ag Suojssie enmiGns eowouoo3 ubjsap aids 7oaT ABUT OUI SHEL SHUE TES J9n09 PewUsIeNA sue, Aovotiow3 SoURITSHUTE SET SON pabewep seunsse,di@A0 YS|H) qu23@|0) aK aunssosd 381Ng 0},.68099 sieiedo ueD suopeyeisul mou 20) 3SN LON OG sip 1n9 22p104 SIP UI SepeIa BUY, swigoid eames pinbrs peBewep j! ainssaidieno soyeeu8 ye yung Aeyy quesat0) aah aunssaid sing 40.%06~ 0} dn ajesedo UES S\Nae J0pUN soomues pani 0 soden, seunsseud ysang pay] queIsis@) Uo}s0I09 ATYBIH, S,AMd J80UN LON SBOIAIBS UO}SOLIOD, yydesé peuyoeny = ysig eumidn ; amssaud Hos jo %08~ 1e aje10d0 KUO paBewep fuses auesquIsNy Sea001d seoues jo eBues pin SunuowBey-u0N, S\Add J2pun ‘SEOIMIES pinby 30 10dan, ‘se8001d uy sjees euesquieN aunjey {a1/SU9} Os}U09 YSIP UI SIOIS aysodwog 81g eumidnay ainsseid ‘SAbid RUN ION ‘SeO;IES 10 s0den une UoIsueL,API 510 A.L/Engineers Responsibilities Exercise Read the API 510 Code and determine the responsible person(s) Aetivity AY] Bue [ALAND Eng.or Cor. Specialist? ‘Assure owner that testing, nspeation, and examination activities meet 510 Code Evaluate and accept NDE examination resulls Review inspection plan for elevated temperature equipment inspection ‘Approval of thickness measurement procedure fo determine actual thickness is greater than that on the data report for use when determining MAWP. Review and approve RBI approach that extend inspection beyond 10 years Determine if on-stream extemal inspections may be substituted for internal inspections Determine most appropriate corrosion rate long term or short term Determine fa pressure test is required ‘Approve all methods of design, materials, WPSs, NDE and testing ‘Authorize ait vessel Te) Authorize all repairs to Division, 2 vessels ‘Authorize al alterations ‘Approve all repair and alteration work al completion of work Designate hold points for fabrication inspection and approval ‘Authorize the repair welding of cracks ‘Authorize the repair welding of cracks athigh stress points Review the use of Preheat in lieu of PWHT. Review the use of controlled deposition welding In lau of PWHT Review the use of fo PWHT | PWHT in place of ful encirclement Review the repair procedure for Stainless Steel cladding Monitor the repairs made to cladding ‘Approve the use of filet-welded paich repairs Allow temporary welded repairs to remain in place (until next fepair opportunity) ‘Approve use of lap band repair ‘Approve substituting NDE for a pressure lest after repairs ‘Approve alternative NDE to ASME requirements after repairs or alterations Perform calculations for re-rating ( unless performed by manufacturer) Oversee the aitachment of a nameplate aller re-ralingSaaS oT ULF J0jeanssosdiono 400, ‘uo sainssaud 08 way eiqeyene saz eoyo eae] reaqwoucos + sypien ‘fa pepwerd cain) Gunees + s0owes ejdonsns y Supoy6s06nxenue%o « ‘ugyedwco esmeseduoy ‘BIEOUALD 3 Sp00B YOS + ‘sounssaid 28 ed og eroge aIgeIEASION TROBE pus amnssardiero (ews + feunssexd ypeq 0} eNSLES ION) + Arges amnssard ys wry qwowobuerewtendeg + seowns ajgydeoens ‘uy Buynoysibind equ} + Aejqednoo exryeseduoy 13 JeoRWeLp yu SpO08 YOS « ‘WROD, ue onssaidiona Joes enesaxd ‘emsseudypeq 0} engsue5 ON + Y2s.0)50509 ayed0 ueD + Tsuetceie apavoRENSS > ‘anssaud ‘auep sjoquco amen + ‘aie 6upsoe seppaid eunssaid soi) + paBewep sq ube sueeg + ‘onsuadro ciow Ayei0u9g + Sema ey woy papojadseuoyy) + + | seovues prio 0dens0j poo « ‘Augneded aumerediey » OWA SPAN = sopues ston :0;poodeN =» s80pv28 Pb POOH TON + ‘sons sedan 105009 + funssaxtyoeq oj annysues = 248 40de8 0) po00 oN + rowoueeg + peje ye oinssaidano gz + ‘eumssaidiano oyevoqvodasd yi 9s + Sobesiehpy ‘SOunyeOS OMIT rere TaBtl ieee] Utste) pereye |IRC ‘ASME IX AND V TEST copYRIGHT 2900. IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED 00 NOT cOFY OR DISTRIB! QW-482 (Back) ws Rev Mo [POSITIONS (QW-405) [POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove: __ALL temperatuie Range Hetng Progression: Up__X down x | Time Range. aa Positions(s) of Filet Scorer erereereceeeeear PREHEAT (QW-406) GAS ((QW-408) Preheat Temp Min: __ 100° MINIM Percent Composition | interpass Temp Max ___650° MAXIMUM Gasies) (Mature Flow Rate Preheat Maint Shielding: _YES 00% AR___10-15 CEH ‘Trang: NONE. ERR Nig POR INT ‘Backing: YES TSARI25CO2 __2.CFH ELECTRIGAL CHARACTERISTICS (QW-408) Current AG or DC _DC Polarity_REVERSE ‘Amps Range _ 100-120 Volts (Range) _24-27 ange ardels ange SOU be read foreach tered se Penge shea eT rforaton say belie 3 ‘Sr trm sma at hown betow ) Tungsten Electrode Size and Type ‘Pare Targaan Be Thad Ge SPRAY OR SHORT ARC. Boray are. show creung are cre) Mode of metal Transfer for GMAW Electrode Wire feed speed range ‘TECHNIQUE (QW-410) String or Weave Bead STRING Orifice or Gas Cup Size 412" peer esnd interness Cleaning (Brushing, Ganding, ete) BRUSHING AND GRINDING Mathod of Back Gouging ‘AIR AR Oscillation REVERSE Contact Tube to Work Distance ia ‘Multiple or Single Pass (per side |_____MULTIPLE. Multiple or Single Electrodes SINGLE {SIEM - 30 1PM. NONE Travel Speed (Range) Peening Other ae i | ie 7 Type | wera Da Polar ame | j_tevera | Process Case ange lL aL Gina | ERSOS BF) TAB -ST_ | CRP ea) Tea FM L SPRAY i c i t 7 £ t i T i r L i C i cOPYRIOGHT 2i- IRG?SCHINDLER & ASSOCIATES - ALL FIGH HTS RESERVED -00 NOT COPY OR DIgpuucacacooansacomsosanageasonoeeann ASME IX AND V TEST IRC COPYRIGHT 2000-IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘API 510 COURSE ASME V AND IX TEST ANSWER SHEET COPYRIOGHT 1 RC7SCHINDLER & ASSOCIATES -ALL RIGHTS RESERVED -00 NOT COPY OR OISTRIBUTScage aR ASME IX AND V TEST IRC COPYRIGHT 2000: IRCISCHINOLER 2 ASSOCIATES _ALL RIGHTS RESERVED. 00 YOT COPY OR DISTRIBUTE ‘QW-483 (Back) PQR No: GMAW-SP-1 Tensile Test (QW-150) eee Type of 1 Specimen | Total Loaa Faiuro & No. Width | Thickness | Area) bb. ra HA [soa DIA) tg7__| 4.200 DF-HAZ acer NA “500 DIA. “186 | 12.000 DE-HAZ : t i = C L I i i Guided Bend Tests (AW-160) ype and Figure No. Result FACE Wis" GRACK OK ROOT ‘CORNER CRACK OK FACE NO INDICATION OK ROOT 1ia° CRACK OK Toughness Tests (QW-170) innpact Values specimen | Notch | Specimen | Test scien | Not | reise. | Temp. | Fetbs. | %Shear | mils | Drop Weight Break (VN) | i | T 1 1 t Comments: Fillet Weld Test (QW-180) Satisfactory: Yes: No: Penetration into Parent Metal: Yes: No: Result Macro ~- Results’ z Other Tests Type of Test: Deposit Analysis: Other: Welders Name: _JOE BLOW JR. Glock No. ‘Stamp No.: Tests conducted by: _ XYZ COMPANY. Laboratory Test No: _1234 We cortty thatthe statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer: _ XYZ COMPANY. Date: By: _JOE BLOW SR. COPTRIGGRT UT IRGTSGHINDLER & ASSOCIATES -ALL RIGHTS RESERVED -DO NOT COPY OF DISTRIBUTEoe ASME IX AND V TEST IRC COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT GOPY OR OISTRIBUTE ‘QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boiler & Pressure Vessel Code) Company Name: __ XYZ COMPANY. By:__ JOE BLOW SR Welding Procedure Spec. No.: _GMAW-SP-1 Date: Revision No: _0 Date; _2-2-92 Welding Process(s):_GMAW-SPRAY ARC _ Typet JOINTS (QW-402) : eras Joint Design:_SEE PRODUCTION DRAWINGS. Backing: (Yes) _X wo) _X. Backing Mateflal: (Typey WELD METAS, if USED ‘Refer fo both backing & retainers) XMotal | Nonfusing Metal ) should be 16" c @ should be 1/16" - 500° should be 3/16" = 2° 29 The preheat temperature shawn on the WPS. is acceptable should be increased to 20°F should be decreased to 50°F ‘should be increased to 180°F COPYRIOGHT 2)-1RC7SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRISUTE31 32 33 36 ASME IX AND V TEST COPYRIGHT 2000- IRC/SCHINOLE! ‘Tha tension iests shown on the PC! 22 acceptable 2= shown ‘are dimensionally unacceptable to the Code ‘The bend tests shown on the POR: are acceptable 2s shown should be all side bends are unacceptable because the root bend has a corner crack none of the above goce ‘The ultimate stress shown on the POR: a. is unacceptable for T-2 1B, is unacceptable for T-1 @ is too high for both specimens @ should be at least 75,000 PSI for both specimens ‘The joint design specified on the WPS is: acceptable as shown, ifthe drawings show the required details should show only a single vee groove weld should not address backing should be drawn on the WPS as a sketch nord ‘The POR is unacceptable because: the position of welding does not match the product welded the gas backing mixture does not match the WPS: the joint design is not shown as a sketch on the POR: the travel speed is too fast ‘The A# shown on the WPS and POR: is acceptable as shown ig unacceptable because ait should have been used a 5) is unacceptable because it does net correlate to chrome filer metal d ts unacceptable because A-t filler metal requires PWHT per ASME IX COPYRISGHT U- RC?SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBU IRC RASSOCIATES -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE.ASME IX AND V TEST IRC IRCISCHINDLER & ASSOCIATES -ALL RIGHTS RESERVED .DO NOT COPY OR DISTRIBUTE “GW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PGR) (See QW-200.2, Section IX, ASME Boiler and Pressure vessel Code) Record Actual Conditions Used to Weld Test Coupon Company Name: _XYZ COMPANY Procedure Qualification Record No.: _ GMAW-SP-1 Date: 2-29-82 |AW-SP-1 (GMAW (SPRAY ARC) ‘ute ‘SEMEAUTO. JOINTS [aw-402) Groove Deigna! Test Cosson ( oreoronation qusfcasons the daosiag wos meal edness sa be cored ft ach er mete proves use} [BASE METALS (GW-403) POSTWELD HEAT TREATMENT (QW-407) | Material Spec.:__SA 387 CL.4 ‘Temperatu: Type or Grade: GR 22 Time: NONE, P-No. 5A ‘to P-No: 5A Other ‘Thickness of Test Coupon:, 500 Diameter of Test Coupon: __N/A aoe Other: COMPOSITION - 27/4% CHROME, 1% MOLY PASS THICKNESS 1/5” GAS [QW-A08) Percent Composition FILLER METALS (QW-404) Gas(es) (Mixture) Flow Rate SFA Specification: _5.8 | AWS Classification: ER 90SB2 Shielding: _YES 400% ARGON 20-30 Cf Filler Metal F No:: 6 Trailing: _ NONE Weld metal Analysis No 1 Backing: YES 00% ARGON 10-48 CPHL Size of Filler metal: _1/8 ELECTRICAL CHARACTERISTICS (QW-408) j Other: 2 114% CHROME Current:___DC | FILLER METAL Polarity: REVERSE Weld Metal Thickness: _.500 Amps.:___128 Vents: 24 Tungsten Electrode Size: NIA FOsTION(aw4s)SS—~—~SN othe: eee te Position of Groove: 6G Weld Progression (Uphill, Downhill): UPHILL TECHNIQUE (W470) Other: |_| Travel Speed: _12 1PM String or Weave Bead: STRING. Oscillation REVERSE, ae Preheat Temp. 250° Multipass or Single Pass (per side):__MULTIPASS Interpass temp.; 650° MAX Single or Multiple Electrodes:__ SINGLE - Other: SOLID WIRE ONLY, NO SUPPLEMENTAL — | Other: POWDER, FILLER, OR FLUX USED PREHEAT (QW-406) COPYRIGHT TI IROTECHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTEead APIS%0 FINAL EXAMINATION 1 - OPEN-BOOK ec COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES = ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE apisio FINAL EXAMINATION #1 OPEN BOOK DATE, NAME. Suet eee Questions 4-10 analy to WPS 11 ang Susoorting POR #15, attached on back. Ht The P #'s shown on the WPS are: F A. qualified by the POR B should be changed to P3 to P3 only should not show P #4 D- should show P1 to Pt only 2. The AWS Classification shawn on the WPS: a, A. should be changed to & 71T1-4 B is acceptable as shown Cig a 90,000 tensile electrode 1. is acceptable ff the "T” was changed to “S" 3 The base metal thickness range shown on the WPS: A, Is correct as shown B. should be 1/16" = 1/2" CC should be 3/16" = 1/2" ©. should be 3/16" 1" 4 The pestweld heat treatment condition shown on the PAR: ‘A. is not acceptable to the Code Bis acceptable to the Code © should be changad to show PWHT was done 1D should show the required pre-heat 5 ‘The ges mixture shown on the WPS is unaccepteble because! ao A. the CO2 was not property qualified 5 the Argon was not properly qualified C. the flow cate is beyond the range allowed 0 bon S&C above 4 6 The tensile test results shown on the POR are: -eptable as shown 8 ‘otable - the tensile strength on 7-1 is too low © unacceptable - the load on T-2 is too low D. unacceptable - the area calculations are incorract on ‘The bend test results shown on the PQR are: acceptable as shown Unacceptable - side bend #1 has unacceptable porosity unacceptatle - not snough specimens were tested both B & C above vam» |S ASSOCIATES - ALL FIGHTS RESERVED -0O NOT COPY OR OISTRIGUTE COPYRIGHT 20¢0 = 1RCISCHINO10 2 COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIAT APIS10 FINAL EXAMINATION 1 - OPEN BOOK IRC “ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE The POR should be A, notarized B legalized © rormaiized D certified The pass restriction of QW 403.9 is: acceptably addressed on the WPS only acceptably addressed on the POR only acceptably addressed on both the WPS and PAR unacceptably addressed on both the WPS and the POR o0n> ‘The A# range shown on the WPS is: unacceptable - should show A-t only ‘unacceptable - should show A-2 only ‘unacceptable - should show A-3 acceptable as shown comp A pressure vessel has been designed using SA516 - 60 material (32,000 yield). Totallength of ‘support is 8 feet. The stamped MAWP (external )is 180 psig @ S00°F. Theod is 48°. Can this vessel be safely operated If the thickness has correded down to 250"? A yes. this vessal is safe down to 250" 5 no. this vessel is not safe for 150 psig CC. not enough infarmation provided to solve the problem Dyes. this vessel could actually be operated at 250 psig ‘An existing vessel is inspected on a given year end found to be 500” thick in the shell and heads. The next inspection is performed 3 years later, anc the thickness of the shell and heads is shown to 2 310° (uniform) The vessel minimum thickness is calculated to be 200°. From this information. the Remaining Life (RL) and internal inspection Interval (1) on this vessel is approximately 13 A. Syears RL. 10 years LI B 7 years RL. 15 years | © 173 years RL 173 years I DB tO years RL. 10 years L MOMT of -38°F. (not ‘niuch wail require 'cact testing? ‘An ammonia processing vessel is stamped for an MAWP cf 50 asig with ‘examoted per UG-201) Various materials have cracked and/or coi welded recairs Which of the following materials, if any. will require © A. SA 537 Class 1, 3/4” thick BSA 387 Grade 21 normalized and tempered, 4/8" thick © SA 516-70 normalizec thick’ none of ne above will require impact tests A full size (or standard) Charpy impact specimen is: A ue xe B 10mmx 10mm © temx 10cm D 3eex tem ERVED 00 NOT 79 OR OISTAIBUT: NGHTS Fi COPYRIGHT 2000 IRCISCHINDLER & ASSOCIATES - A17 18 20 API 510 FINAL EXAMINATION 1 - OPEN 300K IRC COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIGUTE. ‘Avvassel shell is 66° .O and is made from material with a stress value of 13.200 psi. The vessel has Category A Type 1 buttwelds and is stamped “RT-2". Ifthe thickness has corroded down to 285° thick, what MAWP can oe allowed on this vesset? A. 400 esi B. 190 psig © 250 psig D139 psig ‘Awire 10! with a diameter of 020° would be found in an ASTM SET A a c D cour ‘A fat unstayed circular head with a diameter of 14” is operating at 360 PSI @ S00*F. The stress value Is 17,500 PSI with an efficiency of 1.0 and aC Factor of 33. Can this head be operated with @ corroded thickness of 1.25"? A. yes, can continue to operate B. na, cannot be operated . °C" Factor is incorrect for design D. circular heads cannot be use at 1 25° ‘Avvessel has @ nozzle installed as shown In Figure UW-16 Sketch (using two equal size fille welds The shell thickness is 3/4” and the nozzle wall thickness is 7/16". Using equalleg fillet welds, wnat eg dimension is required on these welds, rounded up to the next 116°? A gne B 76" coune 0 3a" In visual examination. the procedure is qualified by using @ test methed thet allows resolution of a fine fine that is __" or less in wath. A132 Be C18 Dove Gna 1" thick piece that will be MT tested by procs. the soacing Setwsan the prods wil ‘ct amp range fer this spacing would be: 4900 - 2000 ames 150 - 300 amps 106 -125 ames 500 - 825 amps A © D An ASME vessel is to be repai stamped °RT-3". and the total length of the buttw Complete the work on both patches How many radiographs will be 10 API S10? nas to the shell The vessel is ‘One waider wil be used to Wired. f the work is core sw Aus is willbe by adding wo cour OPY OR OISTRISY COPYRIGHT 2000 ~IRCISCHINDLER 8 ASSOCIATES ~ALL RIGHTS RESERVED 00 W'23 24. 25 28 2 28 wz 2 ‘API510 FINAL EXAMINATION 4 - OPEN BOOK IRC COPYa:GH? 2000 IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY C2 DISTRIBUTE ‘An exampie of 2 ‘siandard pressure par on a pressure vessel would be: A. apiece of 1 nick piss &. a welded elliptical head. C. a pipe fitting (Forged) 3 22 length of SA-106 B pipe 9 A radiograph is produced to “full RT requirements Thrae elongated slag inclusions are seen the radiograoh that are measured individually at 1/2" long, 3/4" ong. and 3/8" erg. Tne weic 1s 3 1/2" thick The interpretation of this radiograoh i See eee : B. unacceptaole C. slag inclusions are not a factor in RT D. none 6f the above ‘A standard seamless torispharical head has a skirt od, of 56" and a correded micxress of 1.27" The material stress value is 16,100 psi, and the head is atached to the bottom cia vertical ves: that {5 20' tall ful of water. Ifthe vessel is stamped "RT-2", what approximate MAV/P would be allowed on this vessel? Sea A. 600 psig 8 402 psige-~ C704 psig D302 psig Aweld repair is made on P-4 material, 3 1/2" o.d. pipe, 3/8” thick, carbon con minimum preheat of 200°F is maintained. Is PWHT mandatory on this repair? A no Byes ©. depends upon servic: D depends upon joint efficiency 10%. anda A2" thick carbon steel pressure vessel is to be postweld heat treated, The re: (ebove 300°F up to 1100*F) on this vessel shall nat exce: A. 400°F ne B g00*Fmr 200°Fihr ‘A vessel is ultrasonically inspected when itis new and cold in June 1987 anc thick in the shell. The next inspection is done in June 1995 and the vessel is teu": 50° thick. If the minimum thickness by calculation is $10", when (approxime: I or on-streem inspection be scheduled, per API 5107 wary 1989°~ 8 November 2010 ©. June 2005 © October 2002 An example of a “double wall exposure, double wall view" would b: A, ellicical exposure (ellips®) 5 suermposed exposure C_ single wall exposure (sour D both A&B above in middle of cylinder) CosvaiGHt 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OF 2ISTRI23 30 1 32 33 API510 FINAL EXAMINATION 1 - OPEN BOOK IR COPYRIGHT 2000 ~IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE A welding cperator is qualified by making a radicgraph of her first production wele an 2 spot (R7- 3) vessel that is 1/2" thick. The weld shows several rounded incications that are 1/4” diameter tnat are interpreted as gross porosity. This welder would be: A. accepted to weld in production 5. accepted 10 wela in progucuon, put on: © not accepted to weld in production —~ ©. automatically requalified by welding two more test coupons 1 a 26 posicn ‘Acozzle is 1" thick and is attached to a pressure vessel 1 1/2" thick using a joint configuration waters Sig Wane # Geateh tak Tea af theags ar he sor curation (tc) wou" be ar 8 saute & sa Bt Reinforcing plates and saddles attached to the outside of a vessel with filet welds shall be provided with at least one tell-tale hole with a maximum tap size of NPS Auge 812 C13 Dt ‘A hydrostatic test is conducted on a vessel that is 60' tall, A pressure gauge is located 35° up from the bottom of the vessel. If the stress ratio Is 1.0 and the MAWP of the vessel is 100 Fsi, what zoproximate‘fressure should the gauge read to mest ASME Vil requirements? A. 141 psigh B 143 psig ©. 130: D188 psig ‘Awelder hes been qualified in the 6G position on 3/4” thick material, How many bend tests wit bee required? A, 4 side bends-~ & 2 side bends © 2 root bends no bend tests - tension tesis only All of the following statements conceming a “UM’ vessel are true xceat A. “UM" vessels are exempt from inspection by API 310 © “UM" vessels Mig. Data Raports are not signed by an Al ~ © "UM" vessels are exempt ay ASME Vill from the scope of the Code 1D “UM vessei manufacturer's must maintain an inspection agreement wits an AIA Atensicn tast specimen is made from welded plate, SA-299. The diameter of the turned: simen ig 300° and the load is 15 KSI. Does this specimen mast ASME IX requirements? A no B yes © tension specimens are nat required by ASME 1X D. the diamater of tne specimen does not mest Cace & ASSOCIATES - ALL RIGHTS RESERVEO -00 NOT COPY OR OISTRIGUTE COPYRIGHT 2000 ~ IRCISCHINOLFAPI 510 FINAL EXAMINATION 1 - OPEN BOOK IRC COPYRIGHT 2000 -IRCISCHINDLER & ASSOCIATES ~ ALL RIGHTS RESERVED -00 NOT COPY OR OISTRIGUTE, ‘QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boller & Pressure Vessel Code) Company Name: XYZ COMPANY, By JOE BLOW Welding Procedure Spec. No _11 Date: .57-82Supporting PR No. (s):_46 Revision No.:_0 Date: FCAW-SPRAY ARC TRANSFERType(s): _SEMI-AUTOMATIC Welding Procass(s) -SEMI-AUTOMATIC _ (Automatic, Manual, Machine, or Semi-Auto JOINTS (QW-402) = Details Joint Design:__ DOUBLE VEE GROOVE, ONLY Backing: (Yes) x. (No} Backing Material: (Type): WELD METAL ONLY (Refer to both backing & retainers) xXMetal + Nonfusing Metal + Nonmetalic + Other ‘Sketches, Production Drawings, Weld Symbols or Written Description ROOT OPENING - 1/16" - 1/8" ‘Should show tne general arrangement of the parts to be'welded. Where GROOVE ANGLE - 60° - 70° 2pplcable. the root spacing and the details of weld greove may be ecified Gettne option ofthe Migr, Sketches may be attached to Mustrate ont Gesign. weld layers. and the bead sequence, e.g. for notch toughness procedures. for multiole process orocedures, etc.) TBASE METALS (QW-403) Z P-No.___3 Group No. 1 to P-No. Pd. 3.1 Group No. 1 oR Specification type and grade to Specification type and grade oR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness range: Base Metal: Groove: _1/16" Pipe Dia. Range: Groove: ALL Other:_NO PASS GREATER THAN 1/2" THICK Fillet: ALL ALL TFILLER METALS (QW-404) Spec. No. (SFA): SFA 5.29 ee AWS No. (Class): __E81T4 (1.2.3.4) TS Filler Metal F-Nos 6 ne Chem. Comp. -A No TOR2 ee Size of Filler Metais: ALL a Weld Metal Thickness range Groov: Te MAX —————— Fillet ALL oO Electrode-Flux (Class): Flux Trade Name: Consumable Insart: oe Other, _NOSUPP. FILLERS OR PeReeeeeere eee eeeeee POWDERS TO BE USED = Zach base metabfiler metal combination should be recorded individually {VEB 00 NOT COPY OF DISTRIBU COPYRIGHT 7000 = IRCISCHINOLER § ASSOGIATES “ALL RIGHTS1 Scalia etme ir tn Aa ET EN BOOK IRC =DO NOT coPY OR DISTRIBUTE API 510 FINAL EXAMINATION 1 COPYRIGHT 2000 - IRC'SCHINOLER & ASSOCIATES ~ALL RIGHTS ‘Qw-482 (Back) WPS No: Rev Nos [ POSTTIONS (aw-405) | POSTWELD HEAT TREATMENT (W607) 1 Position(s) of Groo ALL Temperswure range 1130 = 1200¢ Welding Progression: Up __X Down | Time Range 1 HR PER INCH, 15 MINT MINIMUM Positions(s) of Fillet__ALL | | GAS (ance) Parcent Composition 1p Min.:200° MINIMUM Interpass Temp Max:__650° MAXIMUM Gas(es) (Mixture) Flow Rate Preheat Maint: NONE. Shielding ARGONICO2 _75%-25% __ _10-20 CEH ina Traling? ; Backing: _O2 700% 5.10 CF Ta We MGs Ee TE ET ELECTRICAL CHARACTERISTICS (QW-408) 7 =, ‘Currant AC or DC —_DC. Polarity_REVERSE ee ‘Amps Range __ 100-150" Volts (Range) _18-25, {Amps and vls Tage should Be recorded for eat elecade SB. positon, and ikness, ete. This information may be std in {ular form sia to rat show below.) ‘Tungsten Electrode Size and Type, ‘Pars Tongaien, Be Thersied. we] Mode of metal Transfer for GMAW SPRAY ARC TRANSFER ONLY ‘(Soray ae anor rearing we ee) oo Electrode Wire feed spaed range FECHNIQUE (QW-410) String or Weave Bead _BOTH. Orifice or Gas Cup Size iz _ Initial and Intergass Cleaning (Brushing ie. ) BRUSH AND GRIND BY USING MANUAL METHODS af Method of Back Gouging ___ CARBON ARC Oscillation _NONE _ Contact Tubs to Work Distance 1/4" = 1/2" Multiple or Single Pass (per side)_MULTIPASS a or Multiple of Single Siectrodes: SINGLE. a es Peerage Reece Teen cee Sree eae ALLOWED otner | RE ar ae 7 1 i veg. seman reve, | Sonmane met f wate Spee d years) | Prats | cess Renae q ALL ALE DCREV_ 100-150 a 1 | amo Pare r T L 1 i T EB 190 NOT COPY OR DISTRIBU GASSOCIATES - ALL RIGHTS RESERVE! COPYRIGHT 2000 ~IRCISCHIND.API 510 FINAL EXAMINATION 1 - OPEN 800K IRC COPYAIGHT 2000 = IRC/SCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED .50 NOT COPY OR DISTRIBUTE ‘OW-183 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (POR) (See QW-200.2, Section IX, ASME Boiler and Pressure vessel Code) Record Actual Conditions Used to Weld Test Cougon Company Name:___XYZ COMPANY n Record No.: 44 Date: 8-31-82 Welding Process(s): FCAW (TUBULAR) — Types (Manual, Automatic, Semi-Auto. ): __ SEMILAUTOMATIC SPRAY TRANSFER, JOINTS (Gw-202) Groove Design of Test Coupan (For combination quaifcations, the deposed wold metal thickness shall be recordad foreach Mer metal of process used.) BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407) Material Spec: __SA 302. ‘Temperature: _NONE USED Type or Grade: __ GRADE 5. Time: 2.No: __3 to PN 3 Other: Thickness of test Coupon:__/2 THICK E Diameter of Test Coupon: ___N/A= PLATE Other. NO PASS GREATER THAN 1/8" THICK GAS (QW-408) FILLER METALS (GW-404) Percent Composition SFA Specification: _SEA- 6.29 Gas(es) (Mixture) Flow Rate AWS Classification: _E7iT1-4 Shielding: _CO2 100% 42.18 CEH Filler Metal F No. € Trailing: __NONE. Weld metal Analysis No. A2(80,000 TENSILE). Backing: NONE Size of Filler metal: _1/8"___ ELECTRICAL CHARACTERISTICS (QW~403) Other: NO SUPPLEMENTAL FILLERS OR Current: _ DIRECT POWDERS USED. Polarity: REVERSE rece Weld Metal Thickness: __ 1/2" THICK Amps.:____130 Volts: 28 Tungsten Electrode Sizer __ Other: : POSITION (QW -405) Position of Groove:__ FLAT Weld Progression (Uphill, Downhill: NIA TECHNIQUE (aW-10) Other: Travel Speed: __15 12M String or Weave Sead: _ WEAVE Oseillation: NONE Multipass or Single Pass (per side):_MULTIPASS Interpass temp! Single or Mu Other: Other: PREHEAT (W205) Preheat Temp.:___400°F le Electrodes:_SINGLE ___ ‘caPYRIGHT 20¢0 ~IRG:SCHINO! RIGHTS RESERV: ‘API 510 FINAL EXAMINATION 1 - OPEN BOOK IRC (COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 09 NOT COPY OR DISTRIBUTE QW-483 (Back) PQR No: __14 Tensile Test (QW-150) | | [ _Uitinaie’ | Gisate | Type of Specimen Total toad | unit stress | Falture & No. | Width _| Thickness |__Area_ | tb. |__Lecation we | ae se [OG | SRBASE | | METAL [eae | besASe METAL i 1 1 T i 1 I I i [os I i Guided Bend Tests (QW-180) 7 Type and Figure No. Result = | [SEBEND HT ow-622 POROSITY - Ge" DIA) - ACCEPTABLE | [SIDE BEND #2 - QW. 462.2 ‘CORNER POROSITY - 1/8” DIAM. - ACCEPTABLE Toughness Tests (QW-170) Impact Values = Specimen | Notch | Specimen | Test No. | Location ize _|Temp.| Ft.Lbs. | %Shear| mits | drop Weight Break (YIN) = { Comments: Fillet Weld Test (QW-120) Result — Satisfactory: Yes: No: Penetration into Parant Metal: Yes:_No:_~_ Macro — Results: Other Tests Type of Test: Deposit Analysis: Other: Welders Name: JOE BLOW JR. GlockNo: A Stamp No __4 Tests conducted by: __ BILLS TEST LAB. Laboratory Test No.:_123. We cartify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Cade Manufacturer: ___XYZ COMPANY. 8/31/92 a By! _JOE BLOW SR. COPYRIGHT 2000 ~ IRCISCHINOLER 2 ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OR CISTRIBUTEASME IX AND V TEST IRC SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE AP! 510/570 COURSE ASME SECTION IX AND V TEST (ALL OPEN BOOK) NAME DATE, 1. AWS s primary purpose is to: a qualify the POR qualify the WP sc, provide direction to the welder during production welding document all non-essential variables 2. APQR's primary purpose is to: sa,’ qualify the WPS qualify the WPQ cc. _ provide direction to the welder when making the test welds d— botha&c, above 3 AWPQ's primary purpose is to: a. _ chow ine ranges quid by 2 wolderopeator b show the actual variables used to qualify a welder/operator A Reet per eet & a all of the above 4 ‘The nan-desvucve examination tht wil be covered bythe AP 510/570 sxrinaton a # > F elton $e 5 What ypes of ane maybe detected by PT? ay sutece only B Mea ony c surface cracks. only Fee erty abeutace é—sanduest acceptance cite is specifedin Paragraph __ of ASME Seton ik 2 awass 2 Santee 2 Bates § Gkagh 7 Wanting the SMAW process a decrease of more han YOO" in the peseat temperature qualified is an variable Essential Non-Essential Supplementary Essential Not a variable COPYRIGHT 2/- IRCZSCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE10 " 12 13 14, 15 ASME IX AND V TEST IRe COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE SFA 5.28 's considered to be an Fi, per ASME IX. A penetrameter is used for? Judging RT flim density by Judging RT fim sensitivity ¢ Judging RT film exposure qd Judging UT acceptability ( ‘What is the minimum frequency range of ultrasonic instruments to be used for ASME Code examination? a 25 MHz b 18 Khz cc 8-10 MHz d. none of the above What is the difference between X and Gamma Rays? Xi a longer ray than Gamma ‘Gamma is a harder ray than X ‘Tne origination of the ray (source vs machine) Xis only used in alloy analysis MT using AG yokes is: acceptable to find all discontinuities acceptable to find surface discontinuities, only acceptable to find sub-surface discontinuities acceptable to find cracks, only What device or devices may be used to measure RT film density? 2 Calibrated density strip b Calibrated densitometer c Calibrated penetrameter @— Botha&b. above ‘Tension tests may be used to. a Qualify a welder b Qualify a walding operator c Prove the ductility of a proposed welding procedure: Qualify a welding procedure Essental variables must be addressed on a wes b PAR c¢ wpa d— Allof the above COPYRIOGHT 2)- IRC?SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTEEXAMINATION 1 - CLOSED 800K IRS IACISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE, copyaIGHT 20% = sessure test shail be p: 18 Ahar rapairs are completed to a pressure vessei [Atha repairs an alteration 3.) the API-510 inspector believes one is necessary C the Pressure Vessel Engineer believes one is necessary D. no NDE is done in iau of the pressure test 17 The ASME Code requires that safety valves be marked wit! A. tbine steam capacity (8) MAW of the valve C. valve supolier D bursting pressure Se {8) An exchanger that has a tube bundle that is free to move in the snaii, which pam \/ expansion and contraction with temperature changes is 2 Ax, Floating Tubesheet exchanger (B) Floating Head exchanger © Floating Body exchanger D. Fixed U Tube heat exchanger ‘The scope of API 510 includes: CA.) miniature vessels (UM stamped vessels) Coast Guard vessels C. vassals rated for 10 psig D none of the above 20. _Erasion problems would be more likely in which of the following concitions A, sampling lines (3 impingement point across from a vessel nozzle inlet T the battom of a fractionating tower ©. the bottom of a kettle-tyoe re-boiler Sensitization (or carbide precipitation) occurs in stainless steels when heated in the temperature range of °, and then slowly cooled ‘A. 2000 - 25000 5 Git D 22 Aprassure vessel is 4° thick and made from carton steel (P-1 material) This vessel will hav sired with a flush patch using a Category A butweld. Per ASME Vill. this recair will EA, szot radiographed © fully adiographed C radiographed, if 2 joint efficiency of 1 0 is used © Ulrasonically examined per UW-12 requirements COPYRIGHT 2000 ~IAGISCHINOLER & ASSOCIATES - ALL RIGHTS RESEAVEO - 00 NOT CO?¥ OR OISTRIE:API510 FINAL EXAMINATION 1 - CLOSED BOOK IRC COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OF OISTRIBUTE 23. Aradiograph that meets ASME V requiremients will have a density range of i produced with an X-Ray source A 20-40 18-40 13 (composi © 23-38 24 Amateriai test report is requires for au rai par ASME vin @rse and plate product pipe © fiting. D pressure-retsining 25 The allowable mill undertalerance an piping is B 12.5% : © 125% = 1s at D. 01" of 6% of ordered thickness: (2s ,) Acomman type of stress corrosion cracking that occurs in carton stee!s in petroleum refineries is that caused by sodium hydroxide This type is commeniy called: ‘A, chloride cracking ‘B.)caustic embritiement © erosion/carrosion © high temperature embrittlement 27 When repairing vessels with stainless steet weld averiay and cladding (vessels constructed of P-3 Pot. or P-5 base materials) the base metal in the area of repair should be examined for cracking by UT per ASME Section V This UT inspection should be made at least hours aiter repairs have been completed for equipment in hydrogen service. Fapedaly for chromium-molyodenum alloys that could be affected dy delayed cracking ANZ (Bye ‘C38 D 42 ® 28 For corrosion calculations the surface of the weld is considered to De! Bs inch en eter se ofthe wel orice the minimum heknes onan side of he sna wsicnave is greater whicneve 8 23 até o2 times the minimum biekness on ether side of viatea hisnaveriegrestar ee ee weld or ties the minimum tienes on "enet icneveris greater cee ene ee rea eld or 6 ies the minimum thickness on siter side of Sane michaves is greats: & er side o 28 Which of the following is not a tool for measuring thickness of vessel shells? A ecoustic emission transducers 'B ultrasonic instruments C radiography with step gages © corrosion buttons and depth drilling a & ASSOCIATES - ALL RIGHTS RESERVEO - DC NOT COPY OR DISTRISYAPI510 FIK COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES ~ ALL RIGHTS RESERVED . DO NOT coPY OR DISTRIBUTE 30 Vessel production i \JA) the base metal must be impact tasied 8 raculred by the Inspector CC the metal will be operated 2¢ -20°F ©. UHA St requires them to be performed 31 ita WPS shows a single "Vee" Groove weld is to be used and the POR was qualified witn a double "Vee" Grocve: A. the WES can be used without requalification 5 the WPS must be requalifie C, the POR must be retested ‘D> the WPS must be modified to show the A. itis always used in vapor service , itis always used in hazardous service : Circular Flat Unstayed q 1D. Hemispherical 40 Ifa steel has exceeded its yield point upon the removel of pressure and heat it wil ‘A. return to its original shape CB) contain a permanent deformation “6 spitrupture D be scrap 41 Of the lypes of stresses placed on a thin walled cylinder, the most severe is A) circumferential B longitudinal C compressive D radial rsile strength men is 15 KSI The ultima: 42 The ultimate load on a $10" diameter tensiie sp: on this specimen is approximately’ A) 73.528 psi 90.200 psi C 85 100 psi D 18.389 psi 43. The “Piezoelectric” effect is used in: 44 Onthe PH Scale 2 reading of 7 0 would be A. acidic yn C alkaline BD fatwlant 45 One of he most common welding defects abserved in the root pass of 2 welc Coe YRIGHT 2000 = IRCISCMINDLER & ASSOCIATES - AL! RIGHTS RESERVE™ AP} 510 FINAL EXAMEIATION { - CLOSED BOOK IRC IGHT 2000 ~ IRGISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DG NOT COPY OR DISTRIBUTE, A, porosity B. lack of penetration C tergster inc! D overies 48 _ Ifa probable corresion rate cannot de determined from reviewing data from ihe same or similar service vessels or estimated form published data, on-stream determinations shallbe made after approximately hours of service by using NDE methods anda corrosion rete is established @> 1900 Cc” 3000 © 10500 47 What datarminas the inspection interval af 2 pressure-reileving device? ‘A. The interval is determined by the authorized pressure vessel inspector 'B The interval is determined by the owner-user. Grain growth. D Graphitic corrosion. 64 —_In-cases where the remaining safe operating life is estimated to be less than 4 years, the inspection interval may be the full remaining safe operating life up to @ maximum of 8 (> mus be at least 20°F above MON 3 mended tobe a least 30°F above MOLT 63 “CREEP’is affected by: ep strength 09 HoT cory oF OIS TRIS COPYAIGHT 2006 ~ IRCISCMINOLER & ASSOCIATES - ALL RIGHTS RESER'/AP! 510 FINAL EXAMINATION 1 - CLOSED BOOK IRC COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE A guy wire is used for: ar QD sesing tetra wind lading) suppor to a tat vss $ooig Hon eo ut vee! uiding 2 level gauge through 2 tower © pre-placement of insulation over a corroded surface oak 68. _ The two NDE methods referenced by API 510 for measuring metal thickness ars (Ac REET 8) RT. UT UT, AET OD MiPT 6 Radiography of zirconium (P51 ~ P62 metals) for purposes of welder qualifications is: é permitted by ASME IX 6. 5} not alowed by ASME IX net addressed by ASME (X D acceptable per ASME Vil 70 Ralleving devices in a dirty, corrosive service must be removed and inspected at least every: A. 10 years B. year (E> 5 years oy 5 10 years if the Inspector approves 71 The primary difference between GMAW and FCAW is: B) the gas used the wire used D the power source used i 6 the wire feeder used 72 Ifthe ownership and location of a vessel are changed the vessel must oe: A. revregistered withthe state 3 tevheat treated after instalation G. cleaned before moving (Gdinsoected after instalation atthe new location should have 3 on the downstream side to indicate if leakage or rupture 73 Acupture has occurred (Bnscatng lasso ole ots é fr D alarm 74 Anameplate shell be attached to a vessel after 2 A repair _&, alteration (i erating D allof the above comYRGMT 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - D0 NOT COPY OR DISTRIBU)a API 510 FINAL EXAMINATION 1 - CLOSED BOOK IRC CCOPYaIGH? 2000 -IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRISUTE High temee: drogen attack wil usually ocxur at temperatures above A, 1900°F 8 10.000°F 20°F (D.450°F 76. When the temper-bead welding technique is used in lau of PHT per APi 510, the minimum praneat temperature shall be __ °F and the maximum wierpass i! shall be A, 350. 450 B 450.550 , 850, 750 D. 280, 380 17. Cathodic protection systems are normally supplied in either one of two ways: A, expressed current or impressed current (B) impressed current or sacrificial anode sacrificial anode or impressed anode D. sacrificial anode or artificial cathode 78 Before a hydrostatic test of an existing vessel is performed: (CAbithe vessel should be checked to ensure itcan withstand the lcadings frem the height of the water the vessel must be fully rauiographed C the vessel should be PWHT'd D the vessel should be purged of air by opening a connection at the lowest point on the vessel ina pressure vessal record file 78, The three types of information that should be retainex (according to API 510) are! A. crawings. caleulations, specications 2 permanent, progressive, historical © Sperating and inspection history. construction design and repair. alteration anc m_ferating information (basic deta, field notes, data accumulated in a “continuous file” 80 An Authorized API Inspectors duties may include: (A, “authori approve re-rating designs repairs & alterations 5 C periarm radiography D. install nameplates er SB fatigue © corrosion © brittle fracture COPYRIGHT 2000 ~IRC'SCHINOLER & ASSOCIATES -ALL RIGHTS RE!83 a4 8s, e6 ar 88. a3 API 5t0 FINAL EXAMINATION 4 - CLOSED 800K IRC (COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OF DISTRIBI Fer ASME IA, a welding operator may be Gualified by test plates (bend tests) production weld radiography Raciograohy of a tast pipe ‘D) all of the above Goer Which PT examination may not follow the other? (@ fuorescent my not follow visible visible may not follow fluorescent C. mutidicectional may not follow longitu D_ exponential may not follow subrotational ‘When conducting extemal vessel inspections, specific attention shoult be directed to: A tray support rings 8 downcomers . Cskirt attachment area ‘Dantivartex devices ‘The dish of a torispherical head will normally be than an elliptical head, and therefore will have to be thicker for the same pressure A, thinner |B. rounder ©) hater D_ more obround A pressure vessel that reduces vapor to liquid is called a: A, heat exchanger 8. seboiler (C) condenser “D. mutti hoon Per Ariicie 9. personnel perierming visual 2: A. be qualified to SNT-TC-1A B. have 20 years experience . have an annual vision testo J-1 Standards _¢&) have an annual vision test to 12 Stancarcs shall ‘An inquiry submitted to the AP! committee requesting an interpratation on an API S10 requirement should be composed so that the committee reply can be made in a format. ‘A Nes or no” B. legal ©. lengthy D. narrative When steel is heated to a high temperature followed by rapid cooling, the substructure becomes very hard This is caused by the formation of (martensite 8 austenite C bainite ©. pearite The scope A, vessels rated for less than 15 psig (Ep vores less nan carte non-stationary vessels (moveable vessels) over 15 psig D piping and {In checking a bbe oriented Ay parallel fired heaters wald fer longitudinal tothe cracks (8) perpendicular © aligned © similar .SME VII! includes which of the following: Jes using the MT method, the magnet field should Graphitization is @ phenomena that occurs when steels operate for 2 fong time in the. TSF - 100" 250°F - 504 gio w > cosvaicHt 2000 *F range }O°F range 11,000°C - 15.000°C range 25°F - 1.400°F range IRCISCHINDLER & ASSOCIA’ ALL RIGHTS RESEAVED - GO NOT COPY CR DISTRIEUTSAPL510 FINAL EXAMINATION 4 - CLOS=D BOOK IRC COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE, 97. When relief valves are transported from a valve repair faciity back to a plant after they have been 2d they shoul A shipced laying down B. shipped is Sealed conainers C shipped in visqueen “) shipped inthe upright poston 98. An UT indication in excess of % of the DAC must be investigated to determine its validity. per ASMEV A 20 B 90 c.30 D 50 99 Anchor balts (holding a vessel in place) should be examined visually and also should be tested for soundness by 4B) tapping with a hammer ulrasonics ©. eddy current ©. excavating and checking any available NOE method 100 An owner-useris responsible for developing, documenting. implementing, executing, end ‘2ssessing pressure vessel inspection systerns and inspection procedures that will meet the requirements of API §10. These systems and procedures will b= A. maintained in a engineering procedure document & kept as a standard procedure. (E, contained in a quality assurance inspection manvel. 1D in hand and available at owner-user headquarters 401 A pressure test is normally required after ‘Aan alteration “8. 2 repair ©. allighining strike D. aunt upset 402 The external inspection of a pressure vessel should start with: A. vessel foundation and anchor bolts. (Bladders, stairways, platforms. or wakways conne \¢nazzles and connecting siping D protective coatings and insulation ted or bearing on the vessel 403 When a pressure-relief valve is first received in the shop. what should be cone? A dismantle and clean the valve 8 check the valve spring for corrosion © dip the valve in 2 cleaning solution 1D ‘test pop the valve to determine the."as received" relieving eressure coeYAIGHT 2060 LASSOZIATES -ALL RIGHTS RESERVED -00 NOT CO*¥ OR OFa 108 108 107. 108 103 110 ‘AP|510 FINAL EXAMINATION 1 - CLOSED BOOK IRC COPYRIGHT 2006 ~IRCISCHINOLER @ ASSCCIAT "VED -DO NOT Copy OA DISTRIBUTE The maximum allowable warking oressure for the continued use of a pressure vessel shal 2 Dasea on computations determined by using ine Aa wen of xa National Boller the vessei was buiit (BNlatest edition of the ASME Code or the con: “uit. latest ecition of the APVASME Code or the construction cade to which the vessel was built © lates: ection of the Underwriters Laboratories Code or the construction code to which the vessel was built the vessel was ‘CUI must be investigated for vessels operating between which may have had moisture ingress ose 25°5 -250°F 8 250°F - 800°F C OF -10°F D, 100% - 1200°F ‘The Remaining Life of a vessel is calculated by which of the following formulas: A. tacua-tpresaue minima A A eal crac re Gy ial bern oot a ran Sion alewanee Corrosion in refining processes are divided in 3 major groups. One of these groups is: ‘A. corrosion from components in crude oil corrosion from chemicals used in the refining process C. environmental corrosion “ seco 1 « L z D With P1 backing onty + dame eh be Can cr ba weeel poe 26. Immediate retests of welders qualifications coupons A. Must use the same method i he 3. May use any method © Are not alowed D. ReauireInepector approval Hee ae eetnt 27 Welder performance qualification records must describe all the variables specified A Essential & nonessential B Nonessentiat © Essential © Brazing 28 Awelder depositing 1/2" of weld metal with the SMAW process is qualified to epesit up to of weld metal. ag B Max to be welded 29. "P" numbers are used to designate groups of A Electrodes 8B Flux © Base metals D Joints 30 A welder qualifying by welding P-No 21 to P-No 21 is qualified to wale A Pal Pet to Pet Pott 5 P8-PB © P-21-P-25 to P-21 = P-25 © P2t to P21 only 31 Welding electrodes are grouped in Section IX by COPYRIGHT 2000 = IRG/T. SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTE 5ASME IX PRACTICE QUESTIONS COPYRIGHT 2000-IRCIT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘A. AWS class. B ASME specification C SFA 1D "F* number 32. Ferrous weld metal chemical composition may be designated using AP" number B Welder 1D C -"AY number D page number 33. For welder qualification with the SMAW process. is an essential variable A Base metal thickness 8 Peening C. P-number D Electrode diameter 34. Each welder must be assigned a(n) A P number B Unique identifier GC Hood & gloves © Inspector 35 May a welder, qualified in the 2G position on 1/4 inch thick plate, weld a 1 inch outside diameter pipe. 1/4 inch thick in the horizontal position without requalification? A Yes wd B No , CNet enough information provided D. Yes, provided pipe is carbon stee!. Pit 36 Whatis the basic difference between gas metal arc welding and gas tungsten arc welding processas? A. How they are produced B The,SFA specification of the filer metal C The Fé of the filler metal 9 GTAWis run with gas: gas is optional with GMAW 37 Awelder has been tested in the 6-G position. using an E-7018 F-4 electrode. on 6” sch 160 (718 nom) SA 1088 pipe Is this welder qualified to weld a 2" 300# ANSI schedule 60 bore fienge toa 2” schedule 80 SA 106 B nozzle neck? Yas No Not enough information provided Yes provided a backing strip is provided in the 2° weld pour 28 May a welder who is quaified using a double-groove weld, make a single V-groove weld without backing? COPYRIGHT 2000 IRCIT, SCHINDLER & CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 638 40 at a2 43 a4 45 ASME IX PRACTICE QUESTIONS - COPYRIGHT 2000 -IRCIT. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE A Yes B No Not ercugh infomation provided D. Yes. because backing is not an essential variable for a welder May a GTAW welder be qualiied by radiograpty, in lieu of bend tests? The test coupon walle -22 material and the production welds will be P-22 also A Yes 3 No © Not encugh information provided 5 Yes provided the P-22 is welded with F-22 filers Who is responsible for qualification of welding procedures. welders and welding operators? A. The Inspector 8. TheAt © The Shop Foreman 1D. The Manufacturer of Contractor Awelding electrode has the marking £-6010. The “1" marking indicates: A. Flat position only B_ Horizontal position only © Allpositions D. Only good for heat treated welds May a FCAW welder qualified using UT. be used to weld in production? A Yes, welder can be used B_ No welder cannot be used CC Yes. # welder is using GMAW (Short Arc) D. Yes. ifweider is qualified with backing ‘A welder may deviate from the parameters specified in 2 WPS if they are @ nonessential variable (True oF False) A Tue B False ‘A repair organization has a WPS which states itis qualified for P-8 to P-8 material welded with dither £308 E308L. £309. E316. electrodes (SMAW process) The PR, supporting this WPS, cuates the weld test coupons were SA-240 Type 304L material, welded with £308 electrodes Is the WPS properly qualified for the base material listed? A Yes 8 No Not enough information given D Yes if properly heat treated What positions are necessary to qualify a welder for all position pipe welding? A 3G and 4G B 2Gand 8G COPYRIGHT 2000 ~IRC/T SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBU= ASME IX PRACTICE QUESTIONS. COPYRIGHT 2000 ~ IRG/T. SCHINDLER AND CODEWEST ~ ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE C 3Gand 1G D 4G and 5G 46 What ASME Code Section has welding electrode storage requirements? A. ASME IX B ASME Vili © ASME B31 1 D ASME I Part C 47 What are the numberof transverse guided bend tests required for Performance Qualifeation in @ 6G postion? vomr 148, May a GMAW, shor circuit transfer, welding procedure be qualified using real-time ultrasonics? A Yes . B No © Not enough information given D_ Yes, provided bend tests are done 49 Three are welding processes are: A BMAW, SMAW, EFGAW B FCAW, SAW, ESW © SMAW, GTAW, PAW D PTAW. SLAW, PEAW 50 You are reviewing a WP (QW-484) for a welder testing in the 6-G position: on SA-53 grade B pipe (TS-60,000 psi) The test results indicate the folowing: #1 Tensile developed 51,000 psi, broke in the weld 22 Tensile developed 56,500 psi, broke in base metal #1 Transverse root bend satisfactory #2 Transverse face bend satisfactory Will these test qualify the welder? Yes No Not enough information given Tension test is acceptable but #1 is unacceptable poe 51. Is awelding procedure qualified under the 1965 ASME Code Section IX still applicable? A Yes B No. must be requalified CIs only applicable for 1985 pressure vessels COPYRIGHT 2000 ~ IRCIT, SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUT=ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 -IRCIT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRISUTE 'D_ Cannot be used for new construction - repairs only 52. A nonessential variable must oe aocumented on: A The wea B The POR C The WPS D Allof the above 53. What are the various positions in which a welder may quality for plate groove welds? 1G 3G 4G All ofthe above ooo 54 Awelderwas qualified with a P-t test coupon using SMAW E7018 electrodes. May the welder Onis bt material using E8028 electrodes with backing in production? (Assume the P-4 procedure Using £8028 electrodes has been qualified ) A Yes 8 No C Not enough information provided 1D None of the above sj5. What are the primary classifications of guided-bend tests permited by the Code?” A. Side and Transverse B Face and Root © Transverse and Longitudinal D Side and Face 56 Awelder quaified by welding in the 5G position is qualified for what position on plate? Which oft following is a covered electrode? A &8010 B E7018 c E9028 D allof the above 58 Apolicabie essential variables must be documented on which of the following? A The WPS: B ThePOR C The wPa 1D Allof the above COPYRIGHT 2000 -IRG/T SCHINDLER & CODEWEST - ALL. RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE 9ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 - IRCIT. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 159. In performance quaitfication of pipe welds to ASME Section IX, which positions require more than two guided bend specimens for qualification? A. 5G and 6 5 2G and 4F © 4G and 5G 4 None of the above 60 Name two defects that would cause visual rejection of @ welder's test ipe or plate? A. Porosity, underfill 8 Lack of penetrationifusion © Slag, overlap D. Anyof the above 1 Avariable that, when changed will cause a change in the mechanical properties of the weldment is calied a: A Essential variable B. Non-essential variable © Supplementary essential variable D Allof the above 62. The test that determines the ultimate strength of groove-weld joints is a! ‘A Notch Toughness Test B Tension Test C Fillet Weld Test D Guided-Bend Test 63. The procedure qualification tast is used to determine: ‘A. The skill of the welder © That the proposed production weldment is capable of having the required properties ©The corrosion -resistance of the proposed weldment 1D None of the above ‘aa Achange ina supplementary essential variable requires requalfeation when notch toughness iS @ consideration True or False (circle one) 65 When using Mecto-examination of fila weld test, the weld and the HAZ must not revel cracks when magnified at. A 8x B 2x © 10x No magnification is required - visual examination is requirec only 66 A non-essential variable may be changed without re-qualifcation because, ‘A. Nobody cares about non-essential variables 8 The welder is allowed to change variables at his discretion . Nemcessential variables do nat affect the mechanical or notch-toughness propertias 'D. Non-essential variables cannot be changed without re-qualification GoPYRiGHT 2000 ICT SCHINDLER & CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 10ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 ~IRCIT, SCHINDLER AND CODEWEST - ALL FIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 67, The data recorded on a POR (nor-etitorial) may be changed provided: ‘A. The Al approves 2 The test data on a POR is a record of what occurTed and should never be changed. srged on a POR Srly editors © The API 510 Inspector approves D. The date of the WPS is changed 68 A WPS must only address essential and, if applicable, supplementary essential variables True or False (circle one) 68 Tension tests may be used in lau of bend tests to qualify welders or welding operators True or False (circle one) 70 A groove weld bend test reveals a linear indication on the face of the bend surface that measures eacily 1/8" long. No other indications are seen. Does this coupon pass or fal? A Pass Fall 71. Unless notch-toughness is a consideration, ¢ qualification in any position qualifies a welding procedure for all positions, Tre or False (circle one) i 72 The purpose of a WPS and POR is to determine #f a welder has the ski necessary to make sound production welds True or False (circle one) 73 Welders can be qualified by radiograph when using P 6X materials? True of False (circle one) 74. itis permissible to sub-contract welding of coupons as wal as ether work to prepare coupons True OF False (circle one) Variable QW 402 4 for SMAW procedure qualification is a variable A Essential 8 Non-essential Supplemental essential D_ None of the above 76. Variable QW 404 24 for SAW procedure qualification is an variable A. Essential 8 Non-essential C. Supplemental essential None of the above 77 Each manufacturer must certify the POR (by signature) indicating that the information given is CosYRIGHT 2000 -IRCIT SCHINDLER & CODEWEST -ALL FIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE n78 73 80 a 82 83 a4 85 8% 87 ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 - IRC/T. SCHINDLER AND CODEWEST ~ALL RIGHTS RESERVED - DO MOT COPY OR DISTRIBUTE true and correct Tre Or False (circle one) Welder variable QW- 405 1 (for welders qualifying with the SMAW process) is & vanadie A. Essential 8 Non-essential C Supplemental essential 1D Noné of the above The purpose of a WPS and POR js to determine if a proposed weldment to be used in construction is capable of providing the required properties for the intended sppication True or False (circle one) A qualification in a 4G position qualifies a welder for all groove weld positions. Tre or False (circle one) AWPS must address all applicable non-essential variables True or False (circle one} Groove weld coupons shall be tested by macro-examination when qualivrg a welding procedure True or False (circle one) ‘A.welsing procedure must be qualified with impact tests only when requiree by tne appficable ‘construction code, such as ASME Vili Div 1 True or False (circle one) ‘Awelder qualified to weld in the 26 position on pipe would have to be cueied in which of he 50°F 8 100°F © 125°F D 150°F E None of the above ‘welder is qualified to weld all thicknesses of material when’ ‘The test is any thickness above 3/8 inch ‘The test thickness was ¥4 inch ‘The test thickness was 3/4 inch or over ‘The test pipe wall thickness wes 5/8 inch and nominal pipe size was over V4 inches None of the above moaw> What is the maximum defect permitted on the convex surface of a welder cuaification bend test see ynrgrit 2000 IRGYT. SCHINDLER & CODEWEST -ALL RIGHTS RESERVED -O0 NOT COPY OR DISTRIBUTE 1288 9 90 an 2 93 ASME 1X PRACTICE QUESTIONS COPYRIGHT 2000 ~1RC/T. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE afer bending except for comer cracks and corrosion resistant weld overlay? A tis inch 8 1/Binch D ‘What period of inactivity from a given welding process requires the welder to process? A. 3months BS months CS months O12 months E As stated by the Al Notch-toughness requirements are mandatory A. For heat treated metals B. For quenched and tempered metals C Forhardened and tempered metals D For annealed and tempered metals When specified as required by the referencing Code section ‘Awelder qualified for SMAW using an £7018 electrode is also qualified to weit with £7015 E5011 6010 E7024 All of the above moom> Macro examination of an etched filet weld section for performance qualification is acceptable i the ‘examination shows > Complete fusion and freedom from cracks. excepting linear indications not axceeding 1/32 inch ai the root 8 Cancavity or convexity no greater than 1/16 inch © Not more than 1/8 inch difference in Jeg lengths © Allofthe above E Scth Band C above Each manufacturer or contractor is responsible for the welding or brazing dore ay his organization ‘Whenever these words are used in Section IX. they shall include: A, Designer or architect 3 Designer or installer C Architect or installer 1D Installer or assembler E Assembler or designer For P-11 materials, weld grooves for thicknesses. shall be prepared by thermal COPYRIGHT 2000 ~IRCIT SCHINDLER & CODEWEST - ALL RIGHTS RESERVED . DO NOT COPY OR DISTRISUTE 13ASME IX PRACTICE QUESTIONS ‘COPYRIGHT 2000 IRCIT. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTE processes when such processes are to be employed during fabrication A. Less than 5/8 inch c D 7-174 inches E None of the above 94 Awelder using SMAW must be requalified if there is a change in which of the following conditions? A AHS B 6NPS 102 NPS ©. uphill to downhill in the groove D both B &C. above 95 Achange in @ non-essential variable requires re-certification of the POR. True or False (circle one) 96 Reduced-section tensile test specimens conforming to QW-462 1 (b) may be used on al thicknesses of pipe having an outside diameter greater than: ‘| A. 2inches B 2-1/2 inches C 3inches D 3-172 inches E inches 97 Groove weld tests may be used for qualification of welders Which of the following shail be used for evaluation? A. Only bend tests B. Only radiography ©. Both radiography and bend tests D Either bend tests or radiography E None of the above 98 Under which of the following conditions can a welder be qualified during production work? ‘A A 6! length of the first production groove weld may be qualified by radiography 8 Abend test coupon may be cut from the first 12" length of weld Amacro examination may be taken from the first 3" of weld length None of the above ANSWER KEY FOR PRACTICE WELDING QUESTIONS: 9eeeB0000 o COPYRIGHT 2000 -IRCIT SCHINDLER & CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 14ry ASME IX PRACTICE QUESTIONS: | SOPH 000 -MEM_ SANDLER AND CODEWEST ALL UGHTS RESERVED. DOWNoTCOFY OR EISTRIBUTE 4 2 B 0> 00> > O0009>0000F00>0N0000000>0R09>a0NOMND>AD 56 87. 58 59 61 62 63 64 65 moosaarm>room 67 68 z alse COPYRIGHT 2000 -IRC/T. SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 18ASME IX PRACTICE QUESTIONS: COPYRIGHT 2000 IRGIT. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 69 70 7 72 73 74 1 B 7 78 73 False Pass True False False False B A True A True False True False True >oopo>oomm@aoao & COPYRIGHT 2000 -IRGMT, SCHINDLER & CODEWEST -ALL RIGHTS RESERVED - 00 NOT Ci 16 JOPY OR DISTRIGUT:REVIEW OF ASME IX -T. SCHINDLER “COPYRIGHT 2800 -IRCIT SCHINDLER AND GODEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR OXSTRIBUTE API AUTHORIZED PRESSURE VESSEL INSPECTOR PREPARATION COURSE FOR CERTIFICATION EXAMINATION 2000 INNOVATIVE RESEARCH CONSULTANTS ‘SCHINDLER & ASSOCIATES AND CODEWEST AUTHORED BY: T. SCHINDLER ‘coPvmiGHT 2000 sR! SCHNDLER ANO CODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR OSTRIBUTEREVIEW OF ASME IX - T. SCHINDLER. Ccopynicst 2000 IRGIT. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: INTRODUCTION OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE CERTIFICATION TEST WITH TYPES AND FORMS OF INFORMATION IN WHIGH THEY MUST BE KNOWLEDGEABLE REFERENGES:BODY OF KNOWLEDGE, AP! AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION. ASME SECTION IX WELDING QUALIFICATION CODE. INTRODUCTION Section IX relates to the qualification of: = Welders: ‘+ Welding Operators © Brazers ‘+ Brazing Operators © Welding/Brazing Procedures who are employed in welding or brazing in accordance with the: + ASME Boller and Pressure Vessel Code and - + ASME Piping Codes PURPOSE ‘The Welding Procedure Specification (WPS) and the Procedure Qualification Record (PQR) are used to determine that the weldment proposed for construction is capable of having the required properties “The procedure qualification testis to establish the properties of the weldmentVorazement, NOT the skill of the welder/orazer ORGANIZATION Section IX is divided into two parts: + Welding, Identified as QW + Brazing. identified as 08 “These two parts are further divided into four Actes: + General Requirements + Procedure Quelification + Performance Qualification CcoprmichT 2000 «IRC! SCHINDLER AKD CODEWEST -ALL RIGHTS RESERVED - D0 NOT GOPY OR OISTRIBUTE 2REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 7000 - INCI. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE + Data PROCEDURE QUALIFICATION Each process is listed separately with the applicable essential and non-essential variables + Change in an ESSENTIAL variable requires requaiification + Change ina NON-ESSENTIAL variable requires a revision to WPSIBPS + Change ina SUPPLEMENTARY ESSENTIAL variable requires requalification ADDITIONAL RULES In addition to covering various joining processes, rules also exist for special processes: + Corrosion Resistance Weld Metal Overlay + Hard-Facing Weld Metal Overlay . PERFORMANCE QUALIFICATION Each process is listed separately with the applicable essential variables + Welderwelding Operator can be qualified by: + Mechanical Tests + Radiography of the Test Plate/pipe + Radiography of Initial Production Weld + BrazeriBrazing Operators CANNOT be qualified by radiography ARTICLE! WELDING GENERAL REQUIREMENTS QW-1003 WPS. PQR, and Records of Performance Qualification can be used for construction built according to either the , + ASME Boiler and Pressure Vessel Code — orthe = + B31 Code for Pressure Piping Providing it meets the requirements of either the + 1962, or later, editions of Section 1X 2 pre-1962 Edition of Section IX meeting ALL requirements of 1962 oF later. ecitions: ‘A. Qualification/requalification of WPS MUST conform with the current Edition and Addenda of Section IX Scope Rules in this section apply to Qw-101 + preparation of WPS “+ qualification of welding procedures, welders, and welding operator for ALL. manualimachine welding processes permitted in other sections COPYRIGHT 2000 iG! T SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - D0 NOT COPY OR OISTRIBUTE 3REVIEW OF ASME IX -T. SCHINDLER ‘COPYRIGHT 2000~IRGT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE Responsibility Manufacturer/contractor is responsible for welding QWw-103 + MUST conduct tests to qualify Welding Procedure and Welders/Welders Operators, ‘Test results MUST be kept by manufacturer/contractor + MUST be certified by Manufacturer/contractor Types and Purpose of Tests and Examinations Qw-140 Mechanical Tests aw-141 Tension Tests Determine the ultimate strength of groove-weld joints await 2 heey Guided-Bend Tests Determine the degree of soundness and ductility of groove-weld Qw-14t2 joints. Fillet-Weld Tests Determine the size, contour, and degree of soundness of filet welds Qw-1413 Notch-Toughness Determine the notch toughness of the weldment Tests Qw-14t 4 ‘Stud-Weld Tests Determine the acceptability of stud welds Qw-141 5_ Tension Test To determine the ultimate strength of a jeint, expose sample to stress Qw-150 levels exceeding stated limitations Tension Test Sample shall be ruptured under tensile load Procedure ow-182 + Calculation: Tensile Strength = Meximum Load Minimum Cross- Sectional Area ~- Measurements MUST be taken before load is applied Acceptance Criteria Tension Tests Qw-153 Tensile Strength Minimum tensile strength requirements: QW-153 1 + Stated base metal limitation. of + Stated base metal limitation of WEAKEST specimen when two different strength levels are present, or COPYRIGHT 2000-1RG!T SCHINOLER AND CODEWEST - ALL RIGHTS RESERVED -O NOT COPY OR DISTRIBUTE 4REVIEW OF ASME IX -T. SCHINDLER. COPYRIGHT 2000 REIT SCHNDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE + Stated weld metal imitation when the applicable Section requires use of weld metal with @ lower room temperature strength than the base metal + Strength is NOT MORE than 5% below the stated base metal limitation JF the Spesinien breaks outside the Fusion Zone and weld in the base material Guided Bend Tests Using a test jig, bend the sample into a "U" shape Qw-160 ‘Types of Guided Bend Tests aWw-t61 Transverse Side Bend Weld is transverse to the longitudinal axis of the specimen aw-16tt Side surface of the weld becomes the convex surface of the specimen Transverse Face Welds tansverse tothe longitudinal axis ofthe specimen awiet 2 Face surface of the weld becomes the convex surface of the specimen ‘Transverse Root Weld is transverse to the longitudinal axis of the specimen awe foot surface ofthe weld becomes the convex surface ofthe specimen Longitudinal Face Bend Weld is parallel to the longitudinal axis of the specimen Qw-16t6 Face surface of the weld becomes the convex surface of the specimen Longitudinal Root Weld is parallel to the longitudinal axis of the specimen Bend Qw-1617 Root surface of the weld becomes the convex surface of the specimen ‘Acceptance Criteria. Weld and heat affected zone MUST BE ENTIRELY within the bent QWw-163 area of the specimen "Specimen MUST NOT have eny defects greater than 1/8 inch «Measurements ten ampere on ourded surface + Comer cracks disedunted unless evidence of internal defects are present Corrosion Resistant Weld Overlay Cladding requirements: + No defects greater than 1/16 inch (cladding) + Nodefects greater than 1/8 inch (bond fine) =, 4. =e Notch Toughness When required by the Code. one of the following fests MUST be conducted aw:r70 + Charpy V-notch + Drop Weight impact COPYRIGHT 2990 ARC/T. SCHINDLER AND CODEWEST ALL FIGHTS RESERVED “D0 NOT COPY OR DISTRIGUTE 5REVIEW OF ASME IX -T. SCHINDLER Ccoprnich 00 ~IRC/T SCHINDLER AND GODEWEST-ALL RIGHTS RESERVED "00 NOT COPY OR DISTRIBUTE Other Tests and Examinations aw-t30 Visual examination of welder/operator qualification test is required. > Radiographic May be substituted for mechanical testing for weldershwelding operators Examination ———— a 7 Qw-191 MUST meet requirements of Article 2, Section V MUST mest acceptance criteria of QW-191 2 Cannot be used on GMAW short- arc process Stud Weld Tests Procedure Qualification QWw.192, : . Required Tests ‘Ten required for each procedure : Qw-192 1 Five alternately MUST be hammered over untt a 1 +14 of length is flat, » + Bent to na less than @ 15% angle AND returned to original position Remaining five alternately MUST be torque tested “ + Tensile testing also acceptable Bend and Hammering All five studs MUST NOT have visible fractures or separations: aw-192.2 Torque Test or Torque: Tensile Test QWw-1923 + Stud MUST meet required torque before falling Tensile: = Stud MUST withstand at least 35,000 psi before falling Macro-Exemination All five sections, the weld, and the HAZ MUST NOT reveal cracks when Qw-192 4 ‘magnified at 10X Slud Weld Tests Performance Qualification Qw.193 Required Tests Five required for each operator Qwe-193 1 Allfive studs MUST be hammerad or bent as required by procedure qualification Criteria for acceptance is identical to procedure qualifications COPYRIGHT 2000 IRC) T SCHINDLER ANO CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIOUTE 6REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 2000 IRCIT SCHRNDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE General QW.200 Welding Procedure: Specification (WPS) Qw.200 1 Procedure Qualification Qw-200 2 ARTICLE It WELDING PROCEDURE QUALIFICATIONS: ‘Whitten directions for the welder/welding operator making production welds describing all variables involved © ESSENTIAL VARIABLE Welding specification change affecting mechanical properties of the ‘weldment Requires specification requaiification + SUPPLEMENTARY ESSENTIAL VARIABLE Weld specteation change afecng roth toughness properties of the Requires specification requalification + NON-ESSENTIAL VARIABLE Welding specication venange NOT affecting he mechanical or notch Requaification NOT required providing WPS is amended Essential variable for one process may be non-essential for another or may not be required at all for a third process Non-essential variables can be changed without requaiification + Change MUST be documented by variable on either a new, or amended original, WPS: Tests to determine that the weld can provide the required (POR) properties for the intended application All variables of the WPS MUST be followed Base metal of the specimen can be‘in any form + Procedure qualification transferable between plate and pipe welding PQR components: = Allessential and supplementary essential variables used during test coupon welding MUST be recorded” + Anynon-essential or other variables can be recorded at 2 later date + Any vatiables recorded MUST be the actual variable --"> = ‘+ Variables not monitored MUST NOT be recorded + Ifmore than one pracess/filler metal is employed, RECORD the approximate deposit weld thickness of each COPYRIGHT 2098 IRC! SCHINDLER ANO CODEWEST - ALL RIGHTS RESERVED - D9 NOT COPY OR DISTRIBUTE 7COPYRIGHT 200 Multiple WPS's with One POR/Multiple PR's with one wes Qw-200 4 Qw-201 but all ‘Table Gw 282 - aw 265 - General QW-300 Qw-300.1 aw-300.2 Intent Qw-3011 esis, Qualification of Tests QW-301 2 REVIEW OF ASME IX - T. SCHINDLER IRert SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIGUTE ‘Changes! + NOT allowed except as an editorial or addenda + REQUIRES recertification Several WPS's may be prepared from data on one POR ‘One WPS may cover numerous essential variable changes providing a POR existe for all essential and supplementary essential variables Combination welding procedures (more than one process) are allowed; however [ALL variables and ranges for each process shall be applied and identified Note restriction on GMAW -SC are. : Manufacturers/Contrectors. responsibilty to conduct tests, document results, and ‘maintain records NOT permissible to sub-contract welding of coupons, bother work in preparing coupons and testing can be subcontracted \Vetiable Tables per process ARTICLE It WELDING PERFORMANCE QUALIFICATIONS , ‘Welder qualfication is lmited by the essential variabies given for each process Welderfwelding operator can be qualified by +. Radiography of test eounon + Radiography of intial production welding + Bend tests taken from test coupon Visual examination of al tests is required Manufacturericontractor MUST conduct tests to qualify weldersiwelding operators in accordance with a quslified WPS + This is to ensure thet weldersivelding operators can develop the minimum requirements specified for an acceptable weldment Determine the ability of the weldersiwelding operators to make sound welds Performance qualifi ‘WPS jon tests MUST be welded in accordance with qualifies Welder/Welding operator who prepares the WPS qualification test coupon is also qualified within the performance qualification range of the performance variables: COPYRIGHT 2000 Re) SCHINDLER ANO CODEWEST- ALL RIGHTS RESERVED -0O NOT COPY OR DISTRIBUTE 8REVIEW OF ASME IX -T. SCHINDLER COPYRIGHT 2000 ~IRGI. SCHINDLER AND CODEWEST ALL RIGHTS RESERVED - D0 NOT COPY OR OISTRIBUTE Identification of Mustbe assigned an individual identifying WeldersWeldng =” numb, Operators =o aWw.301 3 7 symbol ALL work must be identified in this manner Record of Tests. WP@ record MUST include: QWw-301 4 7 Essential variables 7 Type of test Test results Qualified range of welderiwelding operator Use form QW.-484 oF equivalent Welders Welders MUST pass the mechanical est prescribed in QW-302.1 w-304 + Exception: special requirements Welder making groove-welds using - sMAW + SAW + GTAW ; + PAW + GMAW (except short- 2° SA‘S37 CLASS 2 (MIN w t A tb ta 180009841448 116,000 wm Acceptable Ref QW- 183 (a) tb 1490 0997 1485 114.000 76720 PM Acceptable | Ref QW- 153 1a) 2a 1197 0.960 4137 91,200 80.000 WM Acceptable Ref QW- 153.12) 2 = 1.280 0981 1228 98.000 79,934 WM. Unacceptable Ref QW- 153.1(@) NOTE: Full set unacceptable because of 2b Reference QW-151 1(c) SPECIAL NOTE. The math is incorrect on ta The area is 1 476 which makes the PS! 78.590 which is unacceptable Reference QW-153 1 COPYRIGHT 2000 IRC! T SCHINOLER AND CODEWEST- ALL RIGHTS RESERVED -00 NOT COPY OR OISTHVBUTE 14REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 2000 ~IRCIT. SCHINDLER AND CODEWEST-ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE Qw-150 ‘TENSILE TEST “TURNED SPECIMENS” “0.505” IS Ay) EXAMPLE: Base Metal Tensile Strength = 75,000 NOTE: EACH PROCESS OR PROCEDURE SHALL. BE INCLUDED IN THE TENSION, BEND OR IMPACT TEST SPECIMEN. REF. QW-200.4(a) w t A LOAD Psi Loc. Results 1 ost1D 0.208 15570 75,950 BM 2 0s01D =—0.497 14,520 73,750 wi NOTE: Turned Specimens(QW-151.3) “REF. QW-462.1(d) Ref. QW-153.1(a) D = 0.6000 0.010 In. 2 COPYRIGHT 2000-~iRC)T SCHINDLER AND CODEWEST- ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE: 15REVIEW OF ASME IX - T. SCHINDLER “COPYRIGHT2000 IRGTT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE WELDING DOCUMENTATION AND WELDING REQUIREMENTS Introduction ‘This session will deal with the welding documentation and welding requirements for fabrication to the ASME Boller and Pressure Vessel Code, Section Vill, Division 1. The reader should come away with an tnderstancing of what will be needed regarding welding documents and what parameters these: Gocuments must contain in order to prove qualification in accordance with ASME Section IX and Section vil tn al sections of the ASME Code the responsibly for construction and documentation is placed with he al fecturer or contractor This is true with welding documentation also. The ASME Code requires that rattan provedure be avaliable prior to construction and that the procedure contain directions for the anger and the supervisor to insure that a weld meeting the mechanical property requirements of the ASME Code are met inva welding procedure three distinct types of variables must be adcressed_ The first is en essential (rable, which is a variable that if changed wil cause a change in the mechanical properties of the waigment. Anytime an essential variable is changed outside of the range specified on the welding vrmceure spectieaton, the procedure must be requelfid by performing mechanical testing on & Weldment made with the new parameters “The second type of variable thet must be addressed on every welding procedure specification is called 2 ae onlial variable Changes in these variables can be made without requaliication of the welding procedure; however, the welding procedure must be revised to reflect these changes “The thir type of variable to be addressed on @ welding procedure specification is called a supplementary cecchtisl Conable These supplementary essential variables must be addressed on a welding procedure Specification only when impact propertios are required of the weldment. When impact propettics =r seScired then the supplementary essential variables become essential variables and the welding must be Sane within the specified range of these variables Any changes outside of the range specified on welding procedure specification must be requalified by mechanical ang impact testing “The purpose of this handout is not to instruct the API 510 Candidate in every welding process recognized trite ASME Boler and Pressure Vessel Code, What is attempted isa recap of those variables thet Ti Oa ae amen wring and qualifying a welding procedure for the shielded metal arc welding (SMAW) process Il. Preparing or Reviewing a Welding Procedure Specification (WPS) ie Coney to start wring or reviewing a welding procedure specication ts 10 refer to Acie 2 in ASME Ree reset his instance we wil refer specticall to paragraph QW-253 which oa table that specifes the essential, supplementary essential, and nonessential variables for the SMAW process “his table refers us to eight categories that must be addressed on a veking procedure specication The fret eatagorys welding ont, W402 From QW.253. there are no essential or supplementary essential variebles for joints However, there ore Fae noneccential variables and as previously stated all the variables specified for a particular process toe ee eaced on the welding procedure specification Taking the fist nonessential variable, the Xin Trenelume ncicates that we must refer to OW-402 1 QW-402 1 states that a change in the type of qrosve e.g nonessential variable This means that a change from a V groove to @ U groove, fs 6 chenge Sve a dati variable As previously stated, the welding procedure specification must be revised 1 Teor change, When wring or reviewing a welding procedure specification. there is @ chance Wet rec ah one joint dasign will be used in a weldment Therefore, the welding procedure specification cen Tioraly spect that types of joint design to be used willbe shown on drawing and not resin he Gocument to ary unique joint design COPYRIGHT 2000-IRCIT SCHINDLER AND CODEWEST- AL RIGHTS RESERVED -00 NOT GOPY OR DISTRIGUTE 16REVIEW OF ASME IX-T. SCHINDLER CoprrcitT 2000 - RCI. SCHMDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIGUTE ‘The next variable in the joints category, Is the deletion of backing. This is specified in QW-402 4. Again, a in the joint design, # restrictions are not needed on our production facilties, the WPS can simply Specify thatthe joint can be made with or without backing If the WPS states that the weld is to be made with backing, that is what must happen in production until the welding procedure is revised ‘The next variables in QW-253, are @ change in the root spacing and the addition or deletion of retainers. Because these are nonessential variables, a welding procedure specification should have as wide tolerances as possible for these categories Because the addition or deletion of retainers is @ nonessential variable for the shielded metal arc welding process, it must aiso be addressed If you are not {going to use retainers. you should state this on your welding procedure specification ‘The second category for variabies is base metal These variables are addressed in paragraph QW-403 In this category there are no nonessential variables, and all the variables that are jisted are either essential variables or supplementary essential variables ‘As stated earlier. supplementary essential variables apply only if impact properties are required of the weldment Supplementary essential variables have restrictions on the base material that can only be qualified with a single procedure qualification record. It also puts restrictions on the base metal thickness range that is qualified when qualifying a procedure quaification ‘The list of essential variables starts with the base material and weld metal thickness limitations when trying to qualify for thicknesses greater than 8 inches. The reader is advised that when impact properties are required the supplementary essential variables are additional to the essential variables “The next essential variable addresses whenever there is @ change in the base material thickness qualified Essentially it stipulates that the welding procedure depending on the thickness of the coupon Used in the procedure qualification is qualified fora range of base metal thicknesses, if base metal thickness gges beyond the range of qualification another test piate must be welded and tested to ascertain that the welding procedure develops the required mechanical properties in the new thickness range One essential variable that is often overlooked on welding procedure specifications is that a single pass of weld material that is more than 1 inch thick has @ range of qualification different from that when using weld passes of less then % inch thick This % inch limitation must be addressed somewhere on the welding procedure specification if you are not going to allow welding greater than % inch thickness in one pass, you must state this on your welding procedure specification. ‘The last two essential variables listed for the shielded metal arc welding process have to do with base. material P-numbers Qualifying for P1 material, does not quaiify for any other P-number material. If its desired to weld on other P-numbers, qualification tasts must be performed on materials listed in the P- numbers for which qualifications are sought QW 424 allows some alternatives to be used when qualifying on P-5, P-4. or P-3 materials ‘The third category of variables listed is for filer metals _In this categbry all three variable types are applicable The first two have to do with the chemistry and the types of electrodes used in the welding process The F number is 2 grouping of electrodes that have similar characteristics in the way that they produce mechanical properties and they have similar deposition characteristics The other property thal is, Gealt with as an essential variable is the A-number. This is @ chemical limitation in that electrodes that falt within a particular A-number category have similar chemical properties Changes in either of these variables wil require requaiification of the procedure ‘The diameter of the electrode is listed as a nonessential variable The welding procedure should list 2s many diameters of electrodes to be used 2s possible to preclude problems in production If the writer of the welding procedure lists just one diameter of electrode. before a different diameter of electrode may b= used in production, the weld procedure must be revised to include these new diameters, Two supplementary essential variables are listed under filer metals One refers to QW.404 7 and deals with large diameter electrodes. It states that if impact properties are required and the use of an electrode COPYRIGHT 2060 IRC! SCHNDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 7REVIEW OF ASME IX -T. SCHINDLER. COPYRIGHT 2000 -IRCFT SCHINDLER ANO CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE diameter of greater than a quarter of an inch is necessary, the specific electrode diameter must be {qualified for impact values ‘The other supplementary essential variable fisted in QW404 12 is the AWS classification All filler metal specifications (SFA) presently recognized as standard filler metal by the ASME Code ae listed in ASME Section ll part G.This supplementary essential requires that a change in the electrode SFA number requires requalification of the welding procedure # impact values are required ‘QW 404 30 deals with deposited weld matal thickness (or DWM) This variable is sometimes overlooked, tut must be addressed. especially i restrictions are placed on the DWM, or if partial penetration welds are used “The next category for variables for the shielded metal arc welding process is position. There are three Yerlables listed and, withaut going into detail, the reader should know that when impact values are not required, the position of the weiding is a nonessential variable, meaning that a welding procedure can be {Qualified by running a test plate or pipe in any position and the procedure is then qualified to be used in all positions When impact values are required for the qualification of the welding procedure, position Beeomes an essential variable when changed from any position to the vertical uphill progression. Further, if you change from 2 stringer bead in the vertical uphill progression to @ weave bead, this would also require requalifcation for impact properties. ‘fifth category of variables for the shielded metal arc welding process is preheat. There is one essential Variable, one supplementary essential variable, and one nonessential variable listed in this table The weeentisl variable is that f a procedure is qualified at a given preheat value, the preheat may not be ‘Gecreased more than 100 degrees from that qualified without requalification of the procedure. The onessential variable for preheat has to do with the maintenance of the preheat temperature when post = dield heat treatment is required. The maintenance that is addressed in Section IX is the continuance of the preheat temperature after the completion of welding. The preheat temperature is going to be maintained after completion of welding for 2 period of time or iit willbe allowed to cool in air and not Tronitored after the completion of welding. The supplemental essential variable mentioned in this category Cf variables deals with interpass temperature and not with preheat temperature ‘When a welding procedure requires impact testing, the interpass temperature must be monitored and mnustbe maintained below a maximum value. The supplemental essential variable for interpass: temperature states that ifthe interpass temperature is increased by more than 100 degrees over that qualified, the procedure must be requalified “The next category of variables is postweld heat treatment. The first variable listed is a change in postweld heat treatment and this is classified as an essential variable itis not always necessary to postweld heat treat P-1 material The construction or repair code will dictate when this is necessary However, the Code does specify that a change in the postweld heat treatment is ‘on essential variable and therefore must be addressed on the welding procedure The PWHT treatment ca iabies must be watched closely, as upper/lower critical temperatures on each material may differ. and this may have a bearing on what can be done in production To state that postweld heat treatment is not applicable is not correct_If there is to be no postweld heat treatment then the welding procedure specification should state "No Postweld Heat Treatment” or “None” of somehow indicate that no postweld heat treatment will be performed “The next variable listed for postweld heat treatment deals with a change in the time and temperature range for the postweld heat treatment Whenever the time at temperature or the temperature range itself is changed, (outside of the renge initially writen and qualified) the procedure must be requalfied whenever impact properties are required ‘The last variable has to do with the thickness of the base metal qualified The variable is stated in QW- 407 4 and requires that whenever the upper transformation temperature for the alloy is exceeded. the fraxirum thickness that is quatified with that post-weld heat treatment is 1 1 times the thickness of the COPYRIGHT 2000 RCI SCHINDLER AND CODEWEST- ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 18REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 2000 ~!RCIT SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE test coupon. This is a restriction over the normal 2 X base metal thickness that can be qualified # the upper transformation temperature has not been exceeded, ‘The next variable category in QW-253 is electrical characteristics Both variables listed in this category deel with current and votage The first variable listed is @ change in the current or an Increase in the heat input and this classified as a nonessential variable, which can have an effect on impact values. ‘When qualifying a welding procedure with impact values the amount of heat input due to the welding process must be controlled This variabie stated in QW-409 1 requires that when the type of currant or the polarity of the current are changed, if the heat input is increased, or if the volume of weld metal deposited per unit length of weld is increased, the procedure must be requalified for impact values 2 ‘The other variable isted in electrical characteristics is a change in the type of current or a change in the current and voltage range. This is a nonessential variable. Referring to QW-409.8, if the type of current or polarity is changed or the range of amperage is outside the range inially listed on the welding procedure specification, then the welding procedure must be revised to indicate this new range of weiding Parameters. Voltage for shielded metal arc welding is not a variable, and therefore its not necessary to fiat the voltage range on a SMAW weld procedure specification. Usually the electrode manufacturer's recommendation for amperage is adequate and many manufacturers use this range on their welding procedure specification ‘The last category of variables for the shielded metal arc welding process is titled “technique”. Such things as string or weave bead, the method of cleaning, whether manual or automatic welding. pening, and the method of back gouging a joint must be addressed on the welding procedure specification Since these ‘re nonessential variables, a change may be made without requalification of the procedure. However, the Code is very specific in requiring that they must be addressed on the welding procedure specification. ill Preparation/Review of a Procedure Qualification Record (PQR) ‘The next document that the ASME Code requires for welding is the procedure qualification record (POR). ‘The purpose of this document is to record the essential variables used during the welding of a test coupon. and to record the values of the mechanical properties obtained when testing the welded coupon foend fests, tensile tests, notch toughness tests, oF filet weld tests, as applicable) The ASME recommended form (QW-483), has spaces to list all essential , nonessential, and supplementary essential variables for the various recognized welding processes ‘The only information reauired to be on the POR is the listing of the values for the essential and supplementary essential variables used while welding the test plate and the mechenical values obtained when doing the testing on the test coupons. Ifthe manufacturer or contractor voluntary wishes to list the fonessental variables on this form, the values that are to be listed are those that were actually used or Obtained during the welding of the test coupon For example, the same range of amperage that is Specified on the welding procedure should not be listed on the procedure qualification record, unless that entire range was used during the welding of the test coupon ‘When qualifying welding procedures, two of the primary areas are the base material thickness qualified and the deposited weld metal thickness qualified. The ASME Code allows a range of thickness ‘Qualification when welding a specific thickness of base material for the procedure qualification As en ‘example, when the test coupon is made from a 74" thick plate, the welding procedure is qualified to be Used on a range of base metal thicknesses from 3/16 inch to 1 inch. When qualifying welding procedures the manufacturer or contractor should ensure that the thickness of the test coupon will qualify the weiding procedure over the range of base metal thicknesses that will be needed in production ‘When using a combination of welding processes or a combination of filer materials, each filler or process ‘will have a range of qualification. The thickness deposited by the different processes or the thicknesses ‘COPYRIGHT 2000 RC) T. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE, 19REVIEW OF ASME IX T. SCHINDLER Ccopvmigir 2000 -Incrt, SCHINDLER AND GODEWEST- AL RIGHTS RESERVED - D0 NOT COPY OR DISTRIBUTE deposited by different filer metals must be measured when welding the test coupon for procedure qualification These thicknesses then must be documented on the procedure quaification record. These Values will determine the welding procedure range of qualification. As an example, if a manufacturer were to use gas metal arc welding to run the first 1/4" of weld in a 7 inch thick plate, and then use shielded metal are welding to finish the weld, each process would be qualified to deposit % inch of metal and the procedure would be qualified to weld on base metal up to 1 inch thick. Neither of the welding processes is, ‘Qualified to weld a 1 inch thick deposit in a 1 inch thick plate, but together they can be used to weld a 1 inch thick plate ‘The physical testing criteria should be closely reviewed The number, type and results of the tests should be compared with the applicable acceptance criteria in Articie 1 and the requirements of Article 4 for the test involved All PQR’s must be certified (by signature) by the Manufacturer or Contractor 1V Preparation/Review of a Welders Performance Qualification (WPQ) The last document to be discussed will be the welder performance qualification record The purpose of this document isto lst the actual values used by the welder when welding a test coupon and also to list the thickness ranges for which the welder is qualified Using the table in paragraph QW-353 of Section IX, the essential variables for welder qualifications, are variables that affect welder’s ability or skill and whenever any one of these variables is changed the welder must be requalified The first essential variable in this table has to do with joints and states that if a welder is qualified to weld with backing and that backing is deleted, the welder must requalify to perform an open butt joint. Variables regarding base metal that affect welder qualifications are pipe diameter and a change in the P number material Paragraph GW-423 allows @ range of P-number qualifications by welding on one P-number for welder Gualification, only. As can be seen, it requires a very drastic change in base material before a welder has to requalify due to this essential variable ‘Three variables are listed for filer metal. The first variable regards nickel electrodes (F41. F42, F43, ete} and states that a qualification with any nickel electrode qualifies for all nickel electrodes The second Nariable deals with all other electrodes and fimits the range of qualifications for the various F-numbers ‘The most commonly used range is when a welder quaifies with an F4 electrode He is then qualified to weld with F3. F2, and Ft electrodes with backing, only Any electrodes used above an F4 only qualify for the F number, and F1, F2. and F3 do not qualify.up for F4 deposits. See QW-433 Table “The last essential variable for filer metals is the thickness of the weld deposit and this chart refers to the variable QW-404 3 which limits the welder to the range of thickness qualifications as shown in QW-452 ‘The last category of variables for welder qualification is position ‘The manufacturer or contractor should ‘watch this variable closely As an example. if a welder takes a qualifying test in the horizontal position he js also qualified to weld in the flat position There are several other combinations that can be oblained the proper position for qualification is selected Table QW 461 9 is, often overlooked and misunderstood, sn this context ‘The last variable mentioned in QW-353 is @ change from vertical up to vertical down welding, and refers to paragraphs QW-405 3 ‘As previously stated. whenever any one of these variables is changed outside the range of qualification. the welder must requalify for the new range_ Its the responsibilty of the manufacturer or contractor to insure that welders are qualified for the production welds made This has been a brief review of the three welding documents that are required by the ASME Boiler and Pressure Vessel Code The reader is advised to thoroughly research the requirements of Section IX before undertaking the process of writing or reviewing a welding procedure The reader is further advised that many of the construction codes (Section |, IV. Vill, ll, B3ta) can further restrict welding requirements ‘Many companies are in compliance with the requirements of Section 1X, but net using a welding procedure that is in compliance to the Construction Code Sections of ASME, or other repairlatteration codes. Ccopricitt 2000 IRC! T.SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 20REVIEW OF ASME IX - T, SCHINDLER (COPYRIGHT 2000 IRCIT SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DONOT COPY OR DISTRISLTE COPYRIGHT 2000 4RCIT. SCHINDLER AND CODEWEST. ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE aoF ee i ENT NOL ann API AUTHORIZED INSPECTOR PREPARATION COURSE FOR CERTIFICATION EXAMINATION 2000 INNOVATIVE RESEARCH CONSULTANTS. . SCHINDLER & ASSOCIATES: AND CODEWEST AUTHORED BY: 7. SCHINDLER COPYRIGHT 2000 -IRC/T. SCRNDLER, JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1REVIEW OF ASME SECTION V NDE REQUIREMENTS? ¥, Sci comrntnt a0 mal soanbiee aw OEY AND CODES -ALLNDNTE RECEIVED eh Soe on ISTRBUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW GENERAL REQUIREMENTS FOR NDE OBJECTIVE: _ FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT GENERAL REQUIREMENTS FOR NDE. REFERENCE: ASME SECTION V, ARTICLE 1 7-410 SCOPE A) General requirements for NDE when referenced by other Codes. B) General NDE terims are defined in the Mandatory Appendix and SE-1316 7-420 GENERAL ‘A) Subsection A describes methods of NDE to be used B) Subsection B lists NDE Standards - Standards are Mandatory when referenced by Subsection A C) Reference to a paragraph in Subsection A or referencing Code includes all applicable rules in the paragraph ) Standards in Subsection B are mandatory only to the extent specified when referenced 7-430 EQUIPMENT ‘The manufacturer, installer, of fabricator is responsible for equipment compliance 7-440 REQUIREMENTS. |A) NDE Personnel shal! be qualified per the referencing Code section ; nat aw 22! re ey B) When Article 1 is referenced personnel shall be qualified per: eee ~ ASNT SNT-TC-1A oF - an alternate system accepted by the referencing Code section C) When no personnel qualification standard is referenced qualification may be by demonstration in 7 routine operations of competency in accordance with Manufacturer's procedures: by 1) Limited certification of NDE personnel who perform only one operation of an NDE method or perform within e limited scope may be based on less hours than specified in SNT-TC-1A euch conditions shall be described in the Written Practice and noted on any certfication: 7-150 PROCEDURE {k) Special conditions such as part geometry or materials may requite special procedures usec = If requited they shall: oe “he equivalent or superior to the methods and techniques described in Section V z = produce interpretable examination results Pree ~ be capable of detecting discontinuities oye be submitted 0 the inspector for approval , 8B) The manufacturer, fabricator or installer is responsible for establishing: = examination procedures 7 a - personnel cerlfication procedures COPYRIGHT 2000 -IRC/T SCHINDLER. JW COLEY AND CODEWEST ALL. RIGHTS RESERVED -DO NOT COPY OR O:STRIBUTE 2 cn me BEEREVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000-—IR67T SCHINDLER.JW COLEY AND CODEWEST-ALL RIGHTS RESERVED -DO NOT COPY OR DISTREUTE 6) All NDZ performed shali o& done in accoraance with a written procedure = demonstrated to the satisfaction of the Inspector, L in compliance with the applicable Article of Section V - Made available to the Inspector on request - available to the NDE personnel perfuming the examinations. T-460 CALIBRATION |A) The manufacture, installed or fabricator shall assure that all required calibrations are performed 8) The manufacturer, installed or fabricator shall specify what calibrations are needed when using special procedures; if required T-170 EXAMINATIONS AND INSPECTIONS ‘A) The Inspactor is responsible for: - verifying that all examinations meet all requirements of Section V and referencing Code “witness any examinations to the extent stated in the referencing Code © Hus Jn tev y - Inspector means the Authorized Inspector as defined in the referencing Code 8) Inspection: : L ~ Refers to the functions of the Authorized Inspector“ “ME og ~ Examination = Refers to the functions of the NDE personnel iya- 9 “= 3 Shen = There are some minor conflicts in these definitions in the ASTM documents 7-180 EVALUATION Acceptance standars are as stated in the referencing Code 7-190 RECORDSIDOCUMENTATION - Records shall be in compliance with = The referencing Code and + Section V ~The manufacturer, installed or fabricator shall be responsible for all records and documentation CCOPyRIGHT2000~IRG/T SCHINDLER. JW GOLEY AND CODEWEST -ALL RIGHTS RESERVED 00 NOT COPY OR DISTRIBUTE 3REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2000~ RET SCHINDLER. JW COLEY AND CODEWEST ALL RIGNTS RESERVED - DO NOT COPY OR OSTRISUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW OF RADIOGRAPHIC EXAMINATION METHOD OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH THE REQUIREMENTS FOR RADIOGRAPHY. REFERENCE: ASME SECTION V, ARTICLE 2- RADIOGRAPHIC EXAMINATION T-210-SCOPE When this Article is specified by the referencing Code Section, he radiographic method described in this Article shal be used together with Article 1, General Requirements. Definitions Definitions of terms used in Article 2 are found in Mandatory Appendix V, Standerd Definition of Terms and SE-1316. Some important definitions are: “Defect ~ a flaw (imperfection or unintentional discontinuity) of such size. shape, orientation, location, or properties as to be rejectable -Discontinuity a lack of continuity or cohesion; an interruption in the normal physical structure of ‘material or a product. Evaluation of indications — The process of deciding the severity of the condition after the indication ‘has been interpreted Evaluation leads to the decision as to whether the part must be rejected salvaged, or may be accepted for use -Flaw — an imperfection or unintentional discontinuity which is detectable by NDE imperfection — a condition of being imperfect; a departure of a quality characteristic from its intended condition. indication — the response or evidence from the application of a NDE. limited certification — Limited certification within a given method or technique is defined 2s ‘accreditation of an individual's qualification to perform a limited scope of work -Method — A method is the utilization of a physical principle in nondestructive examination (NDE). “Procedure — In NDE a procedure is an orderly sequence of rules that describes how @ specific technique will be applied “Source side — that surface of an ares of interest being radiographed for evaluation nearest the ‘source of radiation “Technique — A technique is a specific way of utilizing a particular NDE method Each technique is identified by et least one important variable from another technique within the method ( Example RT -- method — X-Ray/Gamma Ray Techniques) COPYRIGHT 2000 - REIT SCHINDLER. JW COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT GOPY OR DISTRIBUTE 4REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER (COPYRIGHT 2090 —IRG/T. SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIBUTE 1-220 GENERAL REQUIREMENTS: 1-221 Procedure Requi ments 7-221 1 Compliance Without a Writen Radiographic Procedure. When Article 2 is required by the ‘eferencing Code Section, the density and penetremeter image requirements of this Aticls on production or technique radiographs shall bé consideréd a satisfactory demonstration of compliance 7-221 2 Requirements and Compliance for @ Written Radiographic Procedure Minimum Contents of a Written Procedure: -malerial & thickness range: isotope used gr maximum X-ray voltage minitnum source-to-fim distance smaximum source size Parc! 1 arson Demonstration of the density and penetrameter image requirements of the written procedure on production or technique radiographs shall be considered satisfactory evidence of compliance with that procedure 7-222 Surface Preparation ye hid precsaze $2204 Mater — 3PM ‘Surfaces shall satisfy the requirements of the applicable materials specification. Additional ccrsiipang ray be required (ginang, ete), necescary by ary sufable process toa degiae {fat sutacs rreguarics cannat manor be confused wih surface dlconinutes| 1-222.2 Welds \Weld ripples or weld surface irregularities on both the inside and outside shall be removed by any suitable process to such a dagree that the resulting radiographic image due to any irregularities cannot mask or be confused with the image of any discontinuity 7-222 3 Surface Finish ‘The finished surface of all butt-welded joints may be flush with the base material or may be reasonably uniform crowns, with reinforcement not to exceed that specified in the referenced Code Section ( API 650 and/or API 652 in the case of Tanks) 7-223 Backscatter Radiation 9 +" Alead symbol “B" with minimum dimensions of 1/2" in height and 1/16" in thickness, shall be attached to the back of each film holder during each exposure to determine if beckscatter radiation is exposing the film 1-224 System of identification Permanent identification system shall be established to trace radiograph to the contract. component. weld or weld seam, or part numbers, as appropriate In addition: - Manufacture''s symbol or name and the date of the radiograph shall be plainly and permanently included on the radiograph =| D system doas not require that the information appear as radiographic image See ne « the information shall not obscure the area of interest 1-225 Mo ing Density Limitations of Radiographs Either a densitometer or step wedge comparison film shall be used for judging fim density COPYRIGHT 2800 —IRCIT. SCHINDLER. W COLEY AND GODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 5REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER Ccopynici 2000 -IRG/T SCHINDLER, W. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OF DISTRIBUTE 7-230 EQUIPMENT AND MATERIALS. 7-234 Film Radiographs shall be made using industrial radiographic film ‘7-232 Intensifying Screens May be used except when restricted by the referencing Code Section 7-233 image Quality Indicator (IQ!) Design - Penetrameters shall be either hole type or wire type = Manufactured and identified in accordance with: ‘SE-1025 (for hole type) ‘SE-747 (for wire type) - ASME standard penetrameters shall consist of those in: ‘Table T-233 1 for hole type (See table in Section V) ‘Table 233.2 for wire type (See table in Section V) * 7-234 Facilities for Viewing Radiographs - Viewing Facilites shall provide subdued background of an intensity that will not cause troublesome reflections, shadows, or glow on the radiograph. Equipment used for viewing shall provide a variable light source: sufficient for essential ‘penetrameter hole or designated wire to be visible for the specified density range - Viewing conditions shail be such that light from around the outer edge of the radiograph or ‘Coming through low-density portions of the radiograph does not interfere with interpretation 7-260 CALIBRATION 7-281 Source Size . ce 7-261 1 Verification of Source Size ~foliow manufacturer's or supplier's publications, technical manuals, or written statements documenting the actual or maximum source size or focal spots 7-261 2 Determination of Source Size ~ X-ray 320 kV or less, use pinhole method = For IR-192., determine by ASTM E 1114-85 ‘T- 262 Step Wedge Film & Densitometer - density of step wedge comparison films and densitometer calibration shall be verified by comparison with a calibrated step wedge film traceabie to a national standard - densitometers shall be calibrated in accordance with Paragraph 6 of SE-1078 COPYRIGHT2000 = IREIT SCHINDLER JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT COPY Of DISTRIBUTE 6REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER see CoPyRoHT2009-REMY SOHNDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED-DONOTCOPYOR DISTRIBUTE =. ‘7-270 EXAMINATION 22%: T-271 Radiographic Téchnique ~ 7-271.1 Single-Wall Technique -Use whenever practical -Radiation passes throtigh only one wall of the weld (mater Adequate number of exposures shall be made to demonst 1-271.2 Double-Wall Technique -Use when a single-wall technique is not practical > -Radiation passes through two walls of the weld (material) ‘Adequate number of exposures shall be made to demonstrate required coverage |) Single-Wall Viewing vie Double-Wall Technique F welds in components viewed for acceptance on the radiograph. rage (s required for circumferential welds, a minimum of 3 exposures. 8 is eachother shall be made" "* Face nt ») Double-Wall Viewing via Double-Wall Technique for materiale and for welds in components 3.5-inches or less in nominal OD. the radiation passes through two walls/weld in both walls is viewed for acceptance 2 only a source side penetrameter shall be used «If the geometric unsharpness requirement cannot be met use single-wail viewing _, 3 1-272 Selection of Radiation Energy 7-272. X-Ratiation - Must show proper 1GI image He -272.2 Gamma Radiation WES From a radicactive isotope for thickness as follows: 8 Recommended Minimum Thickness. Material tridium Cobalt Steel O75" 1s Copper or High Nickel oss" ww ‘Aluminum, 25" Note: Overall radiographic sensitivity is primarily influenced by factors such as: im selection ~intensifying screen selection “geometric unsharpness -film density -maximum thickness for use of radioactive isotopes is primerily dictated by exposure time upper limits are not shown -minimum recommended thickness limitation may be reduced when the radiographic technique demonstrates the required radiographic sensitivity 1-272 Special Conditions -When no! practical to perform radiography with the limitations previously noted “the procedure shall be proven satisfactory by actual demonstration of penetrameter -on the minimum thickness of the material radiographed 17-278 Direction of Radiation : centered on the area of interest whenever practical, ‘COPYRIGHT 2000 - IRC. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOTCOPY OR DISTRIBUTEREVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER copyniGi stnd= MEN SOmnosER JW EOLEY AND CODEWEST Alt RIGHTS RESERVED DO NOT COPY OR DSTIEUTE ‘J-274 Geometric Unsharpness -'") ~-) ~ Geometric unsharpness ofthe radiograph shall be determined in accordance with Ug = FD where: Ug = geometric unsharpness. F” = Source size, the maximum projected dimension ofthe radiating source (or effective focal spot) in the plane perpendicular to the distance D from the weld or object being radiographed, inches D = distance ftom source of radiation to weld or object being radiographed, inches = distance ftom source side of weld &r object being radiographed, inches iu 1-276 Location Markers (See Fig 7-275) + tha film See vo appear as radiographic images on the fim 1 Shal'be placéd on the part not on the exposure holder / cassette —— «Rak tocations are to be pemenently marked on surface of part being raiographed e «Gr on 2 map in'a manner permiting the area of interest to be accurately traceable a ~ Poeduons thal be availabe for the required retention period ofthe raciograph =) ~ EXidonce provided onthe rediograph that the required coverage has been obtained yy, 7-275.1 Single-Wall Viewing A) Source Side Markers: 7 ‘Location markers shall be piaced on the source side when radiogrephing the following: sflat components or iongitudinal joints in cylindrical or conical components “curved or spherical components whose concave side is tower the source ‘and the "source-to-materia” distance is less than the inside radius ofthe component -curved or spherical components whose convex side is toward the source B) Film Side Markers: Location markers shall be placed on the film side when: “radiographing either curved or spherical components/concave side toward the source and the “source-to-material" distance is greater than the inside redius ‘As an alternative to source side placement, location markers may be placed on the film side when the radiograph shows coverage beyond the location markers to the extent demonstrated in Fig T- 275 (2) and is documented in the radiographic report ) Either Side Markers: Location markers may be placed on either the source side or fm side when: Fadiagraphing either curved or spherical componentsiconcave side is toward the source and the ‘"gouree-to-material” distance equals the inside radius of the component 7-278.2 Double-Wall Viewing: - For double wall viewing, at least one location marker shall be placed on the source side surface adjacent to the weld for each radiograph 1-275 3 Mapping the Placement of Location Markers: When inaccessibility or other limitations prevent the placement of markers as stipulated in "Single Wall Viewing” and "Double-Wail Viewing”, a dimensioned map of the actual marker placement shall accompany the radiographs to show that full coverage has been obtained COPYRIGHT 2000 INGFT SCHINDLER JW COLEY AN CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR O1STRIBUTE 8REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER (COPYRIGHT 2060~IRCIT. SCHINDLER, JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-276 101 Selection * er 7-278 1 Q's shail Be of similar alloy gfotips as shown in SE-1025 or an alloy of lower radiation absorption than the material being rediographed . T-276.2 The designated hole penetrameter when essential hole or designated wire diameter shall be ‘ ‘as specified in ASME Code, Saction V, Articie 2, Table 275 (See table in Section V) ~a smaller hole in a thicker penetrameter oF alarger hole in a thinner penetrameter ‘may be substituted for eny section thickness listed in Table 276 provided equivalent penetrameter sensitivity is maintained and all other requirements for radiography are met, Approximate e-quivalence between hole and wire penetrameters is shown in ASME Code, Section V, B-220 of Aricle2 Nonmandstory Appencix B. and may be uscd ts det ‘valence between hole < penetrameters 8... i ; i A) Welds With Reinforcements ‘Thickness of penstrameter based = nominal single wall thickness + the estimated weld reinforcement lap ond. ) = Backing rings or strips are not considered as part ofthe thickness, 4 eo. Actual measurement of the weld reinforcement is not required. Ke! r B) Welds Without Reinforcement ‘Thickness of penetrameter based on: ‘ ~ nominal single wall thickness - Backing rings or strips are not considered as part ofthe thickness T-277 Use of IQ! (Penetrameters) to Monitor Radiographic Examination ‘7-277.4 PLACEMENT OF PENETRAMETERS A) Source Side Penetrameters - Place on the source side except for the condition described under T-277. 1(b). - Place on a separate biock when size of configuration prevents placing on the part or weld: = Blocks shall be made of the same or radiographically similar materials = No restriction on the separate block thickness provided the panetrameter / area-of-inferest density tolerance requirements of Paragraph T-282.2 are met 8) Film Side Penetrameters Where inaccessibilty prevents hand placing the penetrameter(s) on the source side, the penetrameter(s) shall be placed: on the film side in contact with the part separate block or “shim” placed as close to part as possible ~ block shall be larger than the penetrameter/3 sides of penetrameter must be visible on film lead letter “F* placed next to or on the penetrameter =F" may not mask the essential hole in the penetrameter ©) Penetrameter Location for Welds — Hole Penetrameters -Place penetrameter(s) adjacent to or on the weld. = 1D numbers, lead letter "F", shall not be in the area of interest except as in (1) and (2) 1) configuration makes it impractical to place the penetrameters as outlined above 2) when weld metal is not radiographically similar to the base material ( See SE-142) (COPYRIGHT 2000 -IRCVT. SCHINDLER, JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 8 ee EC posronselREVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CCopreiGHT 2000 IRG/T SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE D) Penetrameter Location for Welds ~ Wire Penetrameters on the wala $0 mat ine engin of wifes 1s pempendicuiar is the length af the weld ID numbers. lead letter “F", shall not be in the area of interest except as in (1) and (2) 1) configuration makes it impractical to place the penetrameters as outlined above 2) when weld metal is not radiographically similar to the base material ( See SE-142) E) Penetrameter Location for Materials other than Welds -The penetrameter(s) with the penetrameter ID number(s), and, lead letter "F”, may be placed in the area of interest -277.2 Number Of Penetrameters - For components where one or more fm holders are used, at least one penetrameter image ‘shall appear on each radiograph except as outlined in "Special Cases” ‘A) Multiple Penetrameters = One shall be representative of the lightest area of interest and the other the darkest area of interest; intervening densities on the radiograph shall be considered as having acceptable density B) Special Cases 41) Cylindrical vessels where source is placed on axis of the object and one or more film holders used for single exposure of a complete circumference Three penetrameters shall be spaced approximately 120 degrees apart. ‘Where sections of longitudinal welds agjoin circumferential welds and are radiographed simultaneously with circumferential weld, an additional penetrameter shall be placed on each longitudinal weld at the end of each section most remote from the junction with the circumferential weld being radiographed 2) Cylindrical vessels where source is placed on the axis ofthe object and four or more film holders are used for single exposure of a section ofthe circumference: - Atleast three penetrameters shall be used One stall be in the approximate center ofthe section exposed and one at each end = ifthe section exceeds 240 degrees, the ruie for cyindrical vessels eppiies and additional fim locations may be required to obtain necessary penetremeter spacing otherwise atleast one penetrameter shall appear on each film 3) Spherical vessels where source is located at the center of the vessel and one or more film holders used for single exposure of a complete circumference: - Three penetrameters shall be spaced approximately 120 degrees apart = One additional penetcameter shall be placed on each other weld 4) Segments of spherical vessels where source is located at the center of the vessel and four or more film holders are used for single exposure of a section of the circumference: - At leas! three penetrameters shall be used = One penetrameter shall be in the approximate center and one at each end = When the portion exceeds 240 degrees, the rule for spherical vessels applies and additional film locations may be required to obtain necessary penetramet otherwise at least one penetrameter shall appear on each fim r spacing: 5) When an array of objects in a circle is radiographed, at least one penetrameter shall show on each object image COPYRIGHT 2000 -IRC"T SCHINDLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED 00 NOT GOPY OK OISTRIBUTE 10REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER : CoPYRIGHT 200 = C/T. SCHINDLER. COLEY AND CODEWEST-ALL FIGHTS RESERVED -D NOT COPY OR DISTRIBUTE 6) In order to maintain the continuity of records involving subsequent exposures. all radiographs ‘xhbling penelrameters which qualfy the techniques permtied above must be retained ices esuetay 7-277.3 Shims Under Hole Penetramoters ; : ; ~ material radiographically similar to the weld metal penetrameter if needed " © - the radiographic density throughout the area of interest shall be no more than minus 15% from (lighter than) the radiographic derisity through the penetra : - the Shim dimensions shall exceed the penetrartieter dimensions such that the outine of at least three sides of the penetrameter image shall be visible in the radiograph hall be placed between the part and the Soles 2 7-280 EVALUATION 7-281 Quality of Radiographs ‘Al radiographs must be free froin mechanical, cherticl, or other blemishes to the extent that they do not mask and are not confused with the imagé of any discontinuity in the area of interest of the object Being radiographed Such blemishes include, but are.net limited to: - Sogait a et “processing defects such as streaks, watermarks, or chemical stains Eeratches, finger marks, crimps, dtness, static marks, smudges, oF tears € “false Indications due to defective screens 17-282 Radiographic Density 71-282. 1 Density Limitations. The transmitted film density through the radiographic image of the body of the appropriate hole penetrameter or adjacent to the designated wire of a wire penetrameter and the area of interest shall be: 2 AL& minimum for single fim viewing for radiographs made with an X-ray source 72'0 minimum for radiographs made with a gamma ray source [For composite viewing of multiple fim exposures, each film of the composite set shall have a minimum density of 1.3 - The maximum density shall be 40 for either single or composite viewing {A tolerance of 0.05 in density is allowed for variations between densitometer readings -282.2 Density Variation |A) If the density of the radiograph anywhere through the area of interest varies by more than minus "15% of plus 30% from the densiy through the body of the hole penetrameter of adjacent to the designated wire of the wire panetiameter, within the minimum / maximum allowable density ranges specified in T-262.1: ‘afGedtional penetrameter shall be used for each exceptional area and the radiograph reteken “ihn calculating the alowable variation in density, the calculation may be rounded to the nearest (01 within the range specified in T-282 4 'B) when shims are used the plus 30% density restriction of (a) above may be exceeded: ~ provided the required penetrameter sensitivity is displayed and the density limitations of | T- 282.1 are not exceeded ” “COPYRIGHT 2000 ~ IRCIT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE onREVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDL Ccorruc 20007 REVT. SCHINDLER, JW. GOLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT Gr ‘OR DISTRIBUTE. F-28310! Sensitivity Radiography shatt be performed with 2 technique of sufficient sensitivity to display -the hole penetremeter image and the specified hole “of the designated wire of a wire penetrameter = the radiographs shall play the ID numbers and letters Tine lets noe penelrameter mage and specTied hole, or designated wiro, do not show on any fim in multiple fim technique, but do show in composite fm viewing, interpretation shall be permited only by composite fim viewing i 1-284 Excessive Backscatter (Show ge Date bilfe. = Hfalight image of the "B" appears on a derker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable ~ A dark image of the "B" on a lighter background ie not cause for rejection. 7-285 Geometric Unsharpness Limitations Shall not exceed: Material ug B “Thickness in inches Maximum in inches Under 2" 0.020" — 2a» 2 through 3” : 0.030" Over 3" through 4” 0.040 Groaterthan 4” ss 0.070 NOTE: Material thickness is the thickness on which the penetrameter is based 7-286 EVALUATION BY MANUFACTURER This paragraph was added in the 1998 Addends to clearly refiect that frm review consists of two separate and distinct elements — 1.) A Technique Review — 2) Evaluation and Interpretations ofthe indications present on the film ‘The review form documenting the acceptability of the technique must be completed prior to the evaluation on the film Both sheets must be completed and accepted prior to submittal to the Inspector 7-290 DOCUMENTATION 7-291 Radiographic Technique Details. Details of the radiographic examination technique used shall be documented. As @ minimum the information shail inciude. identification. eg job or heat number “data specified in T-275 3 when applicable (dimensioned or ID marker map) = number of exposures or radiographs ~ isotope or maximum X-ray voltage used + effective focal spot size or physical source size “material type and thickness, weld thickness, weld reinforcement thickness minimum object-to-fim distances film designation and manufacturer COPYRIGHT 2000 INIT SCHINDLER. JW. COLEY AND CODEWEST- ALL FIGHTS RESERVED -D0 NOT COPY OF DISTRIBUTE 12REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000- ROT. SCHINDLER, J W.COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE : - nufnber of films per cassette fs ~ single- or double-wail éxposuré i single: or double viewing. 7-282 Radiographic Review Form # ‘Manufacturer shall prepare a radiographic review form. This form must contain at least: a) Alisting of each film location. b) The information in T-291 or by reference. ¢) Evaluation and disposition of each weld or material d) Name of the Mfg's representative that accepted the film. ge e) Date - Be atiched ele spel daa jeeh on te Ty ec eaters alec Sk Peipy at 1 # baat. Chad ty Lorre or doe bon, Lp at 4 Sree COPYRIGHT 2000 IRCIT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -D0 NOT COPY OF DISTRIBUTE. 3REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER oPrnicus i900 Rar SCHINDLER. JW EOLEY AND COOEWEST ALLRIGHTS RESERVED -DO NOT COPY OR DISTRISUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW REQUIREMENTS FOR ULTRASONIC EXAMINATION OBJECTIVE: _FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT REQUIREMENTS FOR ULTRASONIC EXAMINATION, REFERENCE: ASME SECTION V, ARTICLE 5 J-810-SCOPE “This Article describes or references requirements which are to be used in selecting and developing ultrasonic examination procedures when examination to any part of this Article is a requirement of a referencing Code Section ‘The referencing Code Section shall be consulted for specific requirements for the following: = Personnel Qualification / Certification Requirements, = Procedure Requireinents/techniques = Examination System Characteristics = Retention and Control of Calipration Blocks ~ Acceptance Standards to Be Used for Evaluation - Extent and Retention of Records = Report Requirements ~ Extent of Examination and/or Volume to be Scanned 7-820 GENERAL REQUIREMENTS 7-521 BASIC REQUIREMENTS AND TERMS USED - Use with requirements of Article 1 = Definitions of terms used are in: =a) Mandatery Appendix Il which will send you to: b) SE-1316 (now @ general section on definitions as of the 1994 addenda) - The SA. SB & SE documents referenced are in Article 23. ‘Some commen definitions are given below: ‘A-scan ~ a method of data presentation utilizing a horizontal base line that indicates distance, or time, and a vertical deflection from the base fine which indicates amplitude back reflection — indication of the echo from the far boundary of the material under test ‘contact inspection — the method in which the search unit makes direct contact with the material, with a minimum couplant fn couplant --a substance used between the search unit and test surface to permit or improve transmission of ultrasonic energy. crystal — a piezoelectric element in a probe or search unit duel search unit {twin probes) -— 2 prabe or search unit containing two elements. one a transmitter the other a receiver (T-R. S-E) echo — indication of reflected energy initia! pulse --- the response of the ultrasonic system display to the transmitter pulse (sometimes called the “main bang” ) interface —- the boundary between two materials 2 oss of back reflection — an absence or significant reduction in the amplitude of the indication from tne back surface of the part under examination multiple back reflections —- successive refiections from the back surface of the material under examination normal incidence (straight beam)—- @ condition in which the axis of the ultrasonic beam is perpendicular to the entry surface of the part under examination COPYRIGHT 2000 IRCIT SCHINDLER, JW. GOLEY AND CODEWEST -ALL RIGNTS RESERVED .00 NOT GOPY OR GISTRISUTE 14REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER 2 ‘coprruGit 2000= RGM. SCHINDLER, JM. COLEY AND CODEWEST-ALL RIGHTS RESERVED -DO NOT COPY Of DISTIUBUTE pulse echo method — an inspection method in which the presence and the position of a reflector are indicated by the echo amplitude and time. reference block — a block used to establish a measurdifieht Scale, and a means of producing 4 * ' reflection of known characteristics. i PEEeEEEEet ~ >seanning — the relative movement of the search unit ovér.a test piece. iz searéh unit — a device incorporating one or more transducers. straight beam — a vibrating puise wave train traveling normal tothe test surface. BMG wee ee fransducer — an electro-acoustical device for converting electrical energy into acoustical energy and vice verse Ultrasonic — pertaining to mechanical vibrations having frequency greater than approximately 20,000 He faueratrange 6s t-1 YM) 4 PERSONNEL REQUIREMENTS (FROM API-650, SECTION 6, PARA 6.3.3) Personnel performing the UT examination chall be qualified as required by the referencing Code Section. ( API 853 and API 650 in our case ) Examiner performing UT shall be: - qualified and certified by the manufacturer, Rat peer ~as Level il or Level iil sai 7 : cperASNT SNT-TC-1A = shold ne stat fig b bay (AsMg Vil - Laval 's may be used if: a) given written acceptiteject criteria prepared by a Level Il or Ill b) must be under the direct supervision of a Level It or Itt . au 7-522 WRITTEN PROCEDURE REQUIREMENTS ae) UT examination shall be performed in accordance with a written procedure, Each procedure shall contain at least the following: i “weld types and configuration to be exatnined including thickness dimensions, materials, and product form (casting, plate, etc.) = surface or surfaces from which the examination shall be performed - surface condition = couplant “technique (straight beam, angled beam, contact and/or immersion; angles and modes of wave propagation in the material; : - search unit type, frequency, and transducer size(s) - special search units, wedges, shoes, or saddles ultrasonic instrument type(s) - description of calibration blocks and technique - directions and extent of scanning ~ data to be recorded and method of recording (manual or automatic) = automatic alarm and recording equipment, or both - rotating, revolving, or scanning mechanisms = post examination cleaning ‘COPYRIGHT 2000 ~IRGI. SCHNDLER. JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 15REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER copmmichr2000- RTT SCHMNDLER,JW COLEY AND CODEWEST -ALL RIGHTS RESERVED - DONOT COPY OR DISTRIBUTE 7-523 GENERAL EXAMINATION REQUIREMENTS (FOR OTHER THAN THICKNESS MEASUREMENTS) 7-523 1 Examination Coverage = Scan the entire examination volume by moving the search unit over the examination surface Each pass shall overlap a minimum of 10% of the transducer dimension perpendiculer to the direction of scan 7-523.2 Rate of transducer movement = not to exceed 6" / sec unless calibrated at a higher speed 7-523 3 Record of Sensitivity Level - recording of indications shall be made with respect to the reference level 7-530 EQUIPMENT & SUPPLIES 7531 FREQUENCY « shall use pulse echo instruments generating frequencies of at ieast 1 MHz to 5 MHz “other frequencies may be used if equal or better sensitivity can be demonstrated and documented 7-832 SCREEN HEIGHT LINEARITY Instrument shall provide: «linear vertical presentation within + 5% of the full screen height for 20% to 80% of the calibrated ‘screen height [base line to maximum calibrated screen point(s)] 7-533 AMPLITUDE CONTROL LINEARITY Instrument shall utilize an amplitude contrat accurate over its useful range to plus or minus 20% of the nominal amplitude ratio «Shall allow measurements of indications beyond the linear range of the vertical display on the screen Appendix Il provides procedure for evaluating amplitude control linearity «shall be checked the lesseraf. = before each period of extand@ use or every three months 7-534 EQUIPMENT CALIBRATION «= checks shail include function of the entire examination system - ~ calibrate using a calbration standard «at the beginning of each exam = when examination personnel are changed any time 2 maifunction is suspected “re lest all areas tested since last calibration if mattunction is 7-536 SEARCH UNITS. 2) may contain single or dual transducer elements b) contoured contact wedges may be used fused calibration must be done using the wedges to be used during examination coPvRIGhT 2000~iRGIT SCHINOLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 16REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CoPvRIGHT 2000 RGM SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DONOT COPY OR DISTRIBUTE. T-540 APPLICATIONS Temes us | Several sparifc requirements are given here as related to product form. The specifications referenced are intended for inspection of new materials to be delivered and used in fabrication of new equipment. In seme cases the intended use of the equioment is relevant An examole is SB-509 which is a requirement for inspection of piate for nuclear applications. The inspector should be aware of this as ew materials may be required for repairs and alterations but for the most part we are dealing with T- 54d 2g a general method of taking ultrasonic thickness measurements on equipment that is inservice “not new material to be used in new construction 7-544 THICKNESS MEASUREMENT Applicable Documents: Y= J = SE-114 and SE-797) ~ ‘2) A brief outline of SE-797 is below. Know the location and general scope of both -SE-797 Standard Practice for Thickness Measurement by Manual Contact Ultrasonic Method Significant areas of docurnent 1. Scope Le GBs = for contact puise-echo method + 3 sat temperature <200°F 13.3 ¢ / = in any material in which ultrasonic waves will propagate at constant velocity and “in which back reflections can be obtained and resolved 4. Significance and Use for use at less then 200°F “measurements made from one side only “Used to determine wall thinning from erosion and corrosion 5 Apparatus Flaw detectors.with CRT readout “Flaw detectors with GRT and direct thickness readout = Direct thickness readout — >/< 6 Procedure - Calibration and Adjusiment of Apparatus ~ Contains descriptions of calibration methods for the following: = Case | — Direct Contact, Single-Element Search Unit “Case it - Delay Line Singla-Element Search Unit ~ Case Ill - Dual Search Unit -———_ Ly ~ Case IV - Thick Sections te 7 Technical Hazards op ete cet “surface conditions - roughness Timaterial properties - velocity and attenuation -8 ad . “Scanning speed - for equipment and operator capabilities Sean “part geometry - parallel surfaces, curved surfaces wt “temperature - high temperature correction an = instruments - base linearity check back reflection wavetrain: ~ reduction of error in direct readout instruments «Calibration blocks with equal attenuation characteristics “use instrument with automatic gain control - ORT display recommended for rough, pitted and corroded surfaces caution on use of direct readout equipment in certain conditions - calibration on actual material to be checked at a point of known thickness; @ Procedure Requirements = See T-522 also @ Report - See T-590 also COPYRIGHT 1000 =IRGIT SCHINDLER. JW COLEY AND GODEWEST ALL RIGHTS RESERVED -00 NOT COPY OR DISTRISUTS 17REVIEW OF ASME SECTION V NDE REQUIREMENTS - 7. SCHINDLER copynicht 20 RET SCHINDLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DONOTCOPYOROISTRIEUTE > ‘7-880 EVALUATION 7-581 EXAMINATION USING DAC (DISTANCE AMPLITUDE CORRECTION CURVE) any reflector causing an indication over 20% of DAC must be investigated to the extent that t'can be evaluated in terms of the acceptance standard 7-590 REPORTS AND RECORDS - 2 report shall be made = report shall include: ~ welds or area examined (may be a sketch) -focation of each measurement taken operator for exam or each portion of exam (See T-593), 7-592 CALIBRATION RECORDS caliorations in accordance with T-530 shall be included “system calibration requirements in accordance with T-534 shall be included calibration block identity shall be included 7-593 EXAMINATION RECORDS Identity and recor folowing information for each uitrasonic examination: . = procedure “Uhrasont examination system (equipment) “examination personnel identity and level “Calibration sheet entity . “identification and location of weld or volume scanned “Rurface from which exeminaton is conducted TTnap oF record of nications detected or areas clear Tete ond ime examination were performed ——— gy ~~ couplant io ~ basic calibration block identification io Pome Et “urace eorsition : - : “irequency z "special equipment Pett mold 7-594 EVALUATION RECORD Records of any evaluations of indications shall be maintained and documented coPrmicHT 2000 REM? SCHNDLER. JW. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR OSTRIGUTE 18REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER COPYRIGHT 2000 |RETT SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW REQUIREMENTS FOR LIQUID PENETRANT EXAMINATION OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT REQUIREMENTS FOR LIQUID PENETRANT EXAMINATION. REFERENCE: ASME SECTION V, ARTICLE 6 7-600 INTRODUCTION ‘ - PT is effective method for detecting discontinuities open to the surface of nonporous metals - Typical detectable discontinuities: Roo = cracks: Bestel Ee 7 8BAME oR tore ot mes, “ -laps , ren “cold shuts slaminations ciamingtione Principles “ penetrant applied to surface and allowed to enter discontinuity “excess penetrant removed = partis dried = developer applied a : “developer acts as blotter to absorb penetrant and as contrasting background + peroscore = ere! Becher! alin f pas spe T5101 Liquid penetrant examination techniques describe in Article 6 shall be used when specified by the referencing Code Section Listed SE Standards (ASTM) Provide details which may be considered in specific procedures - SE-165, Standard Practice for Liquid Penetrant Inspection Method * SE-1209. Standard Test method for Fluorescent Penetrant Examination Using Water Washable Process - SE-1219, Standard Test method for Fluorescent Penetrant Examination Using Solvent Removable Process _ SE-1220. Standard Test Method for Visible Penetrant Examination Using the Solvent Removable Process - Use PT method as described in Article 6 togather with Article 1, General Requirements Definition of terms = Found in Mandatory Appendix | of this Article which will send you to SE-1316 COPYRIGHT 2000 -IRGPT SCHINDLER. JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT GOPY OR O:STRIGUTE 19REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2000- CIT. SCHINDLER, JW. GOLEY AND GODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 7-620 GENERAL 7-621 Procedure T-621 1 Initial Procedure Procedure Minimum Information: - the materials, shapes, sizes, to be examined and extent of examination - type of each penetrant, penetrant remover, emulsifier, and developer - details for pre-examination cleaning and drying including the cleaning materials used & minimum drying time processing details for applying penetrant, dwell time, and the temperature of the surface to be ‘examined and the penetrant during the exam if outside 60F to 125F range (NOTE: should be 50°F - committee error) ate - = processing details for removing excess penetrant from the surface, and for drying surface before applying developer - processing details for applying developer and length of developer time before interpretation - processing details for post-examination cleaning “Ss 1-621 2 Procedure Revision Revision 6 procedure may be required when: = change or substitution is made in the type or family group of penetrant materials, or in processing techniques - 2 change or substitution is made in the type of precleaning materials or processes, ~ any change in part processing that can ciose surface openings of discontinuities of leave interfering deposits, such as use of grit blast cleaning or acid treatments 7-630 EQUIPMENT 7-831 Penetrant Materials - Include all penetrants, solvents, cleaning agents, developers, etc. used in the process +. 7-640 REQUIREMENTS - 7-641 Control of Contaminants || ~required for penetrant materials when used on | cnicket based alloys, austenitic stainless steels, titanium eh toy. ss0""7-642 SURFACE PREPARATION °°" 7 @ Awa, ‘A) When as welded, 2s cast, or as rolled congilion is not satisfactory preparation by grinding, ‘matehing or other methods may be required 8) Prior to examination the area to be examined and all adjacent areas within 2t least 1 inch shall be {ee of matter that can interfere with the examination ) Cleaning agents may be used to remove matter that wil interfere with the examination 1) Cleaning agents must meet the requirements of T641 i applicable 7-643 DRYING AFTER PREPARATION - after cleaning drying may be accomplished by evaporation or forced hot or cold air minimum time must be established to assure cleaning agents dry prior to applying penetrant COPYRIGHT 2900 - REIT SCHINDLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 20REVIEW OF ASME SECTION V'NDE REQUIREMENTS -T. SCHINDLER ‘COPYRIGHT 2000~ IRCIT SCHINDLER, JW. COLEY AND CODENEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE, ‘7-60 PROCEDUREITECHNIQUES: 7-851 Techniques: Six liquid penetrant techniques: = color contrast (visible) penetrant water washable = post-emulsifying -solvent removable - fluorescent penetrant: water washable = post-emulsifying - solvent removable 1-852 TECHNIQUES FOR STANDARD TEMPERATURES ard ermperature range: 80°F 0 1289F —— "Sot - local heating and cooling is permitted au 7-853 TECHNIQUES FOR NON STANDARD TEMPERATURES =<“ 853 1 General -below 50° F or above 125° F {procedure qualified for standard ranges must be requaiified for non standard ranges comparator is usad for nonstandard qualification -853 2 Liquid Penetrant Comparator - specific requirements for making comparators are given ‘1653.3 Comparator Application - specific requirements for qualifying procedures for nonstandard temperatures are given 7-864 TECHNIQUE RESTRICTIONS fluorescent penetrant shall not follow a color cantrast examination { intermixing of penetrant materials from different families or manufacturers not permitted “retest with water weshable penetrants may cause loss of marginal indications 7-670 EXAMINATION 7-671 PENETRANT APPLICATION ~ by any sultable means Be bbe em ee wa l Oy “dipping, Spraying. or Brushing < ( “Compressee-er ype spray requires aibe fered to Keep out contaminants <9" 7-672 PENETRATION TIME = Critical = minimum time as shown in Table T: = as qualified by demonstration 72 oF aS COPYRIGHT 2000 = NFT-SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY Of DISTRIBUTE 24REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER ‘GOPYRIGHT2000~ GIT. SCHINOLER, JW. COLEY AND CODEWEST ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE 1-673 EXCESS PENETRANT REMOVAL 7-673.1 Water Washable Penetrants ~ remove with water spray = pressure 50 PSI or less = temperature 110F or less 43.3 ¢ 7-673 2 Post-Emulsifying Penetrants - apply emulsifier by spray or dipping cee ~ emulsification time shall be qualified by actual tests <~ . = remove by water spray using same process as for washable penetrants 1-673.2 Solvent Removabie Penetrants = ramove by wiping with cloth or absorbent paper = traces removed by cloth or absorbent paper moistened with solvent = FLUSHING SURFACE WITH SOLVENT IS PROHIBITED \ SPROHIBITED < __s) 1-674 DRYING AFTER EXCESS PENETRANT REMOVAL ‘A) Water washable or post-emulsifying technique: = Blot with clean materials or by circulating air Air o not raise surface temperature above 125F B) Solvent Removable Technique: = Dry by normal evaporation, blotting, wiping, or forced air 1-675 DEVELOPING - apply as soon as possible efter penetrant removed = time interval to not exceed time per procedure i = insufficient coating thickness may not-deawout penetrant —_ = excess coating thickness may mask indications ===) “use only wet developer with color contrast pehetrants ae “wet or dry may be used with fluorescent penetrants -875. 1 Dry Developer Application = powder dusted evenly over entire surface to be examined, = apply to dry surface only ~ apply by soft brush, hand powder bulb, powder gun. or other means 7-875 2 Wet Developer Application ‘Must agitate suspension type prior to application. Ensure adequate dispersion of suspended particles ‘A) Aqueous Developer Appiication = apply to either wet or dry surface = apply by dipping, brushing, spraying, or other means = thin coating needed over entire surface = dry time may be reduced using warm air so long as surface does not exceed 125F = blotting not permitted B) Nonaqueous Developer Application = apply only to dry surface ~ apaly by spraying can apply by brushing where safely or access preclude spraying = dry by normal evaporation 7-675 3 Developing Time for Final Interpretation = begins immediately after application of dry developer «= begins as soon as wet developer coating Is dry COPYRIGHT 2000 ~IRC/T SCHINDLER. J. COLEY AND CODEWEST -ALL RIGHTS RESERVED 00 NOT COPY OR DISTRIBUTE 22REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINOLER COPYRIGHT 2000 = IRETT SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR O'STRIBUTE 7-676 INTERPRETATION ‘T-676.1 Final Interpret Thelin Ita Borrnutos after developing time Jeed-out does not alter examination results surface (letge area) can nov he cone within orescribed time 7-676 2 Characterizing Indication(s) if penetrant diffuses excessivaly into developer and discontinuities difficult to evaluate, close ‘observation af formation of indications should be done. -678.3 Color Contrast Penetrants - Developer forms uniform white coatir * Bleed-out indicate discontinuities - usually deep red color ~ Light pink color indicates excessive cleaning = Inadequate cleaning may leave excess background ~ Adsgunte iluminalin is fequred to insure adequate senstivty =. head f- val T-676 4 Fluorescent Penetrants Essentially same as Color Contrast process above except examination is by using Ultraviolet Light (black light) Perform examination as follows: ~ In darkened area Examiner in darkened ares 1 minute prior to performing examination i 1 Glasses of lenses wom by examiner shall not be photosensitive ——"\w/~ «Blacklight shall be warmed up minimum of 5 minutes before use or measurement of the intensity of the UV light emitted - Measure biack-light with black light meter * Minimum of 1000 Wisq. cm on surface of part required = Measure intensity at least once every 8 hours ke ‘7-680 EVALUATION T6804 |A) Al indications shall be evaluated in terms of acceptance standards B) Discontinuties at surface will be indicated by blee-out of penetrant "Surface irregularities may produce false indications C) Broad areas of fluorescence or pigmentation can mask Indications ~ Such areas must be cleaned and reexamined ¥-890 DOCUMENTATION Shall be in accordance with referencing Code Section |v COPYRIGHT 2000 -IRCIT SCHNDLER. JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED D0 NOT COPY OR DISTRIGUTE 23REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2000 IRGIT SCHINDLER, JW. COLEY AND CODENEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-741 SURFACE PREPARATION & ENHANCEMENT A) Results ususlly satisfactory when surfa concition ~ Grinding or machining may be necessary where surface iregularities could mask indications .. discontinuities B) Prior to examination: examine surface and all adjacent areas within 1 inch shall be dry, free of dirt ‘grease, Int, scale, welding fiux, weld spatter, paint, ol, and other extraneous matter that could Interfere with the examination ©) Typical cleaning agents: detergents, organic solvents, descaling operations, and paint removers. degreasing, sand or grit blasting, or ultrasonic cleaning methods also may used __-- D) IF coatings left on part, it must be demonstrated that indications can be detected through the 1) maximum coating thickness = When temporary coatings are used to enhance particle contrast it must be demionstrated that ol indications can be detected through the enhancement coating 9. asccast of assforged 7-750 PROCEDURE / TECHNIQUE MT examination procedures shall be based on following information: =the materials, shapes, or sizes to be examined, and the extent of examination 1 + magnetization techniques used equipment 1o be used for magnetization + surface preparation ( finishing and cleaning) “type of ferromagnetic particles to be used: manufacturer, color, wet or dry, ete * ~ magnetization currents ( type and amperage) sdemagnetization cen care stew Arce 2 we! 7-751 METHOD OF EXAMINATION Examination shall be done by the continuous method. “the magnetizing current remaining on while the examination medium is being applied and while the excess of the examination medium is being removed 7-752 TECHNIQUES AND MATERIALS - Ferromagnetic particles shall be either wet or dry = May be either fivorescent or nonfluorescent = One of more of five magnetization techniques shall be used = prod technique -———~ pee ae “longitudinal magnetization technique ries - circular magnetization technique = yoke technique —~ ‘multidirectional magnetization technique COPYRIGHT 2000 IR¢rT SCHINDLER. JW COLEY AND CODEWEST ALL RIGHTS RESERVED -D9 NOTCGPY OR DISTRIBUTE 25REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000-IRCTT. SCHNOLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-753 MAGNETIZING FIELD ADEQUACY AND DIRECTION 1-753.1.1 Pie Shaped Gauges - Place gage on part surface - Clearly dafined line across copper face of indicator indicates suitable flux or field strength = When clearly defined line not present, the magnetizing technique shall be changed or adjusted - Best used with dry particles 7-753.1.2 Other Methods Used to Verify Field Adequacy * = Astificil Flaw Shims - Hall Effect Tangentialfield Probe rv zee Mee ee M, sort 1-753 3 Magnetic Field Direction -Adequacy and Direction of the field can be verified using indicators or shims only with longitudinal, circular, or mult-directional techniques. 1-754 RECTIFIED CURRENT A) when direct current is required rectified current may be used, Rectified current shall be either 3- phase or single-phase B) amperage required with 3-phase, full rectified current / verified by measuring average current C) Amperage required with single phase current / veriied by measuring the average current during the ‘conducting half cycle only. ‘1-755 DEMAGNETIZATION Do any time after completion of examination if residual magnetism in the part could interfere with subsequent processing. 7-760 CALIBRATION OF EQUIPMENT 1-761 Frequency of Calibration (for equipment with ammeters) A) Frequency: ~ Calibrate each piece of equipment at least once per year «Calibrate prior to frst use after major electrical repair, periodic overhaul, or damage B) Procedure: accuracy of meter verified annually by equipment traceable to a national standard Take readings at 3 cifferent current out put levels encompassing the usable range ©) Tolerance: Uni’s meter, reading shall not deviete more than #10% full scale. relative to the actual current value shown by the test meter T-762 LIFTING POWER OF YOKES A) - Check magnetizing force once per year - whenever a yoke hes been damaged = Ifnot used for one year, check before first use £8) - Alternating current yoxe shall have a iting power of atleast 10 LB at the maximum pole spacing to be used — ) - Direct current yoke or permanent magnet yoke shall have a liting power of at least 40 LB at the maximum pole spacing to be used — D) - Test weights to be weighed with a scale from a reputable manufacturer and ste the applicable nominal weight prior to its first use - Verify weight only if damagad in a manner that could have caused potential weight loss ‘led with COPYRIGHT 2000 -IRCrT SCHINDLER, J\W. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE. 26REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER Ccopynichr 000 ROMY SCHINDLER, JW ESLEY AND CODEWEST- AL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-770 EXAMINATION 7-771 DIRECTION OF EXAMINATION = Perform 2 separate examinations on each area “punng 2nd examination, lines of magnetic ux shall be approximately perpendicular to those used during tst examination -Adifferent technique may be used for 2nd examination 7-772 EXAMINATION COVERAGE = Conduct with sufficient overlap to assure 100% coverage at required sensitivity (SEE 1-763) 1-73 PROD TECHNIQUE T-T734 Magnetizing Procedure = Magnetize by portable prod type electrical contacts pressed against area to be examined Avold areitg via remote switch that is operated oniy after prods have been properly posiioned -773.2 Magnetizing Current - Direct or rectified magnetizing current shall be used = Current shall be 100 (min) ampfin. to 125 (max) ampiin. of prod spacing for sections > 3/4” = Current shall be 90 amp/in to 110 amplin. of prod spacing for sections < 3/4” 1-773.3 Prod Spacing - Space shall not exceed 8 in "shorter space to accommodate geometric limitations orto increase sensitivity “Prod spacing less than 3 in. usually not practical, Particles band around prods Keep prod tps clean and dressed : “if open circut voltage is greater than 25 volts, lead, steel, or aluminum (rather than copper) tipped prods ere recommended to avoid copper deposits on parts being examined. = Magnetic field adequacy shall be verified using a using 2 “Pie Gage" (See T-753 & Fig T-775.2) 1-776 YOKE TECHNIQUE 1-776.4 Application i ‘Shall only be applied to detect discontinuities that are open to the surface of the part T-776.2 Magnotizing Procedure ~ Alternating or direct current electromagnetic yokes, or permanent magnet yokes, shall be used 1-778 1 Non-Flucrescent Examinations must have 0 fe (500 ix) light intensity eee 1-778 2 - Fluorescent Particles, = - Examination performed using ultraviolet or “black light” as folows: ~in a derkened area + examiner shall be in darkened area for 5 minutes prior to exam “examiners glasses or lenses shall not be photosensitive ~biack light” warmed up for min of 5 minutes or intensity measured “black light” intensity shall be 2 minimum of 1000 jx W/cm? on the part surface + intensity measured every 8 hours or when work station changed COPYRIGHT 2000 ~IRCIT SCHINDLER, JW. COLEY AND CODEWEST . ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 27REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2600 ~IRGTT. SCHINDLER, JW.COLEY AND CODEWEST ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 7-780 EVALUATION ‘A) - Evaluate all indications in terms of acceptance standards of the referencing Code Section 8) - Discontinuities on or near surface indicated by retention of the examination medium ~ False indications may exist because of localized surface irregularities due to machining ‘marks of other surface conditions ) - Particle accumulations in broad areas might mask indications and are prohibited ~ Such areas must be cleaned and reexamined 1-790 REPORTS, 7-791 Mutidirectional Magrietization Technique Sketch Technique skatch shall be prepared for each different geometry examined {Sketch to show the part geometry, cable arrangement and connections, magnetizing current for each circuit, and the areas of examinatic quate field strengths are obtained - Parts with repetitive geometry but different sizes can be examined using one sketch, provided the ‘magnetic field strength is adequate when demonstrated using the magnetic particle field strength indicator. (SEE 1-7772) Sp leer * inp fae ead : Rad T3794 (longs trdinel Meynels gad YD SY Ange chen . 35.088 (lp )a a. ion Techn vague J Save pT S483 é Yn <4 Ampitun . US ev ee Bh COPYRIGHT 2000 -IRCIT. SCHINDLER, JN, COLEY AND CODEWEST- ALL RIGHTS RESERVED -DONOT COPY OR DISTRISUTE 28REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000 IRCIT. SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ALL QUESTIONS ARE CLOSED BOOK ASME SECTION V PRACTICE QUESTIONS NOTE: Some questions in this section are true/false or essay type questions, instead of multiple choice Historically, it has been shown that test questions on ASME V involves a good deal of theory that cannot adequately be explored through multiple choice questions (although multiple choice questions oniy will be on the test) - 1. Afilmside penetrameter can be used for: A. inaccessible welds ( unable to hand place a source penetrameter) B allwelds all Castings at any time D_ analternative to a source-side wire penetrameter 2. Adark image of the “B" on @ lighter background is ‘A. Acceptable B. Rejeciable © Sometimes rejectable D_ None of the above 3. One of the procedural requirements for conducting PT is to address the processing details for A. Postiexamination cleaning B. Pre-examination cleaning Apply the penetrant D All of the above 4. Non-equeous developer may be applied to a wet surface. True or False (circle one) 5. The accuracy of a piece of magnetizing equioment that is equipped with an ammeter shail be verified A. Each year B Each two years When possibie D Every 6 months 6. When using fluorescent particles, the examiner shall be in a darkened area for at least minutes prior to performing the examination 7 10 9 1 vow 7 Awire penetrameter shall be placed adjacent to the weld, with the wires parallel to the weld True of False (circle one) ‘COPYRIGHT 2000 IREVT SCHINDLER, JW. COLEY ANO CODEWEST ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 23REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CcoPyRIGHT2000 = RCT SCHNDLER, JW. COLEY ANO CODEWEST-ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE. 8. A field indicator is composed of, low carbon stee! pie sections, fumace brazed together. A2 B6 c 10 DB 9 The type and amperage of magnetizing current must be identified on the written MT procedure True of False (circle one) c 10. Certification of contaminants shail be obtained for ail PT materials used on A. carbon steels B. Ferntic stainless steets . Austenitic stainless steels D_ None of the above 11 Black light intensity shall be measured with when conducting fluorescent PT. A. Dark room meter B Phot-meter Black light meter D_ None of the above 12. Astee! bar is 15" long x 3" in diameter What is the proper ampere/tums to be applied when using the coil technique? 45,000 = ampere tums A 4375 uo 8 5,000 ¢ 35,000 D 2,000 13. The location markers required by ASME V are required to appear as radiographic images. True or False (circie one) 44. DC yokes may be used for detecting subsurface discontinulties, per ASME V? True or False (circle one) 15. When coatings are applied to ennance contrast, the procedure must be demonstrated that indications can be detected through the coating True or False (circle one) 16 How many total liquid penetrant techniques are listed in ASME V? goer COPYRIGHT 2000 IRCIT SCHINDLER, JW. GOLEY AND CODEWEST -ALL RIGHTS RESERVED -09 HOT COPY OR OISTRIGUTE 30REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000 -IRG/T. SSHINDLER, JW. COLEY AND CODEWEST - ALL AIGHTS RESERVED -DONOT COPY OR DISTRIBUTE 17. Prior to examination, each adjacent surface shall be cleaned within at least * of the area to be examined ° 18. Weter washable penetrant shall be removed with a water spray not exceeding 60 psi and 100°F. True or False (circle one) 19. Emulsification time shall not exceed minutes, unless other times have been qualified by actual test. AS 8 10 c 45 B 20 20. Densitometers shall be calibrated by verification with a calibrated. A. Densitometer B. Step Wedge Comparison Strip C Light Meter D_ Transmission moniter : 21. If 6000 amp-turns are required to magnetize a part, how many amps are required for a §-turn coi? A 1000 B 6000 c 1200 D 100 22 Around steel bar is 14" long x7" diameter What is the proper amperage to be applied when using @ circular direct contact technique? (300 ~ 900 ampsfinch of diameter required) A. 4900 - 8300 B 2100-5600 © Sturns D_ 1500-1600 23 When a PT test cannot be conducted between 50° - 125°F, what must be done. per ASME V? A The procedure must be quaified B The surface must be re-cleaned © The test cannot be conducted D None of the aoove 24 The sulfur content of @ penetrant is measured to be less than 00259 This material is acceptable for use on A. Nickel-base alloys B Carbon steel C Ferftic steel D_ All of the above COPYRIGHT 2000 = IRCIT SCHINDLER, JW COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR ISTRIBUTE 34REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER . COPYRIGHT 2000 IREIT SCHINDLER, 4. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOTCOPY OR DISTRIBUTE 25. All indications are to be evaluated in accordance with, A. ASME Will 5B ASME V ©. The referencing Code section D. The written procedure 26. The scope of the ASME Boiler and Pressure Vessel Code, Section V includes: A. NDE acceptance criteria B_ How to perform NDE to achieve a desired result C. Where to do NDE (le., what welds to examine) D. Who can be the Al 27. UT equipment is calibrated? A. Before heat-treatment B. After completing the examination ©. Prior fo visual examination D. Prior to PT examination 28. What finished surface is required of butt welds for PT examination? ‘A. Smooth surface prepared by grinding B Cosmetically clean acid etched surface CG Anear white bast surface D None of the above 29. Apenetrameter is used on a DWE/DWV. The penetrameter selection is based on. A. The single wall thickness and weld reinforcement B Both wall thicknesses ©The single wall thickness for Sch 80 pipe D_ None of the above 30. Assuitable means for applying penetrant. A Dipping B Brushing C Spraying D Any orallof the above 31. What materais require the use of tested and certified liquid penetrants as tothe contaminants in the penetrant? A. Nickel alloys B. Austenitic stainless steel alloys © Fertiticimartensitic stainless ste! D Both A & 8, above 32. How shall indications be evaluated, ie , scceptance standards for RT A ToASMEV B To ASME Vill ©. ToB313 D. To the referencing Code section 33 Thicknass readings may be displayed on? coPraiGHT 2600 = RCI SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 32REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER coPyRioiT 2000—IRCIT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE A SRT B PRT c. CRT D. Strip chart recorder 34 How many copies of a procedure must be available to the Manufacturers Nondestructive Examination Personnel? 1 2 3 4 pom> 36. How shall Nondestructive Exemination Personnel be qualified? A To SNT-TC-1A B ToCP.189 ©. To referencing code requirements D TOACCP mules 36 Which NDE methods are considered “stirface” methods? A PT B RT Cc MT BD BothA& C above 37. What designation is used to indicate the penetrameter is on the film side? an"e an“€" oO an“FS" com> 38 What is 2 shim used for? A. UT field adequacy BRT field direction ©. MT field sirength and direction DMT field current applications 39. Why must the surface be closely observed during the application of the PT developer? A To ensure proper coating application B To ensure excess penetrant removal © To allow proper characterization of discontinuities D. To see the “groovy” lines form 40 One of the five magnetization techniques is? A. Round B Circular © Shearwave D. Halleffect Tangential-fietd 41. A true UT indication is one which exceeds A 20% of DAC ‘coPyRIGHT 2000 (Cr SCHINDLER. JW COLEY AND CODEWEST ALL RIGHTS RESERVED -00 NOT COPY ORDISTRIEUTE 33,REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER COPYRIGHT 200 =IRGIT. SCHINDLER, JW. GOLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE B 20% of CAD © 20% of DEC D. 10% of DAC 42. Name one typical discontinuity detectable by the magnetic particle method. A. Lack of penetration B. Interpass lack of fusion Slag inclusions D. Toe cracks 43. For a DWE/SWV RT Technique, a minimum of _, exposures shall be made oop 44, When are location markers placad on the film-side in SWV for curved surfaces? A. Concave side is toward the source B. Source-to-material distance greater than IR © Acobat source is used D Both A&B, above 45. Whats the difference between an inspection and an examination per Section V/ of the ASME Code ‘A. Inspection performed by Al 8 Examination performed by manufacturer's personnel ©. There is no difference between the two D Both &B, above 46. Geometric unsharpness is determined by: A UG=FuD © UG =fdd D UG=fid 47. UT Thickness velocities are usually obtained from: ‘A. Tim's Handy Velocity Book B Similar materials C. Similar product forms D Both B&C, above 48 Name one typical discontinuity detectable by the liquid penetrant method A IP onan NPS2 girth weld B_ IF atthe root of an NPS 2 girth weld CHAZ surface cracks on a NPS 2 girth weld 1D. Slag inclusions on a NPS 8 longitudinal weld 49. What is to be done to excess penetrant remaining on the surface after the specified penetration time has elapsed? A. It must be removed COPYRIGHT 2000 - RCT SCHINDLER. JW. COLEY AND GODEWEST -ALL RIGHTS RESERVED -BO NOT COPY OF DISTRIBUTE 34REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CoPvRiGHT 2000 “IRGIT. SCHINDLER. JW. COLEY AND CODEWEST - ALL RIGHTS RESEAVED -DO NOT COPY OR DISTRIBUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW REQUIREMENTS FOR MAGNETIC PARTICLE EXAMINATION OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT REQUIREMENTS FOR MAGNETIC PARTICLE EXAMINATION. REFERENCE: © ASME:SECTION V, ARTICLE T-710 SCOPE . = When specified by referencing Code Section, the MT techniques of this Article shall be used This Article generally in conformance with ASTM SE-709, Standard Recommended Practice for Magnetic Particle Examination - SE-709 provides additional details to be considered in the procedures used ~ Aricle 7 shall be used together with Article 1, General Requirements = Definition of terms used found in Mandatory Appendix Ii which will send you to SE-1316 1-720 GENERAL, ‘The magnetic particle method is appliad to detect cracks and other discontinuities on or near the surfaces of ferromagrietic materials, ty greatest for surface discontinuities ity decreases rapidly with increasing depth of discontinuity = Discontinuities detected typically are: ~ cracks ~laps = seams = cold shuts = laminations Principle: + Magnetizing an area to be examined ~ Applying ferromagnetic particles to the surface Patticlessfogt) patterns on surface! discontinuities cause distortions in normal magnetic field - Patterns 276 usually characteristic of type of discontinuity detected < Maximum sensitivity isto linear discontinuities oriented perpendicular to the lines of flux-— / "Examine each area twice for optimum effectiveness in detecting all types of discontinuities —> «Lines of flux during one examination to be perpendicular to lines of flux during the other 7-730 EQUIPMENT 4 ~ Suitable and appropriate means used to produce the necessary magnetic flux = Use techniques listed in T-751 and described in 7-770 7-731 EXAMINATION MEDIUM Ferromagnetic particles shall meet the following requirements: - Dry Particles: ~ adequate contrast with surface - specific requirements given in SE-70S =not used over 600° F - Wet Particles: = adequate contrast with surface - specific requirements given in SE-709 ~not used over 135° F ‘COPYRIGHT 5000~IRC/T. SCHINDLER. JW COLEY AND CODEWEST ALLRIGHTS RESERVED -DO NOT COPY OR DISTRISUTE 24REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER. COPYRIGHT 2000 -IROT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE B. Itcan remain on the part ©. Itmust be developed D. Itmust be femoved with water only 50. What must be done to ensure 100% coverage on any NDE method? 51. When surface irregularities may mask indications of unacceptable discontinuities, what is required? 52. List the type of discontinuities magnetic particle examination is effective in detecting 53. What are the six penetrant techniques to be used? 54. What are the approved methods of indicating UT thickness measurements? 55. How isthe “quali of a adiograph evalustes? 56. Where are RT locaton makers placed, on hepato on the radiograph? 57. Penetrameters may be of what Wo ype? 58, How many hoes are in a hole ype 10? 58. Whatidentty must aso be included inthe UT calraion records? 60. The peretvameters normaly placed on which ste of apart? 61. AAT hole on 220 penstrameter has a diameter of 62st 4ypes of blemishes ot permite on fn 53. When sa writen rediogretie procedure required by ASME V7 54. When should the developer be sped? 65. What type of discontinuity is the magnetic particle method most sensitive to? 66. What is the examination medium when using MT? What is the probing medium when using MT? COPYRIGHT 2000 IRC/T SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 35REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000~IRETT. SCHINDLER, |W. COLEY ANO COOEWEST-ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 67. When must ultrasonic equipment be calibrated? 68. How many penetrameters should appear on each radiograph, except for panoramic techniques? 69. Ave intensifying screens permitted for radiography per ASME V? 70. What two radiographic techniques are noted as available for examinations? 71. How can compliance with a written radiographic procedure be demonstrated? 72. List the type of discontinuity liquid penetrant examination is effective in detecting. 73. What must be done when a penetrant is to be applied on parts beyond 50 - 125°F? 74. The lifting power of yokes must be checked when? 75. How should wekled buttjoints be prepared for radiography? 76. Steel greater than * thick should be radiographed with a cobalt source a Tue b False 77 Inmagnetic particle examination of a welded joint using yokes, is alternating current or direct current allowed? 78. What method of Ultrasonic examination of the welds is permitted by the Code? 79. Name three different methods of conducting “Visual Examinations” (VT) 80. From what type of material should shims be fabricated when they are to be used to radiograph welds in pressure retaining itemis? is a device used to determine the image quality of Bt A radiograph a Astep wedge comparison film b Adensitometer c Apenetrameter di Allofthe above COPYRIGHT 2000 ~IRC/T, SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIGUTE 36REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER: [COPYRIGHT 2000 -IRCIT. SCHINDLER, J:W. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DONGT COPY OR DISTRIBUTE @ None of the above? 82. In accordance with Section V, wiretype penetrameters: a Cen always be used. b. Can be used unless restricted by the referencing Code. cc Can never be used. Can be used only with Type 1 film: 83. @ What is meant by “nondestructive examination” of a welded joint? Name four methods of nondestructive examination 84. Ina radiographic film of a weld, how are the following characteristics measured or judged? a. Film sensitivity or quality b Film density 85. What is radiography? 86. Whatis the minimum and maximum allowable density through the image of the penetrameter for radiographs made with: 3 A2000kV tube? . cobalt 60 (C080)? 87. Asingle fim technique was used to make a radiograph using 2 Gobalt-80 source, The minimum permitted density in the area of interest is a4o b 18 c 20 d 13 None of the above BB Under ASME Code Sedtion V, what upper and lower density limits are acceptable for viewing if the density through the body of the penetrameter is 2.77 Assume single fim viewing 89. As a radiographer is removing cassettes (film holders) from a weld seam that has just been rediographed, you notice that there is nothing attached to the back of the cassettes Would these radiographs be acceptable? Expiain your answer. COPYRIGHT 2000 -IRCIT SCHINDLER, JW COLEY AND GODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 37REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER COPYRIGHT 2000 -IRGTT. SCHINDLER, JW. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE ‘90 What is the minimum number of penetrameters required for the following: 18. Acomplete gith seam containing 20 rediographs shot witha single exposure? b. Twelve radiographs on a longitudinal seam shot from the outside with a single exposure? 91. A radiograph is made using an X-ray source, and two films in each film holder. Ifthe film is to be viewed separately the minimum permitted density would be: a 40 7 b 18 20 13 e None of the above? (92. Aweld with @ nominal thickness of 1.8 inch Is o be radographed using a fim side penetrameter ‘The penetrameter designation should be: (NOTE: This is an open book question) a ’ é 35 d_ Both a and b are acceptable? 93. (a}What are hole-type penetrameters and what are they used for? (b) What are wire penetrameters and what are they used for? 94 In radiographing a butt welded joint of 1” thicknass, on what side of the weld is the penetrameter normally placed? 985. What type of flaws may be detected by: Liquid Penetrant testing? Magnetic Particle testing? Radiographic exemination? Ultrasonic examination? 96. What is 2 densitometer used to determine? 97 @._ What is the purpose of shims when performing radiography? b Where are they placed? What kind of material may they be made from? 98. Describe how the following surfaces should be prepared for Ultrasonic examination: 2. Contact surfaces. b Weld surfaces, Base material COPYRIGHT 2090 -IRC/T SCHINDLER. JW. COLEY AND CODEWEST - AL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 38REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2t00 = 1ROTT SCHINDLER, 14 COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 99. Why are lead intensifying screens used in the X-ray examination process? 400. Name two radiation sources permitted for radiographic examination in ASME Boller and Pressure Vessel Code 401. When reviewing a radiograph, a dark image of the letter 8 can be seen on the film. Does this indicate an unacceptable radiograph? 102. Describe how liquid penetrant examination should be performed in order to detect discontinuities which are open to the surface, per Article 6 of ASME Code section V 403. a If penetrameters are not placed on the source side, what rules apply? bb For materials being radiographed other than welds, where are the penetranteters placed? 104. Ifthe density through the penetrameter is 2.50, what would the maximum _ allowable density and minimum allowable density be through the weld represented by this penny? 405. Ona set of cassettes containing film for a seam just radiographed you notice the lead location markers (ie, 1-2, 2-3, etc) are taped to the cassettes Would these radiographs be ‘cceptable? Explain your answer ASME V PRACTICE QUESTIONS ANSWER KEY alse o> mo>> COPYRIGHT 7000 = RCIT. SCHINDLER, J W.COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 39REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER copyrucirr2000 rT. SCHINDLER, .W.COLEY AND CODEWEST -AL RIGHTS RESERVED -D0 NOT COPY OR DISTRISUTE. 7. False an) 9 Tne wo OC un G 2 8B 130 The 14 False 16 Tne FOF ODOTF BOO> OOF OTTOFODBOOPDODY IED 43 50 _All examinations must overlap to ensure 100% coverage of the part 51 Grinding. machining, or other methods 52. Surface and slight subsurface indications 53 Color contrast or water washable a) water washable b) post-emulsifying ) solvent removable 54 CRT. Digital, or meter 55 _Abilty to see the prescribed hole or wire on the designated penetrameter and compliance with density requirements COPYRIGHT 2000 ROT. SCHNDLER. JW COLEY AND CODEWEST- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘40© REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER. CcopyicttT 2000 CMT. SCHINDLER, JW. GOLEY AND CODEWEST - ALL RIGHTS RESERVED - DO HOT COPY OR DISTRIBUTE 56 87. 58 59, 60 81 62. 63 65. 67 68 69 70 n 72 73 74 75. 76 77 78 79 80 ‘On the part Hole or wie types 3 Calibration biock identity Source side 80" a Fogging bb Processing defects Scratches, finger marks, etc False indications due to defective screens ‘When required by the referencing Code section ‘As soon as possible after penetrant removal Surface discontinuties aligned perpendicular to the magnetic field Ferro magnetic particles, magnetic fields, 2) Beginning and end of each examination b) When personnel are changed ©) Anytime matfunction is suspected ‘Atleast one on each radiograph Yes. except when restricted by the referencing Code Single wall and double wall By compliance with density and penetrameter image on the production or technique radiographs Surface discontinuities only ‘The procedure must be qualified using a quench-cracked aluminum block ‘At last once each year or ifthe yoke has bean damaged, ‘The weld ripples or surface irregularities on both the inside {if accessible) and outside shall be removed by any suitable process to such a degree that the resulting radiographic image due to any irregularities cannot mask or be confused with the image of any discontinuity. 15" thick Alternative current is used Pulse-Echo Shear Wave Ultrasonics a Direct indirect or (remote visual examination) c Translucent A shim shall be fabricated of radiographically similar material to the object to be inspected “COPYRIGHT 2600 =IRC/T. SCHINDLER. JW. COLEY AND CODEWEST- ALL RIGHTS RESERVED - DO NOT GOFY OR DISTRIBUTE atREVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER ‘COPYRIGHT 2060 -IRCIT SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE ar 82. 83 85 86 ar 88 89 90 a1 92 93 c A a An examination of a welded joint that will disclose surface and sub-surface discontinuities without physical harm to the welded joint Such exar tic conducted by radiography, ultrasonics, quid penetrant or magnetic particle testing b Radiographic Examination Uttrasonie Examination Magnatic Particle Examination Liquid Penetrant Examination. a Penetrameter b _Densitometers or step-wedge comparison films, ‘A radiograph is a shadow picture produced by the passage of X-rays or gamma-rays through an object onto a fim. When the rays pass through the object, part ofthe radiation penetrates the material and partis absorbed. The amount of radiation absorbed and the amount which penetrates are a function of the thickness of the material. Where a void or discontinuity exists, there is essentially less material to absorb the radiation. Therefore, more radiation will pass through this section and a dark spot corresponding to the projected position of the void will appear on the film y @ 18-40 (for any X-ray source) b —-2.0- 4.0 (for any gamma source) E ~The correct answer is ~15% from the transmitted density through the body of the penetrameter “15% = 2.295 430% = 3.510 No, as @ check on backscattered radiation, a lead symbol “B" with minimum dimensions of 4/2" height and 1/16" thickness shall be attached to the back of each film holder. if a ight image of the “B” appears on a darker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable A dark image on a lighter background is not cause for rejection a Requires at least 3 penetrameters spaced 120° apart b. Requires at least 12 penetrameters, one on each film 8 A (a) A penetrameter is a smal strip of material. fabricated of radiographically similar material to the object being inspected, and having a thickness of approximately 2% of the object being radiographed. The penetrameter has three holes in it The sizes of these holes are 17, 2T ‘and 4T where “T” is the thickness of the penetrameter The 27 is designated as the essentia! hole, 1 the hole whose image must appear on the radiograph Penetrameter thickness and essential hole size requirements are listed in tables in Section V of the ASME Code “The penetrameter is identified with a number made of lead which is attached to the penetrameter This number indicates the thickness of the penetrameter in thousandths of an inch COPYRIGHT 2000 -IRCIT SCHINDLER, JW. COLEY AND CODEWEST - AL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 42: Sarre REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER coPrwoitr 2000 - ROM. SCHINDLER, JW. COLEY AND COCEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘A penatrameter is used for evaluating radiographic technique in that It serves as an image {quality indicator, proper technique should display the penetrameter image and the specified hole, (©) Wire type penetrameters use thin wires to ascertain sensitivity instead of holes The ability to see the wire required by the Code indicates a quality radiograph 94 The panetrameter should be placed the source side of the material being radiographed. However, where inaccessibility prevents this, the penetrameter may _be placed on the film side of the material being radiographed provided a lead letter “F” at least as high as the identification number is placed adjacent to the penetrameter, 95 Surface discontinuities Surface and slight sub-surface discontinuities. ‘Surface and sub-surface discontinuities, Surface and sub-surface discontinuities noose 96. Adensitometer ( or step wedge comparison fim) shall be used for judging film density requirements Film density is a measure of overall readability 87 a_ Shims may be used when necessary to produce a radiograph in which the radiographic density throughout the area of interest is no more than minus 15% from (lighter than) the radiographic density through the penetrameter b.. Thay are placed under the penetrameter c. _Aradiogrephically similar material to that being examined 98 a, _The finished contact surface shail be free from weld splatter and any roughness that would interfere with free movement of this search unit or impair the transmission of ultrasonic vibrations bb _The weld surfaces shall be finished so they cannot mask or be confused with reflections from defects, and should merge smoothly into the surfaces of the adjacent base materials ¢ The volume of base material through which the sound will travel in angle bearn ‘examination shall be completely scanned with a straight beam search unit to detect reflectors which might affect interpretation of angle beam results 99 Lead foil intensifying screens used in the X-ray examination may be placed directly in front of the fim. The screen provides an intensifying action and, in addition, the back one acts as @ filter by preferentially absorbing backscattered radiation from the specimen thus improving image quality. 100. The two common radiographic sources in industria! use today are X-ray machines end attificially-produced radioactive isotopes éf certain metalic elements 101 No 402 The partis frst thoroughly cleaned of ol, dirt, etc., then a liquid penetrant is applied to the surface to be examined and allowed to enter the discontinuities. All excess penetrant is then removed. the partis cried, and a developer is applied The developer functions both 2s a blotter to absorb penetrant that has been trapped in discontinuities and as @ contrasting background to enhance the visibly of penetrant indications. The dyes in penetrants are either color contrast (visible under white light) of fluorescent (visible under ultraviciet light) 403. a _ The penetrameter should be placed on the source side of the material being radiographed However, where inaccessibility prevents this, the penetrameter may bbe placed on the fim side of the material being radiographed provided a lead ietier “Fat least as high as the identification number is placed adjacent to the penetrameter ‘COPYRIGHT 2008 = IRC. SCHINDLER. JW. COLEY ANO CODEWEST - ALL RIGHTS RESERVED - 00 NOT COPY 9 DISTRIBUTE 43REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER. ‘COPYRIGHT 2000 ET SEMNDLER, JW.COLEY AND CODEWEST-ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE For material other than weld a source side penetrameter shall be placed in the area of interest 104 Minus 15% to plus 30% allowed, 26+ 30%=25+ 75=3.25 25-15% =2.5-4= 2.125 405 No. Location markers that are to appear on the radiographic film should be placed on the part being examined and not on the cassettes COPYRIGHT 2000 =IRCIT SCHINDLER. JW. GOLEY AND CODENEST -ALL RIGHTS RESERVED -O0 NOT COPY OR DISTRIBUTE adREVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER: IRC © COPYRIGHT 2000- IRG/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE SOLVING API 510 CORROSION PROBLEMS: STEP 4 - Determine what question is being asked - “What is allowable internal inspection interval for conditions noted? What is corrosion allowance? How many more years may vessel operate within principals of ASME Code?” EXAMPLE: A60" id. pressure vessel in caustic service is measured at 375 thickness one year At the next inspection 5 years later the vessel has thinned to 200" From the above information when should the next internal inspection be scheduled per API §10 f the minimum thickness per ASME is 100"? STEP 2- From API 510-CORROSION = 375-.200= 175" CORROSION RATE = 2 = 035" Per Year 200 - 100 = 100" CORROSION ALLOWANCE REMAINING CORROSION RATE LIFE [STEP 3 - From API 510 - Where remaining safe life is less than 4 years, the inspection internal may be the remaining life up to a maximum of 2 years Internal inspection must be done at 2 years from last internal” STEP 4 - Answer the question - STEP 5 - Circle answer COPYRIGHT 2000 ~ IRCISGHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 18REVIEW OF ASME SECTION Vill . DESIGN - T. SCHINDLER IRC COPYRIGHT 2000. IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE. SOLVING FLAT HEAD CALCULATIONS STEP 1 - Define what question is being asked - "What is the minimum thickness of the head in question? Does the condition given comply with Code requirements?” STEP 2 - Goto UG-34 and Fig UG-34 and determine which picture applies to the condition given in the problem: EXAMPLE: “A fiat circular head of 24" I.D is attached by inside and outside fillet ‘welds as shown in UG-34 sketch f The head is made from SAS 16 GR70 material land the MAWP is 209 psig @ 500 deg. Assuming the filet welds comply with the Code and a"C" factor of 20, what is the minimum thickness required for this head?" STEP 3 - Goto applicable paragraph in UG-34. and solve accordingly tad fe 4, 1730681 28" 20 17,500 1=24X 047 E = 1 (no welds specified assume seamless) rete STEP 4 - Answer the question - “The minimum thickness required is 1.14" STEP 5 - Circle answer NOTE: The only hard thing about these calculations is finding the correct C factor and determining fillet weld size So far this information has always been given, but there's always a first time!!! COPYRIGHT 2000 -IRGISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE 7REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- IRGISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE SOLVING IMPACT TESTING PROBLEMS continued STEP 7 - Go to Fig, UCS-86 1 enter chart on left hand side at 288 - Read over to curved black ling and read straight down to bottom of page. This is the temperature reduction that may be apples to the -5 degree temperature we arrived at in Step 4. Therefore, -5 deg, minus 105 deg = Total of 110 deg F. which is lower than the expected operating temperature of 30 deg F STEP 8 - Answer the question - "Yes vessel can be operated at -30 deg F per requirements of UCS-86 without impact tests STEP 9 - Circle answer COPYRIGHT 2000 ~ IRGISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBL 16REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC (COPYRIGHT 2000-IRG/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED . DO NOT COPY OR DISTRIBUTE ‘SOLVING IMPACT TESTING PROBLEMS STEP 1 - Determine what question is asked - “Does the condition comply with Code? What is the minimum temperature allowed for the material given? Does this material require impact tests?” EXAMPLE: "An existing pressure vessel made of SA516 GR70 material (nocmalzed) is moved into a service where the lowest-expected operating temperature is -30 deg F_ If the material is 2" thick, 60"! D , and is spot radiogrephed with Type 1 joints. can this vessel be operated at the temperature given without impact tests. with a 250 psig MMAWP at S0°F7" (1/2" corrosion allowance is provided) STEP 2 ~ Determine if material is automatically exempted by UG-20(1) or UCS 68(b)(3) Not exempt per UG-20 (2 thick and colder than -20) Not exempt per UGS-65 STEP 3 - Goto Fig UCS-66. Determine what curve SAS16 GR70 is on curve D for normalized SA516 meterial. This is the most important step! Find tho right ‘material on the right curve! STEP 4 - Enter bottom of chart at thickness 2" - intersect curve D material at 2" - Read left to rin design temperature - Approximately -5 deg. This is warmer than allowed so we must see if we can reduce this temperature further as allowed by Fig. UCS 66 1 STEP 5 - Determine what thickness is being used versus how much is required as permitted in Fig UCS 66 + PR. Calculate t from information given per UG-27(c):t, = 350" OK 2 = 176, smaller than 250, (7t,q = 196) smaller then Tt, ~ Doesnt meet Code = 358, lerger than 250, larger than 7t,,, ~ Does meet Cocke STEP 6 ~ Answer question EXAMPLE: “Outside fillet weld does not meet Code requirements because itis smaller than that allowed by Code rules " STEP T - Circle answer COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE. SOLVING HEAD PROBLEMS Step 1 - Determine what question is asked - minimum thickness or maximum allowable pressure? Step 2 - GO TO UG-32 for INSIDE dimensions of: A, 2:1 elliptical heads B. 5% knuckle radius torispherical heads C AID hemispherical heads Step 3 - Determine values for nomenciature necessary to solve formuta (REMEMBER - only one unknown can be solved - elther T or P) write these values down in tabular form: EXAMPLE. (from UG32 ~ 2:1 elliptical head): =? P= 250 (given in problem) + HH D= 60 inside diameter (given in problem) E= 1.0 joint efficiency from Table UW-12 (REMEMBER; UW 11 (A)(5)(b)) 15,000 Stress value (given in problem or in stress tables) ‘Step 4 - Plug in values in formula from UG32 (NOTE: when solving fort" ~ hydrostatic head must always be considered) EXAMPLE: 25E! (for Pressure) PD__ (for Thickness) or Pe Dem 35E-02P Step 5 - Solve mathematically - (WATCH NUMBERS CAREFULLY!) W000 ~ 50 t= 500 LE: "No, head does not meet code requirements because and available thickness is 480° OR "Maximum pressure yacause MAWP on vessel is Step 6 - Answer Question - EXAMPI required thickness is 500" allowed in head is x PSIG - This condition is acceptable be y PSIG Step 7 - Circle answer IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 10 COPYRIGHT 2000REVIEW OF ASME SECTION Vill . DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘SOLVING SHELL CALCULATIONS Step 1 - Determine what question is asked - minimum thickness or maximum allowed pressure? Step 2 - Goto UG-27 for IR. Formula - Appendix 1 for OS R. formula. ‘Step 3 - Determine values for nomenciature necessary to solve formula (REMEMBER -only ONE unknown can be solved - ether T or Pl) Write these values down in tabular form EXAMPLE: t = 2 15,000 (given in problem or stress value from tables for material) 4.0 (Joint efficiency from UW-12 for long seam) 250 (given in problem) + Hydrostatic Head R= 30 (given in problem) amo Step 4 ~ Plugis values in formula from UG27 or Appendix 1 (NOTE: When solving for ""- Hydrostatic Head must always be considered!) Step § - Solve mathematically - (watch numbers carefully!) Work in descending order and BE NEAT! SE Ree (for Thickness) t or (for Pressure) t= T5000: 7500 TERSO t= 505" step 6 - Answer mutiple choice question - EXAMPLE: A. “No; Shell doesn't meet Code requirements because fequired thickness is 505" and available thickness is 480" OR A "Maximum pressure allowed is (x) psig” Step 7 - Circle Answer COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - AL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 8REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER, IRC COPYRIGHT 2000-IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DONOT COPY OR DISTRIBUTE, REMEMBER: Hydrostatic Head must be accounted for on any vessel designed for fluid service, per UG-98 and 3-2 if"T" =X MAWP at the top of the vessel, then T must = X MAWP + 433 psi per linear columin height (L.C.H) of water at the bottom, PR Exemple !: tl 7 SE- Where P = MAWP + 433 psiX L.CH P So if P= 150 and height is 100 ft, P= 150+ (100 X 433) = 150+ 433 OR 1933 WITH HYDROSTATIC HEAD! Solve formula with this value Example 2: Where P = -433 psiXLCH If P = 150 and height is 100 ft, then final adjusted pressure becomes 150 - ( 433 X 100) or 150 - 43 3, or 106 7 psi allowed on vessel. : Do this after solving for “P” . HYDROSTATIC HEAD = 433 psi x EACH 1 FT COLUMN HEIGHT OF WATER . ALSO. MAWP IS EXCLUSIVE OF CORROSION ALLOWANCE NOTES ON ROUNDING IN MATHEMATIC EQUATIONS ‘API has.not published a policy on rounding (either up or down) when calculations are performed as part of the examination. although they have been asked to publish this policy. The calculation answers are normally far enough apart so that rounding does not usually present a problem However, we can only instruct based on (historically) what has worked best (so far). This is the rounding policy that will be used during this course (but may be modified on the exam by API): 1) Thickness Calculations: Round to the third decimal place, and don't round-up/down Example #1 -* 0075" -is " 007° - (same as on test) ‘Example #2 -” 0993" - is" 089" - (may be shown as "010" on test) Example #3 -* 9998" - is" 999" - (may be shown as “1 00" on test) 2 Pressure Calculations: Round to whole single digit as psi Example #1 - "239 3 psi” Example #2 -"1007 9 psi Example #3 - “999 99 psi is 1007 psi" - (may be shown as “1008 psi” on test) “999 psi" - (may be shown as “1.000 psi" on test) 3 ‘Square Root - Do not round any number under a square root Simply hit the square root button (7) on the calculator and utilize that full number ‘COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATE! “ALL RIGHTS RESERVED -DO NOT GOPY OR DISTRIBUTE a 7REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTE UW-12 JOINT EFFICIENCIES ‘Table UW-12 gives the joint efficiencies E to be used in the formulas of this division for welded joints Except as required by UW-11 (a)(5), a joint efficiency depends only on the type of joint anc on the degree of examination of the joint and does not depend on the degree of examination of any other joint ‘Avvalue of E not greater than that given in column (a) of Table UW-12 shall be used in the ‘esign calculations for fully radiographed butt joints (see UW-11 (a)). except that when the requirements of UW-11 (a)(5) are not met, a value of E not greater than that given in column (b} of Table UW-12 shall be used. ‘Avvalue of E not greater then that given in column (b) of Table UW-12 shall be used in the design calculations for spot radiographed butt welded joints (see UW-1 (5). ‘A valve of E not greater than that given in column (cof Table UW-12 shall be used in the design calculations for welded joints that are neither fully raciographed nor spot ragiagraphed (see UW-1 (¢)) For calculations involving circumferential stress in seamless vessel sections or for thickness of seamless heads, E = 1.0 when the spot radiography requirements of UW-11 {a\@)(b) are met. E = 0.85 when the spot radiography requirements of UW-11(a)(5)(b) fre not met, or when the category A or B welds connecting seamiess vessel sections or heads are type no 3.4,5 or 6 of Table UW-12 ERW welded pipe or tubing shall be treated in the same manner as seamless, but with allowable tensile stress taken from the welded product values of the stress tables and the requirements of UW-12(d) applied NOTE: Circumferential stress is the stress exerted on the longitudinal seam while the longitudinal stress is the stress exerted on the circumferential seams COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES - AL. RIGHTS RESERVED - D0 NOT COPY OR DISTRIBUTE 7REVIEW OF ASME SECTION Vill . DESIGN -T. SCHINDLER IRC COPYRIGHT 2000-IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE Paragraph UG-37 gives the requirements for reinforcement around any openings in a pressure vessel. A formula is given for the determination of the total cross sectional area of reinforcement as well as uss for vessels that experience extemal pressure and vessels that experience both intemal and extemal pressure Limits of reinforcement are discussed in Paragraph UG-40_ This paragraph stipulates the boundaries of cross-sectional area in any plane and the physicel location of the reinforcement with respect to the ‘opening Material used for reinforcement shall have an allowable stress value equal to or greater than that of the vessel wall material Requirements for the strength of the reinforcement are discussed in UG-41 and the inspector should be able to understand that the strength of the material used for reinforcement must be at least equivalent to that of the pressure vessel Questions may arise during construction as to what to do about the reinforcement for vessels that have multiple openings that are near to one another Paragraph UG-42 tells the manufacturer how this situation isto be deat with. The overlap of reinforcement areas is taken into consideration and the total are of reinforcement is stipulated. ‘Another area that the certified inspector should be very familiar with is how pipe and nozzle necks are ‘attached to the vessel. The ASME Code gives restrictions regarding material and the design of the joint that makes the attachment Paragraphs UG-45 and UG-48 discuss nozzle neck thicknesses and inspection openings, The inspector ‘should be familiar with both of these peragraphs, because in UG-45 the required wall thickness for inspection openings with weld-on necks is discussed UG-46 discusses in particular the requirements for inspection openings and the circumstances in which inspection openings may be omitted Sizes of manholes, numbers of telltale drains, are also discussed. COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES - ALL. RIGHTS RESERVED - DO NOT COPY OR OISTRIBUTE 6REVIEW OF ASME SECTION Vill - DESIGN -T. SCHINDLER IRC ‘COPYRIGHT 2000. IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE Regarding corrosion. the user or his designated agent shall specify corrosion allowances other than those required by the rules of Section Vili, Div. 1. If corrosion allowance is not provided for, this fact must b= indicated on the data report. When making allowance for corrosion, erosion and mechanical abrasion factors must also be taken into consideration for the desired life of the vessel Any material added fer these purposes does not have to be the same thickness for all parts of he vessel. The rate of deterioration will determine the added thickness requirements ‘Any vessel subject to corrosion must have a suitable drain opening at the lowest point practical in the vessel A pipe may be used extending inward from any other location te within a quarter inch of the lowest point of the vessel Paragraph UG-27 addresses thickness of shells under intemal pressure Formulas are given for calculating minimum thicknesses and maximum pressure for cylindrical and spherical shells Special attention must be paid to circumferential stresses and longitudinal stresses within cylindrical shells. These Gifferent stress categories will determine the minimum thickness or maximum working pressure of the Vessel The API inspector should be aware of the limitations of both of these calculations and the applicability of each. Paragraph UG-28 addresses the thickness of shells and tubes under external pressure. A figure is ‘Supplied in ASME Il Part D to make the determination if the chosen shell thickness value will withstand the maximum allowable working pressure. Using this procedure involves the process of assuming an outside diameter to thickness ratio and using this value and the charts provided, to determine the maximum allowable pressure This procedures applicable to cyinders having an outside diameter to thickness ratio value of equal to or greater than ten’ When the outside diameter to thickness ratio is fess than ten, ther formulas are used for determining the maximum pressure allowable Three configurations are addressed in paragraph UG-28. The two that we have mentioned are the cylindrical shells and tubes with diameter to thickness values of greater than 10 and cylindrical shells end tubes with a diameter to thickness ratio of less than ten. The third configuration is spherical shells The ‘API certified inepector should be familiar with the method usad for determining pressure and thickness in this paragraph and be able to apply these Code rules in any given situation “The inspector should be familiar with the requirements of paragraph UG.31 regarding tubes and pees when used as tubes or shells This paragraph stipulates that the rules of UG-27 or UG-28 shall be apolied depending I the tube or shell is to experience internal or external pressure and further that corrosion snd erosion allowances must be taken into consideration. Threaded tube ends are also a consideration Formulas and rules for using formed heads with pressure on the concave side are given in Paragraph UG- 32. The inspector should be familiar with these formulas and their applicability Definitions of elliosoical torispherical, hemispherical, and toriconical heads should also be understood by the inspector UG-22 presents similar formutas when using formed heads with pressure on the convex side LUnstayed flat heads and covers are discussed in Paragraph UG-34 Figure UG-34 presents some of ne ‘acceptable types of unstaying flat heads The inspector should be aware of this figure and know how recognize the configurations that are exemplifies ‘The formulas given in Paragraph UG-34 must be understood by the inspector Since the inspector ey be in the situation where he would have to verify design calculations. his working knowledge of thes= formulas and the applicabilty of these formulas must be well understood Normally in the construction of an ASME Section Vill pressure vessel, it will be necessary to have ‘openings through the pressure retaining shell As most everyone knows, when a hole is made in pressure vessel it weakens the vessel and therefore it will nt withstand the same stresses as 2 vessel without openings Paragraph UG-36 addresses openings that must be made in a pressure vessel Tne Shape of openings and size of openings are discussed along with any combination of openings anc spacing of openings COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 5REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE FUNDAMENTALS OF ASME Vill PRESSURE VESSEL. DESIGN The API inspector will have to be knowledgeable in the fundamentals ofthe design requirements of the [ASME Boiler and Pressure Vessel Code in order to know what he is looking at end what he must look for ‘when dong inservice inspection of pressure vessels, and to help satisiy bimself thet the vessel is being ‘operated under the proper conditions in this section we will review some of the parameters that must be addressed in design calculations for pressure vessels being built in accordance with the requirements of ASME Section Vill ‘As we know ASME Section Vill. Div 1 is divided into three subsections, a general subsection, a method of fabrication subsection, and material class subsection No matier the fabrication process not the ciass of material used, the requirements for design in the general subsection apply in addition to the specific design criteria given in the other applicable subsections, ‘Such things as minimum thickness of shells and heads, mil undertolerances, pipe undertolerances, and corrosion allowance must be taken into consideration when designing pressure vessels. ‘4 combination of construction techniques may be used in a single pressure vessel, provided the rules applying to the respective methods of fabrication are followed and the vessel is limited to the service permitted by the method of fabrication having the most restrictive requirements ‘Any combination of materials may be used provided the applicable rules are followed arid the requirements in ASME Section IX for welding dissimitar metals are mat Paragraph UG-19 addresses special constructions, such things 2s combination units, special shapes. and the situation where no design rules are given. Design temperatures are addressed in Paragraph UG-20. Stipulations must be made for both maximum ‘and minimum design temperature Normally the maximum design temperature will not be less than the mean metal temperature expected under normal operating conditions. Normally the minimum metal design temperature shall be the lowest expected in service The design maximum metal temperature cannot exceed the temperatures listed in the tables of Subsection C and for pressure vessels under external pressure, the temperature shall not exceed the maximum temperature given on the external pressure charts The design pressure of a vessel covered by ASME Section Vill, Div 1: shall be the most Bevare condition of coincident pressure and temperature expected in normal operation For this condition and for test conditions. the meximum difference in pressure between the inside end outside of the vessel, Of between any two chambers of a combination unit shall be considered UG-22 addreseés loading It states that the loading to be considered in the designing of a pressure vessel shall include intemal and external design pressure, the weight of the vessel, and any of its normal ‘Contents, either during operation or during testing, and superimposed static reactions from weight that is. attached to the vessel. any ioads due to attachment of items, and any cyclic and dynamic reactions It is iso stated that wind. snow. and seismic reactions will be considered Any impact reactions due to fluid Shock and any temperature gradients and differential thermal expansion must be considered Maximum allowable stress values are considered in UG-23 Each class of material has its own maximum allowable stress value and the reader should become familiar with the stress tables referenced in each subcategory of material class. UG-24 contains requirements for specifying quality factors for castings A casting that has no nondestructive examination performed on it will have a lower quality factor than will @ casting that has been examined using nondestructive examination method COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 4REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- RC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY.OR DISTRIBUTE CATEGORY CODE, SEC. CALCULATION/FORMULA. Nozzle Weld Ses | ASME Vill UWS] t,= smaller of 4" oF Th Fig. UW-16 | «= smaller of 3/4” or thickness of parts thets= smaller of 1/4" or 7 tog Leg = 1.414 x throat - Throat = 707 x Leg Carrasion ‘APLB10 and ea ‘Corrosion Rate - Metal Loss Rate/Remaining Life Body of Time __ | Knowledge Corrosion Allowance = Actual T - Min T Remai orrosion Allowence: Corrosion Rate Fiydrostatic Head ASME Vil & UG-58 Hydrostatic Head = 433 psi x each (1) foot of | API 510 Body ‘height 7 of Knowledge Head Depth "ASME Vill UG-32 | Head Depth = 114 x D - Elipical Heads (Dish) Head Depth = 172 x D — Hemispherical Heads COPYRIGHT 2000 + IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 3REVIEW OF ASME SECTION VIll - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000- IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE ‘API 510 CALCULATIONS SUMMARY SHEET A SATEGORY CODE SEC. CALCULATION/FORMULA Min Thickness: ASMEVIN | UG27-1R Ty of Shells APP1-OR (Cylinders) tas Seeete Design Pressure ASME VT | UG2T-IR [p> SE. gpa se on Shells APP1-OR Reo aw (Cylinders) 7 Extemal Pressure on | ASME VIB | UG28and [1 UD, andD, Cylinders Charts Extemal | 2 Goto FigG, find A’ provided with | Pressure Charts | 3 Go to Material Chart test 4 Find "B” calculate PA = —*2 3. » Pain Thickness of | ASHE VI | UG-32 16) (0) 9 | oy, PD, Formed Heads Blip. -t= 25E-2 Torispherical - Hemi - Design Pressure of | ASME VIN | UG-32 (8) | etip -p pe Formed Heads cea Hemi - P Tin. Thickness of ASME VI | UGST CHA yg [ce Flat Heads Formula 1 VE Nowe ~ RSME Vil | UG-37, Fig UG- [A,,A,, A,, must be greater than A for Reinforcement a Nozzles with no repad, Ay Ay Au As and A, must be greater than ‘Alor Nozzles with repad ; impact Testing "ASME VII TEBE. | UG-20(f) for bianket excentions, UCS - 66.67 . UG-84 UCS-66. | 68 for requirements, UG-84 for acceptance 67,68 criteria Fyaro/Preumatic ASME VIN | UG-88. UG-100 TanPxSiressi TesiTemp Hydro - p = SPsSwessie Tne Tests - Siress@ DesignTemp LixPxSiressi@ TestTeme | Pneumatic“ P * “Sires DesenTemp Weld Joint RSME vit | UW-t UW-42 | RI-1-Ful- 10 or 80 Efficiencies Table UW-12 Full on Cat A - Spot on Cat B (UW- 11(ayXS)(b) 1 0.0r 90 RRT-3 - Spot - 1 -50 foot weld -1 for each welder 85 or 80 RT-4 - Combination of above NoRT - 70 or 65 ‘Seamless - 85 UW-11(a)(5)(D) is not met 1.0 is UW-11(a)(5)(0) is met COPYRIGHT 2600 ~ IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 2REVIEW OF ASME SECTION Vill - DESIGN - T. SCHINDLER IRC COPYRIGHT 2000-IRGISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE API AUTHORIZED PRESSURE VESSEL INSPECTOR PREPARATION COURSE FOR CERTIFICATION EXAMINATION, 2000 INNOVATIVE RESEARCH CONSULTANTS: SCHINDLER & ASSOCIATES AND CODEWEST AUTHORED BY: T. SCHINDLER COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 1O@ MISCELLANEOUS QUIZZES COPYRIGHT 2000- IRCIT. SCHINDLER ~ ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE API AUTHORIZED PRESSURE VESSEL INSPECTOR. PREPARATION COURSE FOR CERTIFICATION EXAMINATION 2000 INNOVATIVE RESEARCH CONSULTANTS ‘SCHINDLER & ASSOCIATES , AND. CODEWEST AUTHORED 8) T. SCHINDLER NOTE: These questions represent quizzes that have been given over the years... They are not in the format of the test (multiple choice) but are still very important to the learning process to enourre comprehension, not Just the ability to “pick the right answer”. These questions should be completed prior to the examination to ensure the best possible chance of passing the test. COPYRIGHT 2000 —IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 1NAME, MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000- IRGIT. SCHINDLER ~ ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE API 510 COURSE quiet DATE. PARTI - OPEN BOOK 1 What do the letters "ASME" stand for? 2. Whois the National Board? 3. Whois API? API 510 is identical to NBIC True or False (circle one) 5 The scope of ASME Section VIII includes nearly all unfired pressure vessels used in & refinery True or False (citcle one) 6 Unies adopted by Law, Rule, or Resolution ASME/API Codes do.not have to be followed! 10 be "legal" (matter of contractual agreement) True or False (circle one) COPYRIGHT 2000 - IRC/SCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 2MISCELLANEOUS QUIZZES IRC ‘COPYRIGHT 2000-IRCIT_ SCHINDLER ~ALL RIGHTS RESERVED -DO NOT COPY OR DISTRISUTE API510 COURSE quz#1 PART Ii - CLOSED BOOK 7. API510 states that an Authorized Inspection Agency may be one of seversl entities Name one i 8. An easy way to externally tel the difference between a safety valve and a relief valve is that the relief valve does not have a ? 6. Corrosion in a refinery is grouped into three major categories - those caused by petroleum products, those caused by chemical products, and those caused by’? 10. Erosion is defined as? COPYRIGHT 2000 ~iRCISCHINOLER & ASSOCIATES: ALL RIGHTS RESERVED - DO NOT GOPY OR DISTRIBUTE 3MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000- IRCIT. SCHINDLER - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE API 510 COURSE quiz #2 NAME, DATE, PART | - OPEN BOOK 4. The purpose of a WPS and POR is to determine if a proposed weld ment to be used in ‘construction is capable of providing the required properties for the intended application True or False (circle one) 2 Unless specifically required otherwise by the welding variables, @ qualification in any position qualifies 2 welding procedure for all positions, True or False (circle one) 3. AWPS must only address essential and, if applicable, supplementary essential variables True or False (circle one) 4 The acceptance criteria for tension tests is stated in Para 2 Tensile strength is ‘computed by dividing the maximum load sustained during the test by the of the specimen, measured before the load is applied 5 Groove weld coupons shall qualify the thickness ranges of both and to be used in production 6 Awelding procedure must be qualified with impact tests only when tequired by the applicable construction code, such as ASME Vill Div t True or False (circle one) COPYRIGHT 2000 ~ IRCISCHINOLER & ASSOCIATES. ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 4MISCELLANEOUS QUIZZES "IRC COPYRIGHT 2000- RCT. SCHINDLER. ALL RIGHTS RESERVED -DO NOT COPY OR DISTRISUTE API 510 COURSE quiz#2 PART Il - CLOSED BOOK 7 10 What is meant by the "remaining Ife" of a pressure vessel? Safety vaives are characterized by a ful opening "pop" action, and are usually used for service ‘What is 2 hydrogen blister and what causes this condition? ‘What is an on-stream inspection? COPYRIGHT 2000 -IRCISCHINDLER & ASSOCIATES. ALL RIGHTS RESERVED - D0 NOT GOPY OR DISTRIGUTE 8NAME. MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000- IRCIT. SCHINDLER = ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘API 510 COURSE quiz #3 DATE, PARTI - OPEN BOOK 1 10 4“ 12 ‘Tension tests may be used in lieu of bend tests to qualify welders or welding operators: Tre or False (circle one) Table QW lists the required tests and qualification DWM thickness ranges for welders Awelders qualification expires if he has not used a process during a period of or more E 8018 electrode (1 1/456 chrome, 1/2% molybdenum) is an A#___. Fé SAM. ‘Awelder qualified on P-8 (stainless steel) He is then qualified to weld on P-1 (carbon steel) assuming all other process variables remain unchanged. Tre ot False (circle one) ‘The GMAW short-circuit process has detailed thickness limitations for welders. These restrictions are stated as an essential variable in QW. A515 GRAO has a minimum specified tensile strength of __andisa Pa material A.2G pipe qualification on 1 74" © D pipe will qualify a welder to weld in the _ and position on groove welds in pipe ‘OD and over What is a lead letter "F” used for in film radiography? Magnetic prod spacing shall not exceed when using prods for magnetic particle testing ‘An uitrasonic instrument shall provide linear vertical presentation within 2< 5% of full screen height for 20% to 80% of the calibrated screen height Tre or False (circle one) ‘Awelder qualified on 5/8" thick material wil require how many bend tests per the Code? Number of face and root bends?, or number of side bends? COPYRIGHT 2000 - IRCISCHINDLER & ASSOGIATES- ALL RIGHTS RESERVED - DO NOT COPY OF DISTRIBUTE 6MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000-IRCIT. SCHINDLER - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE, API 510 COURSE Quz#3 PART Il - CLOSED BOOK 13 4 16. 16 17. 18 19 20 Repairers of pressure relief devices must have a written, system, which covers the minimum requirements stated in API 510 ‘All repait and alteration work must be authorized by an Inspector prior to its commencement True or False (circle one) ‘What is @ corrosion allowance? ‘What is a rupture disk, and how does it work? Recertification by written testis required for API Certified Inspectors who have not been actively engaged as an API Inspector for _years : ‘All above-ground vessels shall be given a visual external inspection, preferably while in ‘operation, at least every years or at the same interval or on-stream interval whichever is ass One of the main causes of improper materials being used in the repair and/or alteration of pressure vessels is human error in the selection of materiais. Tre or False (circle one) Permanent and progressive records must be maintained by the owner for each pressure vessel, ‘and must contain copies of manufacturer's data reports, pertinent records, vessel ID #5, relief valve information, and records of repairs, alterations. inspections and reratings True or False (circle one) COPYRIGHT 2000 ~IRGISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 7MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000-IRCIT. SCHINDLER - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE API510 COURSE quiz NAME, DATE, PART! - OPEN BOOK 1 10 1" 2 13 A lead letter “B* must be attached to the back of all radiography film holders as a check on? ‘What is thé difference between inspection and examination, as defined by ASME? (One of the procedural requirements for ultrasonic examination of materials and fabrication is to address the instrument type that will be used. True or False (circle one) “The appropriate penetrameter number designation for 2 1" thick weld with 1/8" reinforcement on both the inside and outside is, (source side). Per Section V, the minimum density of a radiograph mace with a gamma source shall be "The maximum density of all radiographs, regardless of source, shall be. ‘The basic calibration block thickness (for welds to be ultrasonically tested) for welds 2 inches through 4 inches thick is? Prior to a PT examination the surface to be exemined must be cleaned at least sate ack from the area of interest to ensure no extraneous matter could interfere With the examination The magnetizing power of yokes must be checked when? Black lights used in florescent particle MT must be allowed to warm up for a minimum of lor must be measured to ascertain the intensity of the light emitted Visual examinations may be conducted when access is sufficient to place the eye within ____ of the surface to be examined ‘What is dwell time? (What are the penetrant techniques? What are three magnetizing techniques? COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 8MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000-IRGIT SCHINDLER ~ ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE API 510 COURSE Quizes PART II - CLOSED BOOK 14 ‘The maximum allowable working pressure of a vessel is determined by using the calculations and formulas from? 16 16 7 18 19 “20 Sulfuric acid is most commonly found in units. ‘What is thermal shock? A pilot operated safely relief valve is easily recognized because it will always have at least ‘wo interconnected valves or chambers True or False (circle one) [A pressure test per API 510 should be carried out when the metal temperature is between deg. Fand____deg F Preheating to 200 deg, may be considered as an altemative to PWHT per API 810 True or False (circle one) Arerating is the same 2s an alteration (ie: physical change to the pressure vessel must b= accomplished) True or False (circle one) COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 8MISCELLANEOUS QUIZZES IRC (COPYRIGHT 2000-IRCIT. SCHINDLER - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘API 510 COURSE quizes NAME, DATE, PART! - OPEN BOOK 1 A2' thick carbon steel vessel of 45 K S.1_ material requires impact tests, Standard impact specimens for this vessel must achieve an average of tbs of energy to be accéptable 2 Name 6 of the 19 duties of the manufacturer of ASME code vessels 2 Name 6 of the 14 duties of the A 4. The only material required by ASME VIII to have material test reports is? 5 Sketch a nameplate for @ welded vessel that is fully radiographed (complies with UW-11A) is heat treated, and is built for 50 PSIG @ 850 deg and 20 PSIG @ -20 MDMT 6 _ Whatare the seven items that must be marked on an ASME Vill relief vaive? 7 Inrelation to the geometry of pressure containing parts, the scope of Section Vill Div. 1 includes the following termination points where external piping is to be connected to the vessel 8 —_Matetials for pressure parts shall conform to one of those listed in ASME Section and shall be limited to those that are permitted in the applicable part of ASME Vill, Subsection except as otherwise permitted 9 The following nomenclature of Section Vill means the following requirements are covered: us. ues, UHA ow. UNF, UHT. = 10 Transferring coded markings or keeping a material tabulation is an acceptable means of keeping material identified during fabrication per ASME VIII True or False (circle one) (COPYRIGHT 2000 - IRGISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 10" 12 MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000-1RCIT SCHINDLER ~ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE auzs (continued) Accylindrical vessel has 2 nominal diameter of 60", a measured I.D. of 61" at one cross- ‘section and a measured |.0 of 58" at another point Does this vessel meet the Code? Why or why not? Defects in material may be repaired upon acceptance by the manufacturer and owner/user True or False (circle one) COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES- ALL. RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTE "MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000- IRCIT. SCHINDLER ~ ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘AP! 510 COURSE quizes PART II - CLOSED BOOK 8 14 16, 16 7 18 20 ‘What is @ Jurisdiction, per API 510? When measuring the corroded thickness of ellipsoidal or torispherical heads, the governing thickness may be that of the knuckle region or the dished region. True or False (circle one) ACTUAL — T MINIMUM. is the equation for determining CORROSION RATE(INCHES PER YEAR the __of the vessel. Sketch an API-required rerating namepiate ‘What is a repair per API 510? 7 Widely scattered pits may be ignored provided (1) pit depth is no more than 1/2 of the vessel wall thickness, (2) the total area of the pits does nat exceed 7 square inches within any 8 inch iameter cirele and (3) the Sum of the diameter of the pits doesn't exceed 2 inches True or False (circle one) Name three types of equipment encountered in a refinery that would be subject to extreme vibration forces ‘Sketch a balanced bellows safety relief valve COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 412MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000- IRCIT. SCHINDLER - ALL. RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE API 510 COURSE Quizes NAME, DATE. PART | - OPEN BOOK 1 10 rn 12 13 14 ‘What are the arc welding processes permitted by ASME VIII? Welding of test coupons for WPSiwelder qualification shall be conducted by the? ‘The maximum weld reinforcement permitted for a 2 1/2" thick pressure vessel category weld is? SNT-TC-1Ais a guide for employers to establish a written practice for qualification and certification of personnel performing examinations In spot radiography, one shot must be made for each increment of weld. and ‘must include each welder ‘When is @ tapered transition required by ASME VIII? Acceptance criteria for UT is located in Appendix? ' Acceptance criteria for PT and MT is located in Appendix _. and What are 3 conditions that must be met fo allow the use of SA-36 for pressure parts in prescure vessels? ‘The temperature of a furnace shall not exceed deg F at the time the vessel or partis. placed in it for PWHT APS butt welded joint of 1/2" thick does not require radiography per ASME VIll, when designed to UW-82 (spot RT) rules and 85% joint efficiency. True or False (circle one) 3 GR1 or GR2 materials 1/2" thick will require PWHT per ASME Vill True or False (circle one) ; SA-105 3000# couplings (UG-11) would be located along curve, of UCS-86 Vessels designed per UW-12(C) or seamless vessel parts designed with E = 85 do not require 2 corrosion allowance, regardiass of thickness or service True or False (circle one) API 510 COURSE COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE, 8MISCELLANEOUS QUIZZES: IRC COPYRIGHT 2000- IRCYT. SCHINDLER ~ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE. quizes PART Il - CLOSED BOOK 16. 16. 17 18, ‘The comesion compounds that will most likely affect a crude tower flash zone will be inydrogen sutfide, sulfur compounds, and organic acids True or False (circle one) In temper-bead welding, the concept is to "temper" the weld with subsequent weld head layers as an alternative to? ‘Towmersitip of @ vessel s changed without moving the vessel, It must be reinspected before re-use True or False (circle one) Vessels with a nominal water containing capacity of 120 gallons or less for containing water under pressure are exempt from API 510. True or False (circle one) 49-22 Name the four entities that may be considered to be Authorized Inspection Agency. API510 COURSE COPYRIGHT 2000 ~ IRC/SCHINDLER & ASSOCIATES: ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 14MISCELLANEOUS QUIZZES: IRC CtopyRai 200 RC. SCHNDLER ~ ALL RIGHTS RESERVED D0 WOT COPY OR Dis TRIBUTE ANSWER SHEET ‘American Society of Mechanical Engineers ‘An organization comprised of Chief Beier Inspectors from the United States and Canada ‘American Petroleum Institute False True Tre Insurance Company, Jurisdiction, Owner/User Lifting Lever Extemal Environmental Conditions ‘Abrasive wearing away of metal by substance flow quiz2 COPYRIGHT 2000 - IRC/SCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 415MISCELLANEOUS QUIZZES: IRC COPYRIGHT 2000. IRC/T, SCHINDLER ~ ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ANSWER SHEET 1 The 2 Twe 3 False 4 Qw-183, Lease cross-sectional area 5 Base metals, deposited weld metal 6 Tre 7 The maximum amount of time that the vessel can be safety operated within a given safety allowance as established by calculation. 8 Steam 3 _A scab-lke lamination of metal caused by trapped hydrogen reacting with oxygen to form corrosive elements, 410 Inspection of an item while itis in or out of service using any number of NDE procedures To establish the suitability for continued operation API §10 COURSE COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 1610 " 2 13 1“ 15 16 7 19 20 MISCELLANEOUS QUIZZES IRC ‘COPYRIGHT 2000- IRCIT. SCHINDLER ~ ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE quiz 3 ANSWER SHEET False Qw.452 ‘Six months A3, F4, SFAS 4. True QW 404-32 60,000, P-1 Flat and horizontal, 1" 0D and over To denote a film side penetrameter 8 True 1 Face. 1 Root or two Side Bends Quatity Controt True ‘Thickness over and above the required minimum metal thickness required to withstand the expected pressure ‘Athin diaphragm that ruptures at a pre-determined pressure Three S years True True API510 COURSE quiz 4 COPYRIGHT 2000 ~ IRCISCHINDLER & ASSOCIATES- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIB 710 " 12 13 4 15 16 7 16 19 20 MISCELLANEOUS QUIZZES IRC COPYRIGHT 2000-IRC/T. SCHINDLER ~ ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ANSWER SHEET Back scattered radiation Inspection by the Al, Examination by the Manufacturer True 20 20,40 3 inches br t- the deposited weld metal thickness 1 inch “Once a year, or whenever dameged 5 minutes 24 inches “The amount of ime a penetrant or emulsifier is alowed to remain on the surface of a part Weter washable, post-emulsiying, solvent removeble, and color contrast or Muorescent Prod, longitudinal, circular, yoke multidirectional (any three) “The ASME Construction Code the item was built to ora later edition Alkylation “Thermal shock is a sudden change in temperature on a pressure vessel - True 70", 120° The Tre ‘API 610 COURSE Quiz 5 COPYRIGHT 2000 ~ IRG/SCHINDLER & ASSOCIATES. ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIEUTE 8