applicable?
1. Raw, intermediate, and finished petroleum products

2. Water, steam condensate, boiler feed water
3. Raw, intermediate, and finished chemical products
4. Hydrogen, natural gas, fuel gas, and flare systems
5. Some of the classes of piping systems that are excluded or optional

for coverage under API 570 are listed below. Which one is a mandatory
included class?
1. Water
2. Catalyst lines
3. Steam
4. Boiler feed water
37
6. The______________ shall be responsible to the owner-user for determining
that the requirements of API 570 for inspection, examination, and testing
are met.
1. Piping Engineer
2. Inspector
3. Repair Organization
4. Operating Personnel
7. Who is responsible for the control of piping system inspection
programs, inspection frequencies and maintenance of piping ?
1. Authorized Piping Inspector

2. Owner-user
3. Jurisdiction
4. Contractor
8. An authorized piping inspector shall have the following qualifications. Pick the
one that does not belong in this list.
1. Four years of inspection in-service piping systems.

2. High school education plus 3 years of experience in the design,
construction, repair, operation, or inspection of piping systems.
3. Two year certificate in engineering or technology plus 2 years of
experience in the design, construction, repair, operation, or inspection
of piping systems.
4. Degree in engineering plus one year experience in the design,
construction, repair, operation, or inspection of piping systems.
9. Risk based inspections include which of the following :-
1. Likelihood assessment
2. Consequence analysis
3. Operating and inspection histories
4. All of the above
10. An RBI assessment can be used to alter the inspection strategy provided
1. The degradation methods are identified

2. The RBI is fully documented.
3. A third party conducts the RBI
4. Both a and b above
11. Which one of the following is not a specific type of an area of

deterioration?
1. Rectifier performance
2. Injection points
3. Dead legs
4. Environmental cracking
38
12. Injection points subject to accelerated or localized corrosion may be treated as
___________
1. the focal point of an inspection circuit

2. separate inspection circuits
3. piping that must be renewed on a regular schedule
4. locations where corrosion inhibitors must be used
13. The recommended upstream limit of inspection of an injection point is a

minimum of
1. 12 feet or 3 pipe lengths whichever is smaller

2. 12 inches or 3 pipe diameters whichever is smaller
3. 12 inches or 3 pipe diameters whichever is greater
4. 12 feet or 3 pipe lengths which is greater
14. The recommended downstream limit of inspection of an injection point is a

minimum of
1. second change in flow direction past the injection point, or 25 feet

beyond the first change in flow direction whichever is less
2. second change in flow direction past the injection point, or 25 feet
beyond the first change in flow direction whichever is greater
3. second change in flow direction past the injection point, or 25 inches
beyond the first change in flow direction whichever is less
4. second change in flow direction past the injection point, or 25 inches
beyond the first change in flow direction whichever is greater.
15. Select thickness measurement locations (TMLs) within injection point

circuits subjected to localized corrosion according to the following
guidelines. Select the one that does not belong
1. Establish TMLs on appropriate fittings within the injection point

circuit
2. Establish atleast one TML at a location atleast 25 feet beyond the
downstream limit of the injection point
3. Establish TMLs on the pipe wall at location of expected pipe wall
impingement or injected fluid
4. Establish TMLs at both the upstream and downstream limits of the
injection point circuit.
39
API 570 Answers - Closed Book
Q. ANS. REFERENCE
1 3 API 570, 1.1.1
2 2 API 570, 1.1.2
3 1 API 570, 1.1.3
4 2 API 570, 1.2.1
5 2 API 570, 1.2.1
6 2 API 570,4.3.4
7 2 API 570,4.1
8 1 API 570, A.2.1
9 4 API 570,5.1
10 4 API 570,5.1
11 1 API 570,5.3
12 2 API 570,5.3.1
13 3 API 570,5.3.1
14 1 API 570,5.3.1
15 2 API 570,5.3.1
40
ASME Section IX
WELDING QUALIFICATIONS AND ESTABLISHING WPS.
ASME Section IX relates to qualification of welders, welding operators, brazers and

brazing operators and the procedures that they employ in welding and brazing.
It is divided into parts, part QW gives requirements for welding and part QB contains
requirements for brazing. For the purpose of this course we shall deal only with part
QW.
WPS & PQR
The purpose of welding procedure specification (WPS) and procedure qualification
records (PQR) is to determine that the weldment proposed for construction is
capable of providing the required properties for its intended application.
WPS is intended to provide direction for the welder and lists the variables, both
essential and non essential and the acceptable ranges of these variables when using
the WPS.
It is presumed that welder or welding operator performing the welding procedure

qualification test is skilled workman so that welding procedure qualification test
establishes the properties of weldment and not the skill of the welder.
The purpose of performance qualification is to determine if the welder is able to
deposit sound metal or the welding operator is able to operate welding equipment
properly.
Part QW is divided into 4 articles.

Article I - Welding general requirements
Article II - Welding procedure qualifications
Article III - Welding performance qualifications
Article IV - Welding data
Before we proceed let us first understand various test position in groove welds in
plates, groove welds in pipes and fillet weld in plates etc.
(Ref. Figure 461.3, 4 & 5)
In general, 1G or 1F is called flat positions
2G or 2F is called horizontal and circumferential
41
3G or 3F is called vertical position &
4G or 4F is called overhead position
Position 5G is only in welds in pipes. It is a position when pipe axis is held horizontal
and circumferential seam is welded without rotating. In a way it is combination of
1G, 3G & 4G.
Position 6G is also for the pipes when pipe axis is at 45 deg. to horizontal plate and
circumferential seam is welded without rotating the pipe. It is combination of all
positions.
(Refer Fig. 461.1) is the diagram defining the position for groove welds depending on
the inclination of the axis of the weld and the angle of rotation of the face of the weld.
There is similar (Refer fig. 461.2) giving position for fillet welds.
(Refer fig. 451.1) gives the thickness limits and the type and number of the test
specimen required for procedure qualification of groove and (Refer fig. 463.1) a, b, c,
d, e, f shows the method of the taking the test specimen.
In case of weld between dissimilar materials where it is difficult to carry out bending
so that weld is at the center of convex position, transverse bends are replaced by
longitudinal bends and the fig. look like (Refer fig. 463.1 c)
(Refer fig. 451.3 & 451.4) Give the test required to fillet test and (fig462.4) a,d ( it is
similar except that instead of bend there is macro examination of 2 sections of ¼
section.)
(Refer fig. 452.1) gives performance qualification limits and type and number of the
test specimen required table (fig) gives the diameter limits. It is worth noting that one,
two or more welders can be qualified on just one test coupon. Each may be using
even different processes.
42
(Refer fig. 462.4 B & C) gives the requirements for performance qualification of fillet
welds.
(Refer fig. 461.9) gives performance qualification position and diameter limits.
Welding Variables :
Article (IV) gives data about various types of welding variables. It also gives tables
for various welding processes showing essential variables, supplementary essential
variables and non essential variables for procedures qualification; and essential
variables for performance qualification.
Essential variables for procedure are those welding variables whose change will
affect the mechanical properties (other than notch-toughness) of the weldment (ex.
Change in P-number, filler metal, electrode type, preheat post heat etc.)
Supplementary essential variables for procedure are those welding variables for
procedure whose change will alter the notch toughness properties of weldment (ex.
Uphill or down hill vertical welding, heat input, preheat or PWHT)
Non essential variables for performance are those welding variables which will not
affect the mechanical properties of weldment (ex. Joint design, method of back
gauging or cleaning etc.)
Essential variables for performance are those welding variables which will affect the
ability of welder to deposit sound weld (e.g. position, deletion of backing F-number
etc.
Change in process is essential variable for procedure as well as performance.
Before we proceed let us first understand the term P-number A-number and F-
number.
All those materials are divided into various P-numbers depending on their nominal
composition and further divided into groups depending on their nominal composition
and further divided into groups depending on the type of refinement / min. specified
UTS etc. QW-422 gives the full details.
43
Plain carbon steels, C-Si, Cr-Mn & C-Mn-Si are grouped as P-1 materials and
austenitic stainless steel as P-8 material. Ferrous welding consumable are classified
under various A-numbers based on their weld metal chemical composition (table
442) and all welding electrodes and welding rods are grouped in different F-number
depending on their AWS classification which is based on type of flux and chemical
composition (table 432)
Now let us have look on some essential variables tables.

QW 253 WPS- SMAW
QW 353 WPQ- SMAW
The following tables are to be referred frequently for working with ASME Section IX
and hence one has to understand them (how to) in right context.
Refer ASME Section IX.

1. Refer Fig. QW 461.3 - Groove Welds in Test Position
2. Refer Fig. QW 461.4 - Fillet welds in Plates Test Positions.
3. Refer Fig. QW 461.5 - Fillet Welds in Pipe Test Positions
4. Refer fig. QW 462.2 - Method of Taking out the Test Specimen
5. (a, b, c, d & e) (Performance Qualification
6. Refer fig. QW 463.1 - Method of Taking out the Test Specimen
(a, b, c, d,e & f) Qualification)
7. Refer Table QW 451 - Procedure Qualification Thickness Limits
and Test Specimens.
8. Refer Table QW 452 - Performance Qualification and Test
Specimens.
9. Refer Table QW 461.9 - Performance Qualification Position and
diameter limits.
10. Refer Table QW 461.1 - Test Jig dimensions
Acceptance Criteria Procedure Qualification
1. QW 153 Tension Test
2. QW 163 Bend Test
3. QW 183 Micro Examination Procedure Specimens
4. QW 184 Micro Examination Performance Specimens
5. QW 191 Radiographic Examination
44
QUESTION: You have given a WPS and a PQR. You have to find mistakes
made while making this WPS and PQR.
QW-482 WELDING PROCEDURE SPECIFICATIONS (WPS)
(In line with ASME Section IX, Edition 2001, Addenda 2003)
XYZ/WPS/1page 1 of 3
Company Name XYZ Company By Mr. Mathew
WPS No. XYZ/WPS/1 Date 01.01.2001
Supporting PQR XYZ/PQR/1 Date 01.01.2001
No(s).
Welding Process(es) SMAW Type Manual
Joints : (QW 402)
Details
Joint Design : Joints in vessel
drg. (drg. No. ABC/v-101)
Backing (Yes/ No) : No
Backing Material (Type) : - N.A.
(Refer to the both Backing and
Retainers) For double bevel: chip back to sound metal &
(Metal /Non fusing Metal /Non- weld
Metallic /Others)
Base Metal (QW 403):
P. No. ___1__ Group No. ____ _____ to P. No _____1_____ Group No. ___
__
OR
Specification Type and Grade to
Specification Type and Grade
OR
Chem Analysis/Mech. Props to -
Chem Analysis/Mech. Props
Groove Fillet
Thickness Range: Base Metal 1/16” to 2”
Pipe - -
Other N. A.
*Filler Metals(QW 404):
Specification No. (SFA) 5.1 -
AWS No. (Class) E7018, E6013 -
F. No. 4, 2 -
A. N0. 1 -
Size of filler metal  3/32”, 1/8”, 5/32” -
Weld Metal: Thickness Range -
Groove Up to 2” -
Fillet -
Electrode flux (class) N. A. -
Flux Trade Name N. A. -
Consumable Insert N. A. -
45
XYZ/WPS/1 page 2 of 3
Other - -
(Each base metal –filler metal combination should be recorded individually.)
Positions (QW 405):
Position(s) of Groove Any
Welding Progression :
Up/Down
Position(s) of Fillet
Preheat (QW 406):
Preheat temp. (min) 1200 F
Inter pass Temp. (max) -
Preheat Maintenance -
( Continuous or special heating where applicable should be recorded)

Post Weld Heat Treatment (QW-407):
Temperature Range 11000 F  250 F
Time Range 5 min. – 2 hours
Gas (QW-408):
Percentage Compositions
Gas( es ) Mixtures Flow Rate
Shielding
Trailing
Backing
Electrical Characteristics (QW-409):
Current AC or DC
Polarity EP (Rev. 1)
Amp (Range) 60-115 Ampere
Volts(Range) 26-31 V
Tungsten Electrode Size and Type
Mode of metal transfer for GMAW N. A.
Electrode Wire feed speed range N. A.
Technique (QW – 410):
String / Weave Bead String / Weave
Orifice or Gas cup Size  8 mm
Initial / Inter pass Cleaning Brushing + Grinding
(Brushing/Grinding)
Method of back Gouging N. A.
Oscillation  30
Contact tube to work distance N. A.
Multiple Pass or single pass (per side) Multiple
Multiple or single Electrode(s) Single
Travel speed range 4 – 8” /min
Peening N. A.
46
XYZ/WPS/1 page 3 of 3
Other -
-
Wel Proces Filler Metal Current Volt Travel Others
d s Range Speed
Lay Range
er
(s)
Class Dia. Polari Amp. Volts mm/min. Techniqu
mm ty (Rang (Range) e
e)
1. SMAW E 3/32” AC / 60-80 26-30 V 4-8” -
7018 or DC A /min.
1/8”
SMAW E 1/8” AC / 70-100 28-32 V 4-8” -
7018 or DC A /min.
5/32”
SMAW E 1/8” AC / 70-80 26-32 V 4-8” -
7018 DC A /min.
Manufactur
XYZ Company, Indonesia
er
By Mr. Mathew
Date 01.01.2001
47
QW-483 PROCEDURE QUALIFICATION RECORD (PQR)
(In line with ASME Section IX, Edition 2001, Addenda 2003)
Record of Actual Conditions Used to Weld Test Coupon
XYZ/PQR/1 page 1 of 3
Company XYZ Company, Indonesia
Name
PQR No. XYZ/PQR/1 Rev. 1 Date 01.01.2001
WPS No. XYZ/WPS/1 Date
Welding SMAW Type Manual
Process
Joints (QW 402)
Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall be
recorded for each filler metal or process used.)
Base Metals (QW 403):

Material Specifications SA 516 to SA 516
Type OR Grade Gr. 70 to Gr. 70
P. No. ___1______ to P. No ___1_______
Thickness of Test Coupon ¾”
Diameter of Test Coupon
Other
Filler Metals (QW 404):
SFA Specification 5.1
AWS Classification E 7018
Filler Metal F. No. 4
Weld Metal Analysis A. 1
N0.
Size of filler metal  1/8”, 5/32”
Weld Metal Thickness ¾”
Other
Positions (QW 405):
Position of Groove 1G
Welding Progression Uphill
(Uphill/Downhill)
48
Other
Preheat (QW 406):

Preheat temp. 2200 F
Inter pass Temp.

Other
Post weld Heat Treatment (QW-407):

Temperature 11500 F  250 F
Time 45 minutes
Other
Gas (QW-408):
Percentage Composition
Gas(es) Mixtures Flow Rate
Shielding
Trailing
Backing
Electrical Characteristics (QW-409):

Current AC Polarity
Amp 80 A, 100 A Volts 28 V, 30 V
Tungsten Electrode
Size
Other
Technique (QW – 410):

Travel Speed 6” /min.
String or Weave Bead String
Oscillation  30
Multiple OR Single Pass(per Multiple
side )
Single or Multiple Electrodes Single
Others Deposition = 1/8” per pass approximately
Tensile Test (QW – 150)
49
Specime Width “ Thickness Area “2 Ultimate Ultimate Type of
n No. ” Total load Unit failure and
lb Stress psi location
TP – 1 0.746” 0.760” 0.567 38800 71,430 W.M.
TP – 2 0.742” 0.755” 0.530 35700 67,358 B.M.
Guided Bend Test (QW-160)

4T X 180o Bend
Type and Figure No. Result
Root Bend – Sample No. 1 OK, No Crack
Root Bend – Sample No. 2 OK, No Crack
Face Bend - Sample No. 1 Crack in HAZ, 2 mm. Length- OK
Face Bend - Sample No. 2 OK, No Crack
Toughness Test ( QW 170) : N. A.

Specim Notch Specime Test Impact Values Drop
en NO. Location n size temp. ft- lbs % shear Mils Weight
Break
(Y/N)
1.
2.
Comment: ________________________________________________________________
Filler Weld Test (QW 180) :

Result – Satisfactory: Yes ___________ No ___________
Penetration into Parent Metal Yes ___________ No___________
Macro- Results
Other Test:
Type of Test Visual- OK
Deposit Analysis
Other
Welder’s Name Mr. John

Identification No. W-2
Test Conducted by Perfect Lab Testing
Laboratory Test No. TR-625
We certify 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 Code.
Manufacturer XYZ Company
By Mr. Mathew
Date 01.01.2001
ANSWERS FOR WPS / PQR: (mistakes found)
1. The range covered by PQR Thickness ¾” is 3/16” to 1 ½” whereas WPS gives

1/16” to 2 “.
50
2. PQR with E7018 (F No. 4) cannot qualify E6013 (F No. 2).
3. Weld metal thickness qualified in WPS should be upto 1 ½” in place of 2”.
4. The WPS Pre eat temp. shall be 120 degrees F minimum (PQR preheat is
220 deg. F, so –100 deg. F is acceptable.
5. PWHT temp. shall be 1125 deg.  25 deg. F and in WPS the time range for
PWHT shall be 15 min. to 1 ½ hour.
6. In PQR the type of failure is not mentioned.
7. The TP 1 tensile strength shall be 68430 psi. in place of 71430 psi.
8. TP 2 area shall be 0.560 in place of 0.530 and tensile strength shall be 63750
psi in place of 67358 psi.
9. TP 1 & 2 both are rejected.
10. 4 side bends are required in place of root bend and face bend.
11. PQR is not a revisable document. It should not have a revision number.
51
Practice Quiz for ASME Section IX (Pre Course)
There are 25 questions given below which can

help you to have right direction of study.
ASME Section - IX QUIZ
1. A welder is welding plate as like we are writing on a blackboard. The plate is

in vertical plane. This position is:
1. 3G
2. 5G
3. 6G
4. None of the above
2. A shell is welded by a welder. The shell is rotated by rollers and welder is

sitting on fixed platform on the top of the shell. This position of welding is:
1. 1G
2. 2G
3. 5G
4. 6G
3. Guided bend tests are used to determine the
1. Ultimate tensile strength of the weld joint

2. Degree of Soundness of fillet welds
3. Notch toughness of weldment
4. Hardness of weldment.
5. Degree of soundness and ductility of groove weld joints.
4. When radiographic testing is used in place of bend tests in welder's performance

qualification on groove welds on plate, the minimum length at spot to be exposed
is:
1. 6"
2. 12"
3. 15"
4. Not specified
5. Radiography cannot be used as it cannot give idea about ductility
52
5. Tensile test was carried out for qualifying a Welding procedure (PQR). The
minimum specified tensile strength of the base metal is 70,000 psi. If the test
specimen breaks in parent metal (outside weld and fusion zone) and the
tensile strength calculated is 68,000 psi.
1. The test is acceptable

2. The test is rejected
3. The test is void and fresh test plate should be welded.
4. None of the above.
6. The guided bend specimen shall have no open defects in the weld or heat
affected zone exceeding ___________ measured in any direction on the
convex surface of the specimen after bending:
1. 1/8"
2. 1/16"
3. 1/4"
4. 3/16"
7. A guided bend test was performed on a carbon steel plate for procedure
qualification of 1/2" thick plate weld. Mandrel diameter used was 3t instead of
4t. There were no discontinuities observed. What is your decision for this test?
1. Test is acceptable
2. Test is rejected
3. Retest with 4t mandrel diameter
8. A welder is to be qualified for carbon steel plate weld in 1" thick. Required
tests are:
1. Two face bends and two root bends

2. One face bend and one root bend
3. Radiography as per ASME Sect. IX requirement.
4. 2 or 3
5. 1 or 3
9. P nos. are assigned to base metals dependent on characteristics such as:
1. Chemical Composition, Weldability and Mechanical properties.

2. Mechanical properties only.
3. Chemical Composition only.
4. None of the above.
10. A weld procedure is qualified in 1G position. This procedure can be used for
53
welding in _______ position:
1. 1G
2. 2G
3. 3G
4. 4G
5. All of the above
11. For the procedure qualification of SMAW processes joint design is a

__________ variable ?
1. Essential
2. Non-essential
3. Supplementary essential
12. A welder is decided to be qualified on his initial production weld on 1/2" thick
longitudinal seam of carbon steel shell. The first 6” length of the weld was
radiographed. The radiograph reveals slag length of 5 mm. Your decision
in this case will be:
1. Welder is not qualified

2. Welder is qualified
3. Not covered in ASME Sect. IX
13. A welding procedure for SMAW process is qualified using 1” thick plate. The
base material thickness range qualified by this procedure is:
1. 3/16" to 2"
2. 1/16" to 2"
3. 1" to 2"
4. 1" & below
5. 1/2" to 1"
14. A performance qualification test was carried out for a welder in 2G position
with a plate thickness of 15 mm and SMAW process. The test was found
satisfactory. This welder can weld a max thickness of:
1. 30 mm
2. 15 mm
3. Any thickness
4. 15/2 = 7.5 mm
15. The F No. for electrode E7018 is:
54
1. 4
2. 1
3. 2
4. 3
16. A groove weld in pipe having 15 mm OD X 2mm wall thickness was made
for performance qualification. This test was found satisfactory so this weld
can welder a pipe diameter range of:
1. 15 mm OD & above
2. 15 mm OD & below
3. 15 mm OD to 30 mm OD
4. Only 15 mm OD
17. The performance qualification of a welder gets expired, if he has not welded
with that process for ___________ months or more.
1. 6 months
2. 3 months
3. 1 year
4. No limit
18. Welding positions applicable to Pipe are:
1. 1G, 2G, 3G, 4G, 5G, 6G

2. 1G, 2G, 5G, 6G
3. 1G, 2G, 3G, 6G
4. 1G, 2G, 4G, 6G
19. Change in Essential Variable in procedure qualification:
1. Affects Mechanical properties

2. Require Re-Qualification
3. Both 1 and 2
20. In Procedure Qualification following mechanical tests are conducted:
1. Two Transverse Face Bend and two Transverse Root Bend

2. Two Transverse Tensile
3. Hardness
4. Both 1 and 2
21. Which of the following below mentioned statements are correct?
1. WPS can be revised and next revision number can be given.

2. PQR can be revised and next revision number can be given.
3. WPS & PQR Both can be revised.
4. WPS & PQR cannot have revision.
55
22. PQR contains:
1. Variables recorded during welding

2. Test results
3. Name of manufacturer.
4. All of the above
23. Procedure Qualified with10 mm thickness shall qualify thickness from:
1. 10 mm to 20 mm
2. 10 mm
3. 4.74 mm to 20 mm
4. 1.6 mm to 20 mm
24. Procedure qualified one metal from P No. 3 to any metal in P. No. 3 shall
qualify:
1. Any metal from P No. 3 to any metal from P No. 3 or P No.1

2. Any metal from P No. 3 to any metal from P No. 3
3. Both 1 and 2
25. Welder Qualified on 1 1/2" Pipe dia can weld pipes within below mentioned
limits:
1. 1" and above

2. 1 1/2" and above
3. 1/2" and above
4. 1 1/2" to 3" and above
ASME Section IX - Answers

Q A Q A Q A Q A Q A
1 4 6 1 11 2 16 1 21 1
2 1 7 1 12 1 17 1 22 4
3 5 8 4 13 1 18 2 23 4
4 1 9 1 14 3 19 3 24 1
5 1 10 5 15 4 20 4 25 1
56
ASME Section V
NON-DESTRUCTIVE TESTING BASIC METHODS
1.0 Introduction
1.1 Light and Heavy Engineering Industries manufacturing Boilers, Unfired
Pressure Vessels, Chemical Process Plants, Cranes, Structural Frames,
Castings and Forgings need to enforce various quality control methods to
assure requisite quality of their products. These quality control methods
include inspection and testing during in-process manufacturing stages and/or
at final stages as dictated by Clients, Engineering Codes of construction [e.g.
ASME, IS, BS] and Statutory Regulations [such as IBR, SMPV Rules, BARC -
DRP, etc.].
1.2 Some manufacturing firms establish their own Quality Control Department
for inspection and testing. This necessitates employment of qualified
personnel, establishment of Metallurgical Laboratory for destructive testing
and setting up special equipment and facilities for non-destructive testing
(NDT).
1.3 Increasingly stringent statutory regulations, growing awareness about

environmental protection as well as about industrial safety have all led to
greater investment by the manufacturing industry in such programs which
ascertain that the outgoing quality meets Client's requirements.
Quality Control and Non-destructive testing weed out the non-conformities

likely to creep in. Quality Assurance techniques provide necessary confidence
to customer that product quality is consistently maintained at desired level by
preventative actions
57
2.0 VARIOUS NDT TECHNIQUES
A technique by which an item can be tested without causing it any damage is
called Non-Destructive Testing. Following text describes some of the
prevalent NDT Techniques employed for examination of raw materials,
equipments and structures for flaws such as inhomogeneities, cracks,
blowholes, laminations, inclusions, etc.
2.1 Liquid Penetrant Testing (PT) :

This is an NDT method for finding surface discontinuities in solid and
essentially non-porous materials. Liquid penetrants applied on the surface can
seep into a minute surface openings, as fine as 4 microns wide, by capillary
action. When a developer is applied on the surface subsequently by a
blotting-paper like-action, the developer absorbs and indicates on a
contrasting background the existence of the surface flaws clearly. This simple
flaw-checking process is well suited for detection of surface laminations,
cracks, porosities and other discontinuities.
2.2 Magnetic Particle Inspection (MT) :

This is an NDT method for locating surface and subsurface defects/
discontinuities in FERROMAGNETIC materials and weldments. It depends for
its operation upon the physical phenomenon that lies in a direction generally
transverse to the direction of the magnetic field, will cause formation of a
leakage field at and above the surface of the part. The presence of this
leakage field, and therefore the presence of the discontinuity, is detected by
the use of finely divided ferro magnetic particles applied over the surface,
some of the particles forming an outline of the discontinuity, thus indicating its
location, size, shape and extent.
2.3 Radiographic Examination (RT) :

This method is used for non-destructive examination of components,
assemblies and weldments for obtaining a permanent record thereof on
photosensitive films/screens. This method is based on the phenomenon of
differential absorption of penetrating radiation through an item or object being
58
inspected. The radiation is usually of electromagnetic type, of very short wave
length produced by a cathode ray tube or a radioactive isotope.
Because of the differences in density and variations in thickness of the object,

or differences in absorption of characteristics caused by variations in
composition, different portions of the object absorb different amounts of
penetrating radiation. The unabsorbed amount of radiation passed through
the object can be recorded on a photosensitive film or paper and viewed on a
fluorescent/illuminated screen, or monitored by various types of electronic
radiation detectors.
The term Radiography usually implies a conventional radiographic process

that produces a permanent image of cross-section of the object scanned on
a plastic film coated with photosensitive materials. However in a broad sense
it refers to all forms of radiographic inspection. When inspection involves
viewing of a real time image on a fluorescent screen or image intensifier, the
radiographic process is termed as "Fluoroscopy".
Note :In any Radiographic Testing work Safety regulation put forth by (IARC) local
and international regulatory bodies are very important and are to be strictly
adhered to.
2.4 Ultrasonic Examination ( UT ) :-

In this method beams of ultra high frequency sound waves are introduced
into the material/object being inspected. The very short sound waves travel
through the material with attendant loss of energy (attenuation) and are
reflected at interfaces, which may have been caused by discontinuities or
voids. The reflected beam is detected and analyzed to define the presence,
location and size of flaws.
The degree of reflection depends largely on the physical state of matter on

the opposite side of the interface, and to a lesser degree on the specific
physical properties of the matter. For instance, ultrasonic waves are almost
completely reflected at metal-gas interfaces. Partial reflection occurs at
59
metal-liquid or metal-solid interfaces, with the specified percentage of
reflected energy dependant mainly upon the ratios of certain properties of
the matter on the opposite side of the interface.
Cracks, laminations, shrinkages, cavities, bursts, flakes, pores, bonding

faults and other discontinuities that act as metal-gas interfaces can be easily
detected. Inclusions and other inhomogenities in the metal (which do not
behave like metal-gas interfaces) cause partial reflection, scattering or other
detectable effect of ultrasonic waves, and are thus detected.
Most ultrasonic examination instruments detect flaws by monitoring one or

more of the following:
(a) Reflection of energy from metal-gas interfaces, metal liquid interfaces
or discontinuities within metal itself.
(b) Time of transit of an ultrasonic sound wave through the object/test
piece from the entrance point at the transmitting transducer (probe).
(c) Attenuation of the ultrasonic beam by absorption and scattering within
the test piece/object under examination.
Most ultrasonic testing and inspection is done at frequencies between 1 MHz

to 25 MHz, which is well above the frequency range of human hearing (which
is 20 Hz to 20 KHz). Ultrasonic waves cause mechanical vibrations, the
amplitudes of which in metal parts under examination, impose stresses well
below elastic limit, thus preventing permanent effects on the parts.
Many of the characteristics of ultrasonic waves are similar to that of audible

sound waves and to wave motion in general.
Ultrasonic examination is one of the least hazardous, accurate, sensitive and

hence widely used NDT method. The equipment used for this NDT can be
very light and portable. However, technical expertise of the Operator is a
prime requisite. Among disadvantages are difficulties in scanning irregular
shapes, insensitivity at near zones and lack of permanent records. Use of
Reference Standards and efficient techniques are necessary.
60
Misinterpretation of results has sometimes put Ultrasonic examination out of
favor. Latest techniques of "ultrasonic imaging and recording" have removed
this lacuna
2.5 Visual Testing

This a very important method of NDT and can be considered mother of all
other NDT techniques. Visual Inspection involves ‘eye’ as inspection tool. Eye
test for Jaeger ‘J2’ level reading and colour blindness play an important role.
Lighting conditions (at least 500 lux on the surface of part, direction of light),
Surface preparation, measuring tools and their accuracies have important role
in Visual Inspection. Boroscopes, Floroscopes and close circuit TVs are latest
techniques. Visual Inspection if performed properly can help to a great extent
in fabrication Quality Control of activity.
2.6 Other Common Non-destructive Testing Methods :-

i) Leak Testing - Under pneumatic pressure or by using tracer gas detection
ii) Spark Testing - For rough Qualitative examination and segregation of
ferrous materials.
iii) Spectrography- For quantitative analysis of metal composition.
iv) Eddy Current Testing - Used for tubular products like bars, tubes, pipes etc.
for surface and subsurface discontinuities.
v) Acoustic Emission Testing
vi) Acoustical Holography
vii) Optical Holography
viii) Microwave Inspection
ix) Thermography
3.0 Selection of a particular NDT technique :

(Annexure A is tabulating NDT technique selection w.r.t. welding discontinuity and
Annexure B gives the generally applicable NDT w.r.t weld joint types.
 Advantages / Limitations of the NDT Method :
61
The advantages and limitations of the NDT method can be used to determine
which method will provide the best results for a particular test. For example
radiography can detect cracks whose major planes are aligned parallel with
the radiation beam; such cracks are usually normal to the plate surfaces.
Radiography, however, usually cannot detect laminations in plate or cracks
oriented parallel to the plate surface. On the other hand, Ultrasonic can more
readily detect cracks oriented in either direction provided the proper scanning
technique is used.
 Acceptance standards :
The statement “the weld shall be of radiographic quality” has no meaning
unless acceptance standards are stated. Acceptance standards define
different types of characteristics of discontinuities and whether particular types
of discontinuities are permissible. If a particular type of discontinuity is
permissible, then the acceptance standards must specify the maximum size at
which that discontinuity is acceptable. Acceptance standards are an integral
part of most codes and specifications and are commonly used as reference in
purchase specifications.
 Cost :
Different inspection methods have different costs in any particular situation.
Two basic cost factors, which should be considered in the selection of a
nondestructive method, are the initial equipment availability cost and the cost
of performing the inspection. Visual inspection is almost always the least
expensive, but it is also limited to the detection of surface discontinuities. In
general, costs of Radiographic, Ultrasonic, Eddy current and Helium Leak
testing inspections are greater than those of Visual, Magnetic and Liquid
Penetrant inspections. X-ray films are generally imported which constitutes
the major consumable cost in Radiography.
62
Selection of the proper NDT method can be quite complex. It involves manufacturing
technology, possible discontinuities, orientation of discontinuities, accessibility for
testing, physical condition of the job and so many other factors. To meet the
intended purposes and minimize cost, it is suggested that help be obtained from a
qualified nondestructive testing engineer or technician.
ANNEXURE A
Applicable NDT methods / Welding Discontinuities
Applicable NDT Methods

Discontinuities
RT UT PT MT VT ET
Porosity  * a *b a *
Slag Inclusion   NA *b NA *
Incomplete fusion *  NA *b NA *
Incomplete   NA * NA *
Penetration
Undercut  * * *  *
Overlap NA *   * *
Cracks *  a b a 
Laminations NA  a,c b,c a,c NA
Note 1 :
a. Surface
b. Surface and slightly subsurface
c. Weld preparation or edge of base metal
 Applicable method
* Marginal applicability depending on other factors such as material thickness,
Discontinuity size, orientation and location
Note 2 :
Leak testing can reveal only through and through leaks.
63
ANNEXURE B
Applicable NDT methods for Weld joint types
NDT Methods
Joints
RT UT PT MT VT ET
Butt      
Corner *     *
T *     *
Lap * *    *
Note 1 :
 Applicable method
* Marginal applicability depending on other factors such as material thickness,
Discontinuity size, orientation and location
Note 2 :
Leak testing can reveal only through and through leaks.
64
Table (A)
MT PT
For Magnetic Materials For all materials
For surface and sub-surface detect Only for surface detection

detection
Quick & Fast Slower process
Can detect inclusions & foreign Cannot detect such defects

material entrapment
Based on principle of attraction of Based on principles of capillary

magnetic particles to flux leakage action
Easy post cleaning Subsequent cleaning (Post

cleaning) trouble
Best method for detecting stress
corrosion cracks & fatigue cracks
65
Table (B)
UT RT
For internal & surface defects Only for internal defects
More suitable for planer (two Possible to detect only voluminous

dimensional defects) (3D) defects
Accessibility from one side is Accessibility from both sides is
sufficient must.
Size and location of the defect can It is difficult to judge the size &
be judged quite accurately location of defects
Better sensitivity & resolution Poor sensitivity

~ 2% for gamma rays
~ 1% for X rays
Possible to test higher thickness upto Thickness limitations
5 meters
Operator skill is important ------
No safety problem Safety precautions are mandatory
Faster results Slower results in film radiography.

On line radiography very costly
66
Practice Quiz for ASME Section V (Pre Course)
study.
ASME Section - V QUIZ
1. The maximum weight lifted by the DC yoke was 4.5 kg with the pole spacing
of 6 inches. What you can say about the acceptability of this yoke
1. Reject
2. Accept for the prod spacing upto 4 inches only
3. Accept for the prod spacing of 6 inches
4. Refer to Level III
2. Weld under MP inspection shows two porosities (rounded indication) each of

3mm size and a longitudinal crack (linear indication) of 4.5mm in length. Your
decision in this case will be
1. Accept all the discontinuities

2. Repair only longitudinal crack
3. Repair only 2 porosities
4. Cannot decide as the thickness of the part is not given
5. Better to refer level III
3. The black light intensity shall be measured
1. Every 2 years
2. Every month
3. Every year
4. Every 8 hours or work station change
5. Only if lamp is changed
4. Re-examination after repair shall be done in accordance with
1. Same Specification
2. Not-specified in the Code
3. As per customer requirement
4. Need not be done
5. By fluorescent penetrant method as it is more sensitive
67
5. For testing the weld, the pre-cleaning requirement is:
1. Only weld area is to be cleaned

2. Weld area and adjacent a inch area shall be cleaned (1”)
3. Grind the weld area only and then clean by water
4. Weld area and adjacent to two inch area shall be cleaned
6. The application of penetrant allowed
1. Brushing
2. Spraying
3. Dipping
4. 1 or 2 above
5. All of the above
7. A radiograph was taken for a carbon steel 1/2" thickness plate weld with an
acceptable reinforcement of 2mm. A wire IQI ASTM set -1B was used. Total
3 wires are seen on the weld. This radiograph:
1. Meets the sensitivity of requirements of the procedure

2. Does not meet the sensitivity requirement of the procedure
3. Can be accepted as a special case if there is no third party inspection
8. Lead letter 'B' is used as per this procedure, for checking back scatter. The
radiograph shows a dark image of 'B' on a lighter background.
1. Radiograph is acceptable regarding backscatter protection

2. Radiograph is rejected
3. Radiograph needs level III decision
4. Show to customer
9. For single wall viewing of radiographs made by X ray source the density
limitations specified are
1. 1.8 to 4
2. 2.0 to 4
3. 2 to 3.5
4. 1 to 4
10. While radiographing a C.S. 65mm thickness shell long seam, the radiograph
revealed a slag line of length 21mm. This radiograph is (use spot
radiography standard)
1. Acceptable
2. Rejected
3. Acceptable if only internal inspection is there
4. To be discussed with EIL
5. To be referred to level III
68
11. Calibration was made on basic calibration clock with grease couplant. DAC
was plotted to give reference for acceptance. While scanning on the job it was
found that grease used for calibration is consumed and no stock balance. It
was decided to use Glycerin solution as couplant. What will be your
immediate action?
1. Increase 6 dB to compensate for grease to glycerin solution and start the

job.
2. No change required in dB. Directly continue with glycerin as a couplant on
the job.
3. Check again the Basic Calibration Block, with glycerin solution as a
couplant and confirm the reference dB level. If it is changed, correct and
continue with new reference dB level and glycerin as couplant.
4. Insist for grease only. Ask purchase department to cash purchase
12. In the scanning, the overlap shall be:
1. 10%
2. No overlap required if level II is scanning
3. 50%
4. 100% if level I is scanning
5. Scan every place two times
13. Basic calibration block shall be made from
1. Any material
2. Material with same product form and material specification or equivalent
grouping as compared to job
3. Better from stainless steel so that rusting is not a problem
4. Same material as V1 block
5. Aluminum as it is easy to handle
14. The radiographic review form shall include all but:

1. Radiograph location
2. Evaluation & disposition
3. Geometric unsharpness
4. Date
15. The radiographic films shall be retained upto the time:

1. Service inspection is carried out
2. The vessel is in existence
3. Manufacturer’s report has been signed by the inspector
4. Customer inspection is complete
69
ANSWERSHEET
Questions Answers Questions Answers Questions Answers

1 1 6 5 11 3
2 2 7 2 12 1
3 4 8 1 13 2
4 1 9 1 14 3
5 2 10 2 15 3
70

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Preparatory Course for

Document No.: API 570/2001A Rev.4 Dated 01.01.2019

Insight Quality Services, Pune

1.0 Message to the participants

“It is good to have Education, it is better to have Experience,

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

Section Description Page No.

1. Message to the Participant 3

2. Preparation of Study Material 5

5. Publication Effectivity Sheet 17

7. General Information about Exam 22

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

The open book examination is having about 50 questions to be attempted in 3 hours.

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

As the preparatory course duration (6 days) is comparatively short we have made

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

The following information is available on API website www.api.org .The candidates

Preparation and Study Materials

i. API Standard 570, Inspection, Repair, Alteration, and Re-rating of In-Service

ASME publications may also be ordered through ASME’s publications department at

Note: API and ASME publications are copyrighted material. Photocopies of

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

Activity 01 -- Planning and Extent of Inspections - 570

01 . .responsibilities of involved parties (e.g., inspectors, repair organizations)

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

30 .. corrosion rate calculation

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

Activity 05 -- Welding – 570

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

1. You must be employed by or under contract to an authorized inspection

Education Minimum Skills

None 5 or more years Design, construction, repair,

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

The following information is for ASME SECTION DIV 1 .

THE INFORMATION WILL HELP THE STUDENTS TO GET AQUAINTED

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

1.6 Code Sections complimentary to ASME Section VII Div. 1 :

Note : Materials to ASTM specifications, unless adopted as a companion

2.0 Scope of the Code : ASME Section VII Div. 1 : 2001:

2.1 Definition of a pressure vessel as per Code:

i. those covered by other sections.

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

Following are included in the scope of this Code :

i. Pressure Relief devices (Refer to See ANSI/ASME-PTC 25.3)

Such as (a) Evaporators & Heat Exchangers.

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

Part A : Ferrous Materials

SECTION III : Rules for Construction of Nuclear Power Plant Components

SECTION IV : Heating Boilers

SECTION VI : Recommended Rules For Care and Operation of Heating

SECTION VII : Recommended Guidelines for care of Power Boilers

SECTION VIII Division 3 : Alternative Rules for construction of High

SECTION IX : Welding and Brazing Qualifications

SECTION X : Fiber - Reinforced Plastic Pressure Vessels

SECTION XI : Rules for In-service of Nuclear Power Plant Components

IQS/API 510/1001/A Rev.4 Dated 01.01.2019

1. Must be followed explicitly as soon as the latest edition is issued.

2. Clauses in the B 31 code are not necessarily numbered consecutively. Such