API 510 Section 5

1. All in-service pressure vessels in the petrochemical industry must:

a) have been hydrotested prior to service

b) be built to ASME Section VIII
c) be PWHT'ed if the thickness is over 1-1/2"
d) have an inspection plan

d)

2. All in-service pressure relief devices in the petrochemical industry must:

a) have an inspection plan

b) be built to ASME Section VIII
c) be set at a pressure not higher than 120% of MAWP
d) have a balanced bellows

a)

3. The inspection plan for a pressure vessel should be developed by:

a) AI
b) engineer
c) both AI and engineer
d) either AI or engineer

d)

4. The inspection plan for a pressure relief device should be developed by:

a) AI
b) engineer
c) either AI or engineer
d) both AI and engineer

c)

5. When developing a vessel's inspection plan, who should identify the specific damage
mechanisms and their locations?

a) inspector
b) corrosion specialist
c) engineer
d) either CS or engineer
e) either CS or inspector or engineer

b)
6. Who's input is required when developing an inspection plan for a vessel that
operates at an elevated temperature (above 750 F)?

a) AI
b) engineer
c) CS
d) head office specialist

c)

7. Which of the following is not required in a pressure vessel's Inspection Plan?

a) name of individual who will perform the inspection

b) surface cleaning requirements
c) type of NDE that will be used
d) next inspection date

a)

8. In the RBI process, what are the two primary factors used to determine risk?

a) consequence of failure and Service Class

b) reliability and the on-stream percentage
c) probability and consequence of failure
d) inspection effectiveness and corrosion mechanism

c)

9. Who is responsible to decide whether an RBI assessment will be used to determine

inspection intervals for a pressure vessel?

a) CS
b) AI
c) Owner/user
d) Engineer

c)

10. Which of the following is not a significant factor in an RBI assessment of a pressure
vessel?

a) vessel construction code

b) process fluid
c) potential degradation mechanisms
d) effectiveness of past inspections

a)
11. During an RBI assessment of a pressure vessel, which of the following is not a
significant factor that is considered to the analysis of the Consequence of Failure

a) Health
b) Public image
c) Environmental
d) Equipment downtime
e) Equipment damage

b)

12. All RBI assessments must be:

a) thoroughly documented
b) repeated every 5 years
c) approved only by the AI
d) conducted per guidelines in API 579

a)

13. An RBI assessment is used to determine the interval for the internal inspection. In
which of the following situations does the assessment not have to be repeated?

a) after each internal inspection

b) after any significant process change
c) after any change in inspection personnel
d) at least once every 10 years

c)

14. All NDE equipment used in petrochemical facilities must:

a) have a safety rating appropriate for the gaseous environment at the exam
site
b) be calibrated daily
c) be used by a technician that is qualified to ASNT SNT-TC-1A
d) have an ASME Section V approval seal

a)

15. Which of the following is not a requirement prior to performing an internal vessel
inspection?

a) review previous vessel history

b) obtain permission from appropriate operation personnel
c) check that all support equipment used during the inspection is safe to use
d) be certified as an ASNT SNT-TC-1A Level 2 in VT

d)
16. Who is responsible to perform the internal inspection on a pressure vessel?

a) AI
b) examiner
c) AI or examiner
d) AI or qualified others

a)

17. Prior to the internal inspection:

a) all removable internals must be removed

b) all process deposits must be removed
c) all removable internals and process deposits must be removed
d) some removable internals may not need to be removed, but all process
deposits must be removed
e) some removable internals and some process deposits may not need to be
removed

e)

18. Who is responsible to decide whether removable internals (e.g. trays) need to be
replaced?

a) AI
b) engineer
c) operating personnel
d) CS

c)

19. Who is responsible to determine whether process deposits should be removed prior
to the internal inspection?

a) engineer
b) operating personnel
c) CS
d) AI and CS
e) AI and engineer
f) engineer or CS

d)
20. Which of the following describes the needed surface preparation before
performing an internal inspection?

a) 100% of surface to be cleaned to NACE #1 (white)

b) 100% of surface to be cleaned to NACE #2 (near white)
c) 20-25% of surface to be cleaned to NACE #1 (white)
d) 20-25% of surface to be cleaned to NACE #2 (near white)
e) the amount cleaned and the degree of cleanliness is based on expected type
of degradation mechanism

e)

21. An internal inspection is being conducted on a refractory-lined vessel. How much

refractory should be removed to check the vessel's external surface condition?

a) a minimum of 10% of the refractory should be removed

b) a small area of refractory should be removed on each shell course, and each
head
c) at least one small area of refractory should be removed in the most suspect
area
d) removal of refractory is not required unless there is a reason to suspect that
corrosion is occurring under the refractory

d)

22. Who is responsible to perform the on-stream inspection of a pressure vessel?

a) AI
b) examiner
c) AI or examiner
d) AI or qualified others

c)

23. Who is responsible to perform the external inspection of a pressure vessel?

a) AI
b) examiner
c) AI or examiner
d) AI or qualified others

d)
24. Personnel performing the external inspection must:

a) be qualified by appropriate training

b) have a valid API 510 cert
c) have a valid ASNT cert
d) have either a valid API 510 cert or an appropriate ASNT cert

a)

25. During the external inspection extra attention should be given to:

a) anchor bolts
b) attachment welds
c) the nameplate
d) condition of attachment piping

b)

26. Weep-holes in repads should:

a) remain open on in-service vessels

b) be used to test the repad welds during each vessel outage
c) be threaded and plugged after fabrication is complete
d) be used to pump leak sealant compounds in the cavity between the shell and
the repad

a)

27. The inspector should consult with the CS when:

a) CUI is discovered during the external inspection

b) the grounding connection is found corroded
c) the short-term corrosion rate changes significantly
d) determining an external inspection interval

c)

28. Who must assure that personnel performing thickness readings are trained and
qualified?

a) AI
b) the Authorized Inspection Agency
c) some one with a Level III UT cert
d) owner/user

d)
29. CUI is an inspection concern for insulated carbon steel vessels that operate
between:

a) 0-100ºF
b) 10-350ºF
c) 25-250ºF
d) 50-125ºF
e) 140-400ºF

b)

30. CUI is an inspection concern for insulated austinitic stainless steel vessels that
operate between:

a) 0-100ºF
b) 10-350ºF
c) 25-250ºF
d) 50-125ºF
e) 140-400ºF

e)

31. CUI is an inspection concern for insulated vessels that operate at 500ºF and:

a) are in intermittent service

b) are made of stainless steel
c) are made of low chromes
d) have poorly maintained insulation

a)

32. Which of the following insulated vessels is most likely to experience CUI?

a) CS vessel with operating temperatures of 600ºF but is in an intermittent

service
b) CS vessel that operates continuously at 375ºF
c) CS vessel that operates continuously at -20ºF
d) CS vessel that operates at cyclic temperatures ranging between 350-600ºF
e) SS vessel that operates continuously at 100ºF

a)

33. CUI of austenitic stainless steel vessels:

a) occurs at temperatures between -10º and 125ºF

b) normally appears as stress corrosion cracking
c) is the result of using insulation that contains a sulfur compound
d) normally causes deep isolated pitting

b)
34. An external inspection is being conducted on an insulated vessel. How much
insulation should be removed to check the vessel's external surface condition?

a) a minimum of 10% of the insulation should be removed

b) a small area of insulation should be removed on each shell course, and each
head
c) at least one small area of insulation should be removed in the most suspect
area
d) insulation removal is not required unless there is a reason to suspect that
corrosion is occurring under the insulation

d)

35. When thickness readings are due, what is the minimum number of thickness
readings that should be taken during an internal inspection?

a) one on each head and shell course, and one on each nozzle
b) two on each head and three on each shell course
c) four on each head and each shell course, and at least one on 50% of the
nozzles
d) a representative number on heads, shell and nozzles

d)

36. A minimum number of CML's on a vessel are acceptable when:

a) corrosion rate is low and localized corrosion is not expected

b) design pressure is less than 100 psig
c) vessel is in an intermittent service
d) process fluid is either Class 2 or Class 3

a)

37. CML's should always be:

a) measured with a digital UT instrument

b) measured by some one certified to ASNT
c) permanently marked on a drawing and/or on the vessel
d) taken on each nozzle

c)

38. The number of CML's can be eliminated or reduced if:

a) the consequence of vessel failure is low

b) the probability of vessel failure is low
c) both are low
d) either or low

d)
39. Who should be consulted, if CML's on a vessel are eliminated?

a) CS
b) engineer
c) AI and engineer
d) AI and CS

a)

40. Who should be consulted, if CML's on a vessel are substantially reduced?

a) CS
b) engineer
c) AI and engineer
d) AI and CS

a)

41. Examiners performing UT flaw detection on welds on an in-service vessel should be

qualified to:

a) ASNT SNT-TC-1A
b) ASME B&PV Section V
c) API QUTE
d) AWS UT-II
e) GRS UT-FD (Global Rocket Scientist)

c)

42. Which of the following forms of degradation are most easily missed when
performing a visual examination?

a) uniform corrosion
b) localized thinned areas
c) random pitting
d) isolated pitting

a)

43. What is the preferred examination technique for determining the nozzle wall
thickness of a 60" I.D. vessel that has localized thinning?

a) spot UT
b) UT scan
c) UT angle beam
d) profile RT
e) spot UT or profile RT
f) UT scan or profile RT

b)
44. What is the preferred examination technique for determining the nozzle wall
thickness of a 6 NPS nozzle that has localized thinning?

a) spot UT
b) UT scan
c) UT angle beam
d) profile RT
e) spot UT or profile RT
f) UT scan or profile RT

f)

45. Thickness readings are taken using UT. At what temperature should special
procedures be used in order to ensure accurate readings?

a) above 150ºF
b) above 250ºF
c) above 400ºF
d) above 500ºF

a)

46. A pressure test is normally conducted after all:

a) repairs
b) alterations
c) rerates
d) repairs and alterations

b)

47. A pressure test shall be conducted after:

a) repairs if the inspector believes one is necessary

b) all alterations
c) all repairs
d) all repairs and alterations

a)
48. A nozzle has been added to a vessel. Instead of pressure testing the entire vessel,
just the nozzle will be pressure tested (temporary cap welded on the inside of the
vessel). The substitution of a component pressure test instead of testing the entire
vessel requires approval of:

a) just the inspector

b) just the engineer
c) either AI or engineer
d) both AI and engineer

b)

49. A major alteration has been completed on a vessel that was built to ASME Section
VIII 1990 edition. A hydrotest will be conducted. What is the recommended test
pressure?

a) 100% of MAWP
b) 130% of MAWP corrected for temperature
c) 150% of MAWP corrected for temperature
d) at a pressure specified by the owner/user

c)

50. (OB) A major alteration has been completed on a vessel that was built to ASME
Section VIII 2004 edition. A hydrotest will be conducted. What is the recommended
test pressure?

a) 100% of MAWP
b) 130% of MAWP corrected for temperature
c) 150% of MAWP corrected for temperature
d) at a pressure specified by the owner/user

b)

51. (OB) A hydrotest is conducted on an in-service exchanger shell to check for roll
leaks. What is the recommended test pressure?

a) 100% of MAWP
b) 130% of MAWP corrected for temperature
c) 150% of MAWP corrected for temperature
d) at a pressure specified by the owner/user

d)
52. A hydrotest is conducted on an in-service vessel after a major repair. The vessel
MAWP is 100 psig and the test pressure is 150 psig. The close visual examination should
be conducted at what pressure?

a) less than or equal to 100 psig

b) anywhere between 125 and 150 psig
c) at 150 psig
d) at a pressure specified by the owner/user

a)

53. A hydrotest is being conducted on a vessel. The relief device is not removed or
blinded. What other option can be used to keep the relief device from popping?

a) blind the outlet of the relief device

b) place test clamps on the relief device
c) adjust the relief device's valve spring
d) place a rupture disk under the relief device having burst pressure of 1.25
MAWP

b)

54. After an alteration, a hydrotest is being conducted on an austenitic SS vessel that

is 0.5" thick. The vessel was designed to ASME Section VIII 2002 edition. Which of the
following is not a specified requirement?

a) use low chloride water

b) test pressure is 130% of MAWP corrected for temperature
c) inspector validates the vessel is thoroughly drained and dry
d) minimum base metal temperature must be at least MDMT + 30ºF

d)

55. A hydrotest is conducted on an austenitic SS vessel. What is the maximum allowed

content of chloride in the hydrotest water?

a) 10ppm
b) 50ppm
c) 100ppm
d) 250ppm

b)
56. Brittle fractures usually have occured:

a) during startup
b) in vessels made with thinner materials
c) during the first hydrotest
d) in SS vessels

c)

57. Which of the following materials is most prone to temper embrittlement?

a) carbon steel
b) low chromes
c) stainless steel
d) high nickel alloys

b)

58. A hydrotest is performed on an existing vessel following the replacement of a shell

course. The vessel is 1-1/2" thick. What is the minimum allowed shell temperature
during the test?

a) 32ºF
b) 70ºF
c) 10ºF above the vessel's MDMT
d) 30ºF above the vessel's MDMT

c)

59. A hydrotest is performed on an existing vessel following the replacement of a shell

course. The vessel is 2-1/2" thick. What is the minimum allowed shell temperature
during the test?

a) 32ºF
b) 70ºF
c) 10ºF above the vessel's MDMT
d) 30ºF above the vessel's MDMT

d)

60. NDE is substituted for a pressure test on an in-service vessel. Who must approve
this substitution?

a) just the inspector

b) just the engineer
c) either AI or engineer
d) both AI and engineer

d)
61. Per API 510, during repairs and alterations, the inspector shall verify that the new
materials being used are correct. What is the minimum amount of verification that the
inspector shall perform?

a) 100% of all metallurgy's

b) 100% of all alloys
c) 100% of all high alloys
d) a sampling of all metallurgy's
e) a sampling of all alloys
f) a sampling of all high alloys

d)

62. What document provides additional guidance about material verification?

a) API 571
b) API 578
c) API 580
d) API 2201

b)

63. An existing vessel component fails. Analysis of the failure determines that an
incorrect material was inadvertently substituted during fabrication. Who should
determine whether other components should be checked for correct metallurgy?

a) inspector
b) engineer
c) either AI or engineer
d) both AI and engineer

a)

64. During an in-service inspection, a crack-like flaw was discovered in a weld. This
imperfection must be:

a) evaluated to the acceptance standards of the original construction code

b) evaluated to the acceptance standards of the current edition of ASME VIII
c) evaluated by inspector or engineer
d) evaluated by engineer or corrosion specialist

d)
65. During an in-service inspection, preferential corrosion was discovered in a weld.
This imperfection must be:

a) evaluated to the acceptance standards of the original construction code

b) evaluated to the acceptance standards of the current edition of ASME VIII
c) evaluated by inspector
d) evaluated by engineer or corrosion specialist

c)

66. Flange leaks in certain fluids can cause:

a) galling of bolts and nuts

b) bolt lengths to shorten
c) bolts to crack and corrode
d) bolting stresses to decrease

c)

67. Flange bolts are unacceptable if the bolt threads do not extend:

a) beyond the face of the nut by 1 thread

b) inside the nut within 1/2 thread of the nut face
c) inside the nut within 1 thread of the nut face
d) inside the nut within 2 threads of the nut face

c)

68. Additional guidance on the evaluation of flanged joints can be found in:

a) ASME PCC-1
b) ASME Section II
c) ASME Setion VIII, Div.2
d) API 580

a)