4 Tough API 653 Exam Questions … Are you ready?

Question # 1 … Do you know your critical definitions 🡪 See the Chapter 3 word doc
1. A crack ten inches long in a vertical weld on an existing tank (bottom shell course = 1 inch)
was found, resulting in removal and replacement of 12 inches of vertical shell weld (maximum
crack depth was found to be .625 in.). API 653 considers this work after rewelding to be a(n):
A) Alteration B) Repair C) Major alteration D) Major repair
You’ll likely need the book … but you should know the definition of a major repair!
Question # 2 … Do you know the minimum number of settlement points to be checked
2. A tank of 50 feet diameter is to be checked for shell settlement. The minimum number of
equally spaced settlement points to be checked will be ______?
A) 5 B) 8 C) 12 D) 24
You’ll likely need the book … but you should know minimum number of settlement points!
Question # 3 … Do you know all of the rules & exceptions for hydrotesting
3. For a tank made by reconstruction, under what circumstances may a new shell-to-bottom
weld be exempt from hydrostatic testing?
A) When a root pass is visually inspected & a final weld is fully examined (Visual & RT)
B) Reconstructed tanks are never exempted from hydrostatic testing.
C) When a root pass is visually inspected & a final weld is fully examined, (Visual & Vac Box)
D) When a welding method has been reviewed/approved by an engineer experienced in tank
design in accordance with API Standard 650.
You’ll likely need the book … but you should know when hydro tests are always required!
Question # 4 … Do you know how to calculate weld reinforcement when selecting the IQI
4. A radiograph taken after a crack repair in a 1 in. thick vertical joint will require what essential
wire to be visible when a film side IQI is used and weld reinforcement on both sides of the weld
measured the maximum allowed by the code?
A) 8 B) 9 C) 10 D) 30

This is an OPEN BOOK question 100% 🡪 Make notes and references in your books!

Mark answers below before looking on next page 🡪 Do not cheat!

1 = _________2 = _________3 = _________4 = _________
1 correct = average/weak … 2 correct = good … 3 correct = excellent … 4 correct = Great!
Answers found next page!!!

All 4 answers are “B” … Buzzzzzzzzzzzzzzz!

Question # 1 … Do you know your critical definitions 🡪 See the Chapter 3 word doc
Answer: B (Ref: API 653, See Definitions 3.1, 3.24, & 3.18.e)
3.1 – Alteration: Any work on a tank that changes its physical dimensions or configuration.
3.24 – Repair: Work necessary to maintain or restore a tank to a condition suitable for safe
operation. Repairs include both major repairs (see 3.18) and repairs that are not major repairs.
Examples of repairs include: d) Repair of flaws by grinding and/or gouging followed by welding.
3.18 – Major alteration/or major repair: An alteration or repair that includes any of these:
e) Complete or partial (more than one-half of the weld thickness) removal and replacement of
more than 12 in. of vertical weld joining shell plates or radial weld joining the annular plate
ring;
Note 1: If removal & replacement exceeded 12 inches, “D” would have been the correct
answer!
Note 2: Under no circumstance could this be considered an alteration per the Para. 3.1
definition!
Note 3: A Closed Book question could also read … The complete or partial removal and
replacement of 12 inches of vertical weld joining shell plates is considered a(n) 🡪 Repair … OR
The complete or partial removal and replacement of more than 12 inches of vertical weld
joining shell plates is considered a 🡪 Major Repair … but … only 12 inches or less = Repair!
Do you now know the difference between a major alteration and a major repair?
Adding a 12 in nozzle 🡪 Changes the configuration = Major alteration, not a major repair!

Question # 2 … Do you know the minimum number of settlement points to be checked

Answer: B (Reference: API 653, Section 12.5 & Annex B) … The minimum number of elevation
points shall be as indicated by the following equation:

Where N = minimum required number of settlement measurement points, but no

less than eight. All values shall be rounded to the next higher whole number. Maximum
spacing between settlement measurement points shall be 32 ft; D is the tank diameter, in feet
(ft).

Question # 3 … Do you know all of the rules & exceptions for hydrotesting
Answer: B (Reference: 12.3.1.a) … This may also be a closed book question!
Reconstructed tanks ALWAYS require hydrotest 🡪 NO EXCEPTIONS

Question # 4 … Do you know how to calculate weld reinforcement when selecting the IQI
Answer: B … Ref: ASME V, T-276.2.a & Table 276 Column for Source side/Wire Type for
thickness above 1.00 in. to 1.50 in. … Total thickness = 1.00 in. + .093* in. (3 ÷ 32 or 3/32 in)
*API 650, Par. 8.1.3.4 = 3/32 in. reinforcement 🡪 This is NOT doubled on vert. welds
Note 1: Do not expect API 653 exam question weld reinforcement values to be given!
Note 2: If the weld had been ground flush after repair, then “A” would be the correct answer…
Closed Book Exam Q’s
1. When a light image of a “B” appears on a darker background of a radiograph:
A) The film is to be considered unacceptable and was sufficiently protected from backscatter
B) The film is to be considered acceptable and was sufficiently protected from backscatter
C) The film is to be considered acceptable and was not sufficiently protected from backscatter
D) The film is to be considered unacceptable and was not sufficiently protected from
backscatter
Answer: D (Reference … ASME V, Article 2, T-284) … Dark image of “B” is acceptable)
2. Rules given in API 653 regarding tank inspection, repairs, alterations and reconstruction are:
A) Minimum requirements B) Recommended practices
C) Guidelines D) Suggested requirements
Answer: A (Reference API 653, Para. 1.1.1)
3. Roof plates must be repaired or replaced in all of the following circumstances EXCEPT:
A) Corrosion has reduced a roof to an average thickness of less than 0.06 in. in any 100 in.² area
B) Corrosion has reduced a roof to an average thickness of less than 0.09 in. in any 100 in.² area
C) Corrosion has created a hole that has gone completely through the thickness of the roof
plate
D) Corrosion has reduced a roof remaining wall thickness in an isolated pitted area to .06
inches.
Answer: D (Reference API 653, Para. 4.2.1.2)

… See the Exercise Questions in the Study

Module … More coming in 2012